4654870
ASSEMBLY MANUAL
FOR OUTDOOR HOUSEHOLD USE
ONLY. DO NOT USE INDOORS OR
FOR COMMERCIAL COOKING
INSTALLER/ASSEMBLER: Leave
these instructions with consumer.
CONSUMER: Keep this manual for
future reference.
Failure to follow all manufacturer's
instructions could result in serious
personal injury and/or property
damage.
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Manual for Cooking
Instructions
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Read and follow all safety
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statements, Assembly Instructions
and Use and Care directions before
attempting to assemble and cook.
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Some parts may contain sharp
edges -especially as noted in the
manual! Wear protective gloves if
necessary.
•••
If you have any questions or need
assistance during assembly, please
call 1-800-241-7548.
Visit us on the web at:
4654870 / 1 - 4165140 (06-17-02)
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Table Of Contents
Grill Service Center ............................................................ 2
Limited Warranty ................................................................ 2
Table of Contents ............................................................... 3
Safety Symbols .................................................................. 3
General Safety ................................................................... 4
Extension Cord Use and Safety ......................................... 4
Ground Fault Interrupter..................................................... 4
Parts List - Model 4654870 ................................................ 5
Before Beginning Assembly ............................................... 6
Assembly....................................................................... 6-11
Use and Care of Your Grill .......................................... 12-13
Troubleshooting ............................................................... 14
Cooking Chart .................................................................. 15
Cooking Zones ................................................................. 15
IMPORTANT SAFEGUARDS
ELECTRIC SHOCK CAN KILL OR RESULT
IN SERIOUS INJURY.
To prevent electrical shock:
•
Use only with GFI (Ground Fault Interrupter) protected
circuit.
•
•
Do not use grill when raining.
To prevent grill from being splashed or falling into water,
do not use grill within 10 feet of pool, pond or other body
of water.
•
•
Keep grill and electric controller dry and out of rain at all
times.
When connecting controller to grill, plug electric controller
into grill first, make sure controller is set to OFF, then
plug into outlet. When unplugging, turn controller to OFF,
disconnect from outlet, then remove controller from grill.
Safety Symbols
• The symbols and boxes shown below
explain what each heading means. Read
and follow all of the messages found
throughout the manual.
•
•
Unplug grill when not in use and before moving.
Do not operate grill with an electric controller that has a
damaged cord, plug or metal probe. Call Char-Broil for a
replacement controller. The electric controller is made
specifically for this grill.
•
Never remove grounding plug or use with an adapter to
two prongs.
• Indicates an imminently hazardous situation which, if
not avoided, will result in death or serious injury.
•
•
Keep electric plugs off ground and dry.
Never put controller, cord or heating element in water or
any other liquid.
•
•
•
Do not allow cord to touch hot grill.
• Be alert to the possibility of serious bodily injury if the
instructions are not followed. Be sure to read and
carefully follow all of the messages.
Store controller indoors when not in use.
Do not use water or other liquid spray to clean product
without first unplugging electric controller and removing
heating element.
• Indicates a potentially hazardous situation which, if
not avoided, may result in minor or moderate injury.
SAVE THESE INSTRUCTIONS
4654870 • 3
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General Safety
Extension Cord Use and Safety
1. Do not touch hot surfaces with unprotected hands. Use
•
For best grill performance use of extension cord is not
recommended.
handles and knobs provided for operation.
2. Never leave grill unattended when ON.
3. Keep children away from grill both when hot and cold.
4. Use long barbeque utensils for cooking.
5. Allow grill to cool before moving, cleaning or storing.
6. Do not cook under roof.
If you must use an extension cord for your safety:
•
•
Use only outdoor type with 3 prong grounding plug, rated
for 15 amperes or more, approved by UL, marked with a
W-A and with a tag stating "Suitable for Use with Outdoor
Appliance".
Use the shortest length extension cord required. Do not
connect 2 or more extension cords together. A 12 or 14
gauge extension cord of 50 ft. or less is acceptable.
7. Keep grill 24" (2 feet) away from walls and rails.
•
•
Keep connections dry and off ground.
8. For outdoor household use only. Do not use indoors or for
Do not let cord hang over edge of table top or other items
where it can be pulled by children or tripped over.
commercial cooking.
9. Use only ceramic briquettes similar to those provided with
grill.
Ground Fault Interrupter
10. Do not use or store gasoline, kerosene, or other flammable
liquids within 20 feet of this grill when in use.
• Since 1971 the National Electric Code (NEC) has required
Ground Fault Interrupter devices on all outdoor circuits.
• If your residence was built before 1971, check with a
qualified electrician to determine if a Ground Fault
Interrupter protector exists.
11. Store grill in weather protected area or under grill cover
when not in use and electric controller indoors when not in
use.
• Do not use this appliance if the circuit does not have GFI
protection
• Do not plug this appliance into an indoor circuit.
12. Use only accessory attachments recommended by
manufacturer.
13. It is the responsibility of the assembler/owner to assemble,
install and maintain grill.
Do not use 16 or 18 gauge extension cords. Damage to
household wiring and/or fire could result.
DO NOT USE CHARCOAL. A charcoal fire will result and
the grill is not designed for charcoal. The fire will create an
unsafe condition and damage the grill.
4 • 4654870
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Parts List - Model 4654870
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KeyQty-- Description ---------------------------------Part#
A ----- 1 ----Briquets Bag ----------------------------------------- 4158125
B ----- 1 ----Base --------------------------------------------------- 4154381
C ----- 1 ----Lid Handle-------------------------------------------- 4154399
D ----- 1 ----Cooking Grate--------------------------------------- 4152860
E ----- 1 ----Element Assembly --------------------------------- 4159277
F ----- 1 ----Grill Bottom ------------------------------------------ 4509581
G ----- 1 ----Grill Lid ------------------------------------------------ 4509582
H ----- 1 ----Control Leg w/ Slot--------------------------------- 4302497
I ------ 1 ----Leg ----------------------------------------------------- 4302534
J------ 1 ----Leg with Logo --------------------------------------- 4525611
K ----- 1 ----Temperature Gauge w/Wing Nut --------------- 4157142
L ----- 1 ----Controller --------------------------------------------- 4150235
M----- 1 ----Leg Handle------------------------------------------- 4150357
N ----- 3 ----Lid Hangers ------------------------------------------ 4154245
O ----- 1 ----Grease Cup ------------------------------------------ 5156609
P ----- 1 ----Grease Clip ------------------------------------------ 5156610
Q ----- 1 ----Top Insulation Bowl -------------------------------- 4152826
R ----- 1 ----Bottom Insulation Bowl --------------------------- 4152827
S ----- 1 ----Briquet Grate ---------------------------------------- 4156128
#10 Fasteners Bag: 4254040
W
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B
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T ---- 12 ----#10-24 Hex Nut (keps) ---------------------------- 4080208
U ----- 2 ----#10 Lock Nut ---------------------------------------- 4080249
V ---- 14 ----#10-24 x 1" Machine Screw --------------------- 4080302
W ---- 6 ----#10-24 x 7/16 T- Nut ------------------------------- 4080094
Misc. Fasteners Bag: 4253860
V
X ----- 1 ----5/16 Flat Washer ----------------------------------- 4080413
Y ----- 2 ----Insulator Washer ----------------------------------- 4080418
Z ----- 5 ----#12-14 x 1/2" Self-tap Screw -------------------- 4080772
4654870 • 5
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Before Beginning Assembly
s Remove all contents from box. Lay cardboard on the ground when unpacking, assemble grill parts on the cardboard to avoid
scratching surfaces.
s Carefully read and follow all assembly instructions, paying particular attention to parts orientation.
s Easily find fasteners by referring to each item (shown actual size) at the start of each step.
s Minimum tools...for assembly of your grill include screwdrivers (Phillips), adjustable wrench and pliers. A 3/8" nut driver would be
ideal.
Place temperature gauge. Hold it in place as you
turn the lid upside down.
#10 Bag
1
2
Wing Nut
Nylon Insert
249
MISC Bag
302
IMPORTANT:
Be sure all nuts are tightened securely at this time. You will be
unable to tighten these items once the insulation bowl is at-
tached.
Wing Nut
413
413
IMPORTANT:
Be sure hole in top
302
insulation bowl is aligned
with temperature gauge.
Attach wing nut "DO NOT
TIGHTEN" until after Step 3.
249
6 • 4654870
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Lower end of lid hanger bracket must rest
on upper lip of insulation bowl.
3
Lid
772
MISC Bag
772
Lid
Hanger
Bracket
NOTE:
Adjust insulation bowl as necessary to
align upper lip with brackets.
Tighten wing nut.
Repeat for all three holes
Lid
4
Fold flaps inwards and
upwards (90 degrees) so they
are horizontal.
A
B
Align rectangular slots
Push insulation bowl tabs
down and under to
temporarily hold bowl in
C
place while you work.
Grill Bottom
4654870 • 7
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302
A
5
208 between Leg and Grill Bottom
(Finger tighten only)
Align Rectangular Slots
#10 Bag
094
208
(Inside Grill Bottom)
Note: Tighten by
turning screws only
302
Grill Bottom
094
Handle
B
Logo
Attach leg with Logo (B) and plain leg (C) the same as (A).
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8 • 4654870
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6
#10 Bag
A
Legs slide into slots
in base support
208
302
302
B
NOTE:
Leg with handle
must be opposite
wheels in base.
Attach each leg
using screws
and nuts as
shown.
208
Completed
upright view
7
Use 10 or less Ceramic
Briquets. Note pattern
Do not use more than 10 ceramic briquets and
replace frequently. Persistent grease fires can
result. See Use and Care section on Controlling
Grease Fires.
Briquet Grate
4654870 • 9
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IMPORTANT:
Orient heating element so that the notch is on TOP.
("BOTTOM" is stamped on underside of bracket.)
8
772
418
Slide element bracket thru slot in side of insulation bowl
and into rectangular slot in grill body. Element bracket
mounts snugly against inside of grill body.
A
MISC Bag
772
Push insulation side flaps
down flush with bowl.
B
418
Insulated
Washer
Push center flap
down onto element.
9
Cooking grate rests on T-nuts
10 • 4654870
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NOTE - Legs not shown for clarity
IMPORTANT:
Bend tabs of insulation bowl straight down toward
grease cup to avoid grease spillage.
10
11
Clip grease cup bracket onto bar at notches
Final Assembly
Element
Raised Lip
Bracket
Remove protective film from
controller prior to use.
Ensure that controller
knob is fully rotated
counterclockwise to
the OFF position prior
to plugging controller
into grill and outlet.
Raised lip of controller should be
inserted until it is snug against
element bracket
Top View
Congratulations, you have now completed the assembly of your grill. You can now
look forward to hours of enjoyable cooking. For your safety and optimum grill
performance finish reading the instructions on the following pages before using
your new grill.
NOTE:
You may have hardware left over after completing assembly of your grill. This is normal as in some
cases we have included extra hardware to ensure that you have enough.
4654870 • 11
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Use and Care of Your Grill
Before First Use of Grill
• Remove all packaging and sale labels from the grill. Do not
use sharp tools to remove stickers.
• Wash cooking grate with warm soapy water, rinse and dry
thoroughly.
Use care when operating your grill. Be sure you read
and understand all the information and safeguards in
this manual before operating this grill.
Before Each Use of Grill
• Use grill only on a firm and level surface to prevent tipping
over.
In case of fire turn controller to OFF, unplug grill
from outlet and allow fire to burn out. Do not use
water to put out a fire in this or another electrical
appliance.
• To prevent household circuit breakers from tripping, keep
electric controller dry and do not use other electrical products
on the same circuit.
• Check grease cup to make sure it is empty and is mounted
under the drain hole.
To avoid electrical shock disconnect electric cord
and remove electric controller before removing
heating element and cleaning grill. Never immerse
electric controller or heating element in any liquid.
• For stick-free cooking, apply a thorough coating of vegetable
oil or vegetable oil based spray to the cooking grate.
Turning Grill On
• Ensure electrical controller is turned fully counterclockwise
to OFF position.
To avoid the possibility of burns be sure grill is cool
before removing and/or cleaning electric controller
and heating element.
• Plug power supply cord into a properly grounded, GFI
protected outlet. If extension cord must be used refer to
"Extension Cord Use and Safety" on page 4 of this manual.
• With controller fully seated in grill, turn knob clockwise.
Indicator light should come on.
Preheating the Grill
• Keep lid closed.
• Preheat for searing, 15 - 20 minutes with controller set to
MAX. (See illustration below)
• For foods requiring a lower cooking grate temperature use a
setting lower than maximum. See cooking chart.
• When the controller light turns off, the maximum temperature
has been reached for that knob setting. During use this
light will cycle on and off.
Do not use sharp or pointed tools to clean grill.
These type cleaning tools may tear or puncture the
insulation bowl.
Do not use abrasive oven cleaners, steel wool or
metal brushes to clean porcelain grates or grill body.
These will damage the finish.
Replace damaged insulation bowl(s) only with
Char-Broil certified replacement parts. Do not
attempt to repair damaged parts.
OFF
MAX
Align settings on controller knob with light/pointer
on controller casing as shown above.
12 • 4654870
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Grilling
Cleaning Your Grill
Excess build up of burned grease and food particles will reduce
the grill's cooking performance. To obtain optimum performance:
• For best results, cook with lid on the grill to hold in heat and
provide thorough cooking.
• Temperature gauge on the lid indicates approximate
cooking temperature inside the grill.
• Clean the lower insulation bowl at least once a season, more
often with heavy use.
Note: Insulation bowl will darken as it becomes seasoned.
Do not attempt to restore a shiny or aluminum appearance
when cleaning.
• Best results are obtained by brushing particle buildup
downward and through drain hole in bottom of grill.
• Using a mild detergent or hot soapy water, moderately scrub
surface of the lower insulation bowl with a plastic or brass
bristle brush.
• During initial cooking phase it is common for the gauge to
show the temperature falling below original preheat value.
As time continues temperature will rise somewhat,
indicating food is being properly heated and cooked.
• Controller settings for various foods are dependant upon
conditions and personal cooking preferences. Refer to page
15 for guidelines.
Controlling Grease Fires
• Clean porcelain grates regularly with warm soapy water or a
baking soda and water solution. Use nonabrasive scouring
powder for stubborn stains.
• Clean porcelain lid and body with a nonabrasive cleaner.
Use Creme of Tartar for stubborn stains.
Although some flare-up is desirable as burning juices give meat
that char-broiled flavor; too much flare-up can result in a fire
hazard and overcook meat. To aid in controlling grease fires use
the following precautions:
• Replace ceramic briquets as frequently as necessary to avoid
grease buildup and flare-ups.
• Keep grill free from grease; chance of fire is greatly increased
by grease buildup.
• Replacement of flavorized ceramic briquets will restore
hickory smoke and charcoal flavor.
• Use 10 ceramic briquets maximum. Replace or remove
greasy briquets to avoid grease fires.
• Removing briquets and grate, or reducing number of briquets
to 5 will decrease chances of flare-up.
Storing Your Grill
• Trim excess fat off meat and use less fatty cuts of meat to
reduce chance of grease fires.
• If flare-up occurs during cooking reduce controller setting
and close lid.
• If flare-up continues turn controller to OFF and unplug the
power cord.
• Clean cooking grates and discard old briquets.
• Remove electric controller from grill. Store controller
indoors.
• Store grill in weather protected area or under grill cover when
not in use.
Food Safety
Turning Grill Off
• Turn controller knob fully counterclockwise to OFF position.
• Unplug cord from outlet.
• 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:
• Remove controller from grill and store indoors.
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.
Cleaning Electrical Controller and Heating Element
Bracket
• DO NOT IMMERSE IN WATER
• Clean controller case by wiping with a damp cloth using a
mild detergent or hot soapy water.
• It is not necessary to clean the heating element. However, the
element bracket may be cleaned with a damp cloth using a
mild detergent or hot soapy water.
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 (202) 720-
3333. 10:00 am - 4:00 pm Eastern time.
• Dry electrical controller and heating element before use.
4654870 • 13
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Troubleshooting
Explanation / Possible Cause
Problem
Prevention / Solution
Controller turned off.
No Power.
Grill not heating
Turn controller knob to maximum setting.
Be sure controller is fully seated in heating element bracket
and grill is properly plugged into outlet.
Check for tripped household circuit breakers or GFI (Ground
Fault Interrupter). Reset or replace if necessary.
Try another outlet.
Faulty controller or heating element.
Power Surge
Replace controller or heating element.
Circuit breaker trips
or fuse blows
Turn controller to OFF position before plugging into electrical
outlet.
Another appliance plugged into same circuit as grill.
Moisture or water in controller or electrical connections
Do not use other electrical appliances on the same circuit.
Keep controller and all electrical connections dry. Do not
operate unit when raining.
Damaged cord or electrical connections.
Lid off of grill.
Replace damaged controller or extension cord.
Place lid on grill while cooking.
Grill will not cook
properly
Insufficient preheat or temperature set too low.
Inappropriate extension cord.
Excessive buildup on insulation bowl.
Too many ceramic briquets.
Excess fat in meat.
Preheat 15-20 minutes. Increase controller setting.
Replace with appropriately rated cord (15 amps)
Clean lower insulation bowl.
Use 10 ceramic briquets maximum.
Flare-ups
Trim fat from meat before grilling.
Excessive cooking temperature.
Grease build up.
Adjust (lower) temperature as needed.
Clean grill and replace briquets (10 maximum).
Increase knob setting or wait for light to cycle on.
See "Grill not heating."
Normal controller cycling.
No power.
Controller indicator
light is OFF.
Faulty controller
Replace controller or heating element.
Grease trapped by food build up.
Persistent grease fire.
Turn controller knob to OFF. Keep lid on and let fire burn out.
After grill cools, remove briquets and clean insulation bowl.
Grease soaked briquets.
Replace with fresh briquets.
Do not apply water to fire.
Personal injury may result.
DO NOT RETURN YOUR GRILL TO THE STORE.
CALL:
1-800-241-7548
(
(
14 • 4654870
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Cooking Chart
Cooking Zones
First preheat on HIGH to maximum sustained temperature.
Cooking times and temperatures may vary according to specific
recipes, cooking conditions, or barbecue equipment used. Take Then place food on grill and adjust controller to obtain
this into consideration to insure best results.
desired temperature on cooking chart below.
INITIAL SETTINGS:
Zone II
Zone I
Zone II
TIME
ITEM
SIZE / QUANTITY
TEMPERATURE
ZONE
Rare: 7-10 minutes
Medium: 12-15 minutes
Well: 18 - 20 minutes
Steak
(T-bone, ribeye, sirloin,
filet mignon, etc.)
1 inch
500°F - 600°F
500°F - 600°F
450°F - 500°F
350°F - 450°F
I
Rare: 6 - 7 minutes
Medium: 8 - 10 minutes
Well: 12 minutes
Steak
(T-bone, ribeye, sirloin,
filet mignon, etc.)
1/2 inch
1/2 inch
1 inch
I
I
Medium: 8 minutes
Medium/Well: 10 minutes
Well: 12 minutes
Hamburgers
25 minutes
Pork Chop
Pork Chop
*
Marinade
Internal temp. 160O F
Dry Rub
I II
IDry Rub II*
IDry Rub II*
IDry Rub II*
20 minutes
1/2 inch
350°F - 450°F
350°F - 375°F
Marinade
Marinade
Marinade
10 minutes per side
Boneless, Skinless,
Chicken Breast
8 ounces
10 minutes per pound
Internal temp. 180O F
Whole Chicken
1 each
350°F - 375°F
350°F - 450°F
Rare: 7 minutes
Medium: 12 minutes
Well: 15 minutes
Tuna/Sword Fish
1 inch - 8 ounces
II
8 - 12 minutes
3 - 5 minutes
Whole Rainbow Trout Filet 8 ounces
350°F - 450°F
400°F - 425°F
II
II
Shrimp, Medium,
8 ounces
peeled and deveined
30 minutes
1 hour
Corn on Cob
1 each
350°F - 400°F
350°F - 400°F
350°F - 400°F
350°F - 400°F
350°F - 400°F
350°F - 400°F
II
II
II
II
II
II
1 each
Baking Potatoes
Mushrooms, Button, Whole
Yellow Onions
6 minutes
8 ounces
1 each
12 - 15 minutes
15 minutes
8 - 10 minutes
Half
Tomatoes
1 medium size
Zucchini/Yellow Squash
and Eggplant
* Increase cooking time 5 minutes or to desired doneness.
4654870 • 15
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2
3
1
4
5
8
Lid features 3 stainless
hanger brackets for hands-
free storage when lid is
removed.
6
NOTE: ALWAYS COOK WITH
LID ON.
10
9
7
11
NOTE: For transport, lift and
pull front handle while rolling
on transport wheels.
12
KNOW YOUR GRILL
1
2
3
4
5
6
7
8
9
Porcelain coated lid and bottom
Porcelain coated deluxe wire grate
Electrical heating element with stainless element bracket
Removable electric controller with power "on" light
Temperature control knob
Insulation bowl (top bowl not shown)
Temperature gauge
Stainless lid hanger brackets for temporary lid storage (as shown)
Grease cup
10 Charcoal Flavorized Ceramic BriquetsTM
11 Transport wheels
12 Front handle for transport
16 • 4654870
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