Char Broil Gas Grill 4638220 User Manual

Natural Gas Grill  
4638220  
ASSEMBLY, USE AND  
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  
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.  
If you have any questions or need  
assistance during assembly, please  
call 1-800-241-7548.  
Visit us on the web at:  
WARNING  
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.  
4638220 / 0–4165056 (01-04-02)  
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Table of Contents  
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), as follows:  
(1) The aluminum top and bottom castings for the life of  
original purchase, excluding the paint finish;  
(2) The burner/venturi assembly for a period of three (3)  
years from the date of purchase; and  
For Your Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
Call Grill Service Center for Help and Parts. . . . . . . . . . . . . 2  
Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
Installation Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . 2  
Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  
Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10  
Connecting Your grill to the Natural Gas Source . . . . . . . . . 11  
Use & Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-15  
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16  
(3) All other parts for a period of one (1) year from the  
date of purchase.  
Manufacturer will, at its option, refinish or 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 refinishing or 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.  
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; 6,279,566; 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; and D449,492. Other Patents Pending.  
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.  
4638220 • 3  
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Parts List - Model 4638220  
Key Qty. Description  
Part #  
Key Qty. Description  
Part #  
A
B
C
D
E
F
G
H
I
1
1
1
1
1
1
Warming Rack . . . . . . . . . . . . . . . 4152125  
Cooking Grate . . . . . . . . . . . . . . . 4152741  
Leg Extender Assembly . . . . . . . . 4154468  
Handle . . . . . . . . . . . . . . . . . . . . . 4154488  
Drip VapoRISER Bar . . . . . . . . . . 4156418  
Wheel Assembly . . . . . . . . . . . . . 4158100  
W
X
Y
Z
1
1
1
1
1
1
Side Shelf, Left. . . . . . . . . . . . . . . 4154456  
Grill Lid. . . . . . . . . . . . . . . . . . . . . 4581964  
Logo Plate Assembly . . . . . . . . . . 4157147  
Grease Clip . . . . . . . . . . . . . . . . . 5156607  
12’ Natural Gas Hose. . . . . . . . . . 4158033  
Hardware Bag . . . . . . . . . . . . . . . 4253990  
- - - Briquets (1 bag) . . . . . . . . . . . . . . 4158125  
Replacement Ignition Module Bag . . . . . . . . 4506709  
1
1
6
1
2
2
2
1
1
2
1
1
8
1
4
Brace . . . . . . . . . . . . . . . . . . . . . . 4502155  
Front Panel . . . . . . . . . . . . . . . . . 4503076  
#10x1/2”, T-20, Self-Tap Screw . . 4080043  
Briquet Grate . . . . . . . . . . . . . . . . 4151002  
Valve Clip. . . . . . . . . . . . . . . . . . . 4156172  
Casting Seat Bracket . . . . . . . . . . 4500222  
Leg Assembly. . . . . . . . . . . . . . . . 4502156  
Burner/Collector Assembly. . . . . . 4505069  
Control Panel Assembly. . . . . . . . 4530074  
Control Knob . . . . . . . . . . . . . . . . 4154470  
Grill Bottom . . . . . . . . . . . . . . . . . 4580149  
Back Panel. . . . . . . . . . . . . . . . . . 4502064  
#10x1-1/4” Self-Tap Screw. . . . . . 4080041  
Side Shelf, Right . . . . . . . . . . . . . 4154459  
Shelf Arm . . . . . . . . . . . . . . . . . . . 4502121  
J
K
L
M
N
O
P
Q
R
S
T
U
V
4 • 4638220  
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X
D
Y
A
E
O
P
O
O
U
B
G
V
T
V
R
T
K
W
H
S
J
M
P
N
V
J
T
J
Z
M
V
Q
J
P
N
T
L
P
L
I
F
C
4638220 • 5  
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Remove end of rating label located on your  
grill’s back panel (see parts list to identify)  
and apply to your warranty card in box #5.  
If label cannot be removed, write the numbers  
on your warranty card.  
1
This label contains the model and serial number for your grill. You  
should also write this information on page 2 of this manual in the  
“Warranty Information” box.  
1ST  
2
2ND  
Qty. 4  
1. Unfold legs to position shown,  
laying grill ON ITS BACK.  
3RD  
IMPORTANT:  
Place top of front panel UNDER  
control panel. Rest lower portion  
of panel on legs, aligning panel  
holes with leg holes.  
Top edge of front  
panel fits  
UNDER  
Qty. 4  
control panel.  
2. Attach panel and brace with four  
bolts and nuts. BRACE  
ATTACHES TO RIGHT  
SIDE.  
NOTE: To prevent scratching, lay grill on packing material to assemble.  
6 • 4638220  
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3
2ND  
Text to  
inside  
Tab  
Qty. 4  
Press  
Notch  
1. Stand grill upside down and  
attach back panel to legs and  
brace with four bolts and nuts.  
2. Facing back of grill, depress  
buttons and snap leg extender  
assembly into right legs and  
wheel assembly (text facing  
inward) into left legs.  
Qty. 4  
1ST  
IMPORTANT: Align tabs with  
notches in legs.  
1. Place 16 briquets onto briquet grate.  
Arrange briquets as shown below.  
4
2. Position Drip VapoRISER Bar as shown  
and place above burner, resting on  
supports at each end of grill bottom.  
Do not let briquets  
cover burner port holes.  
2ND  
1ST  
Briquet Placement  
FRONT  
BACK  
BACK  
FRONT  
4638220 • 7  
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Hinge pin only  
Hinge pin  
and hitch pin  
5
You may have:  
2ND  
OR  
3RD  
1. Place lid onto grill bottom.  
Attach with two hinge pins.  
Qty. 2  
2. Insert handle into grill lid.  
Attach with two wing nuts.  
3. Be sure clips are attached  
to logo plate posts. Snap  
logo plate into grill lid.  
1ST  
Qty. 2  
1. Insert pivot wire of SwingAway  
into grill lid. Flex leg wires to  
insert into grill bottom (see inset).  
6
2. Place cooking grate into  
grill bottom.  
1ST  
Leg  
wire  
Back of  
SwingAway  
pointing  
upward.  
Pivot  
wire  
2ND  
8 • 4638220  
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1. Install side shelves by sliding shelf tubes over ends of leg tubes. Press firmly so that holes are aligned.  
Secure with one push-fastener on each leg.  
7
Qty. 4  
1. Hang grease clip from center of grill bottom. Use an empty soup can  
(not included) to hang from grease clip.  
8
Center of  
grill bottom  
Grease clip  
CAUTION  
• Failure to install can in clip will cause hot grease to drip  
from bottom of grill with risk of fire or property damage.  
4638220 • 9  
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1. Beneath control panel, attach  
12’ natural gas hose to valve.  
9
2. Tighten the connection with  
an adjustable wrench.  
3. LEAK TEST AS SHOWN ON  
PAGE 12 BEFORE USING GRILL.  
10 • 4638220  
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Connecting Your Grill to the Natural Gas Source  
1. Coat pipe nipple with gas resistant dope. Screw socket onto  
gas manifold at gas source (A).  
With proper assembly, plug cannot be removed without  
pushing sleeve back. To disconnect, push sleeve back and pull  
plug out of sleeve (this automatically shuts off gas).  
2. Connect unattached end of natural gas hose to socket. Push  
sleeve back on socket (B) and insert plug until sleeve snaps  
forward, locking plug into socket.  
Please Note: Hose and assembly are A.G.A. Certified and  
C.G.A. Listed for natural gas, manufactured gas, mixed gas  
and for liquefied petroleum and for LP Gas-Air mixtures on  
basis of 0.64 specific gravity for 1000 BTU’s per cubic foot of  
gas at 0.3 in. Water column pressure drop. Only ANSI Z21.54  
approved hoses should be used with this grill.  
When socket and plug are connected, valve in socket opens  
automatically to permit full gas flow. When coupling is  
disconnected, valve in socket instantly and positively shuts off  
flow of gas. Because valve in socket positively shuts off flow  
of gas, grill can be disconnected from gas source by  
disconnecting hose from socket. Socket can be left on  
manifold of gas source if so desired.  
The appliance and its individual shut off valve must be  
disconnected from the gas supply piping system during any  
pressure testing of that system at test pressures in excess  
of ½ psig (3.5kPa).  
The appliance must be isolated from the gas supply piping  
system by closing its individual manual shut off valve during  
any pressure testing of the gas supply piping system at test  
pressures equal to or less than ½ psi (3.5 kPa).  
WARNING  
• Connection to gas source must be done by a certified  
Plumber.  
WARNING  
• Do not use hard metal piping of any kind to connect this  
type of grill to natural gas source. Use ONLY hose  
specified by manufacturer. Using hard metal piping is  
an unsafe practice. Movement of the grill can cause  
Breakage of metal pipe.  
A
Pipe Nipple  
Socket  
Sleeve  
Gas  
Flow  
Hose  
Plug  
Insert cover in socket  
when hose is removed  
Gas Manifold  
Push sleeve back to attach  
B
Socket  
Plug  
4638220 • 11  
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WARNING  
• Do not use grill until leak checked.  
• If leak is detected at any time, STOP and call the Fire  
Department.  
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.  
Do not block holes in bottom or back of grill.  
Check burner flames regularly.  
• If you cannot stop a gas leak, immediately close LP tank  
Valve and call LP gas supplier or your fire department!  
Use grill only in well-ventilated space. NEVER use in  
enclosed space such as carport, garage, porch, covered  
patio, or under a surface that can catch fire.  
Do not use charcoal in a gas grill.  
Leak Testing Valve and Hose  
1. Turn all grill control knobs to OFF.  
2. Check to make sure grill is connected to natural gas source  
and gas supply is turned on.  
3. Brush a soapy solution onto areas and connections shaded  
In illustration below.  
• 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 Never remove opening  
at end of valve.  
• Apartment Dwellers:  
Check with management to learn the requirements and fire  
codes for using an Gas Grill in an apartment. 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 made  
of wood.  
4. “If growing” bubbles appear, there is a leak. Turn gas off at  
control knobs and gas source 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.  
• NEVER attempt to light burner with lid closed. A  
buildup of non-ignited gas inside a closed grill is  
hazardous.  
Safety Tips  
s When grill is not in use, turn off all control knobs and gas  
source.  
s Never move grill while in operation or still hot.  
s Use long-handled barbecue utensils to avoid burns and  
splatters.  
s Maximum load for side shelves is 10 lbs.  
s A soup can must be attached to grease clip and emptied  
after each use. Do not remove soup can until grill has  
completely cooled.  
s If you notice grease or other hot material dripping from grill  
onto valve or hose, turn off gas supply at once. Determine  
the cause, correct, clean and inspect valve and hose before  
continuing. Perform a leak test.  
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 gas  
source off.  
• Do not leave grill unattended while preheating or  
burning off food residue on high. If grill has not been  
regularly cleaned a grease fire can occur that may  
damage the product.  
Before Your First Cookout  
s If you have a grill problem see the "Troubleshooting  
Section".  
• Light burners, check to make sure they are lit, 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.  
12 • 4638220  
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Ignitor Lighting  
s Do not lean over grill while lighting.  
1. Open lid. Turn on gas at gas source.  
Valve Check  
• Important: Make sure gas is OFF at gas source 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. Turn LEFT knob to  
3. Push IGNITOR Button  
lights and stays lit.  
IGNITE.  
rapidly to light. Be sure burner  
4. If burner does not light turn knob(s) to OFF, wait 5 minutes  
and try again.  
5. Turn RIGHT knob to IGNITE to light other burner.  
6. If IGNITOR does not work, follow match lighting instructions.  
Hose Check  
Before each use, check to see if hose is cut or worn. Replace  
damaged hoses before using grill. Use only valve and hose  
specified by manufacturer.  
After Lighting: Turn knob to HIGH position for warm-up. Do not  
warm up grill with knobs on IGNITE. Knobs and handle will  
become uncomfortably hot if left in IGNITE positions.  
CAUTION  
Clean burner prior to use after storing, at the beginning  
of the grilling season or after a period of one  
month not being used. Spiders and insects  
like to build nests in burner tubes  
Match Lighting  
s Do not lean over grill while lighting.  
1. Open lid. Turn on gas at gas source.  
2. Place lit match into match lighting  
hole from outside grill bottom (as  
shown).  
(especially during colder months).  
These nests can cause fires in  
3. Push in and turn RIGHT knob to  
Match  
IGNITE. Be sure burner lights and  
stays lit.  
4. Light left burner by pushing LEFT  
knob in and turning to IGNITE.  
burner tubes or under grill.  
See following pages for specific  
cleaning instructions.  
Typical spider webs  
inside burner  
lighting  
hole is in  
bottom  
or side  
General Grill Cleaning  
After Lighting: Turn Knob to HIGH for warm-up.  
• 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 to insides of grill lid and bottom. Rinse and allow  
to completely air dry. Do not apply a caustic grill/oven  
cleaner to painted surfaces.  
CAUTION  
• If burner does not light, turn knobs to OFF. Wait 5  
minutes and try again. If the burner does not ignite with  
valve open, gas will continue to flow out of the burner  
and could accidently ignite with risk of injury.  
• Plated wire grate: Wash grate and drip vaporiser bar with  
concentrated grill cleaner or use soap and water solution. Dry  
thoroughly and store indoors between cookouts.  
HIGH  
Burner Flame Check  
• Light burner, rotate knobs  
LOW  
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.  
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.  
• Porcelain grate: 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.  
Turning Grill Off  
• Turn all knobs to OFF position. Turn gas OFF at gas source.  
Ignitor Check  
• Stainless Steel: Wash with mild detergent or nonabrasive  
cleaner and warm soapy water, wipe dry with a soft  
nonabrasive cloth  
• Turn gas off at gas source. 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.  
• Briquet grate: This grate will eventually decompose and  
weaken with use. Remove grate from grill and tap to loosen  
any scaling. Brush grate vigorously with a wire brush to  
remove any additional scaling, rust or residue.  
4638220 • 13  
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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 gas source.  
2. Remove cooking grate and drip vaporiser bar.  
3. Discard used briquets before removing burner and briquet  
grate.  
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, hold briquet grate and  
burner together angle into grill bottom (D).  
4. Under grill remove grease cup and disconnect short ignitor  
wire (A) and clips from burner (B). To remove clips pull down  
on large end of clip attached to the valve, turn away from  
valve, rotate upward and remove small end of clip from  
burner tube.  
9. To reattach clips hold large curved end away from burner  
tube, insert small curved end into hole under burner tube,  
turn clip towards valve, snap into place.  
VERY IMPORTANT: Clips must be attached correctly for  
proper grill function (B).  
5. Inside grill remove burner assembly and briquet grate (C),  
clean ceramic portion of electrode with rubbing alcohol and a  
swab. Remove scale from briquet grate, replace if  
necessary.  
10. Reattach ignitor wire to ignitor (A).  
11. Do not use more than 16 new briquets on briquet grate  
around burner. Do not let briquets cover burner holes.  
12. Reposition drip vaporiser bar and cooking grate. Reattach  
clean can to grease clip.  
6. 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.  
13. Before cooking again on grill, follow "Burner Flame Check".  
Briquet Grate  
D
Burner  
Electrode  
Valve  
Clip  
Burner  
Tube  
B
C
A
Short Ignitor Wire  
14 • 4638220  
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Cooking Chart  
Food Safety  
Cooking times and temperatures may vary according to specific  
recipes, cooking conditions or barbecue equipment used. Take  
these factors into consideration to insure best results. If you use  
the indirect cooking method (lighting only one burner and placing  
food on opposite side of cooking grate), allow more grilling time.  
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.  
Temperatures: High = 650 F° / Medium = 450 F° / Low = 300 F°  
Food  
Setting  
Cooking Time  
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.  
Beef  
Hamburger ½” thick  
Medium  
Med: 7-10 min/Well: 10-15 min  
Steak ½”  
Roast  
Medium-Hot Rare: 3-6 min/Med: 6-9 min/Well: 9-12 min  
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  
Low  
Rare: 18-22 min per lb/Med: 22-28 min  
per lb/Well: 28-32 min per lb  
Pork  
Chops ½”  
Medium  
Well: 15-20 min  
How to Tell if Meat is Grilled Thoroughly  
Ribs 5-6 lbs.  
Roast 3-5 lbs.  
Ham Steak ½”  
Low-Medium Well: 45-90 min  
Low-Medium Well: 18-23 min per lb  
Medium-Hot 12-15 min  
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.  
Ham 5 lb. fully cooked Low-Medium 20 min per lb  
Whole poultry should reach 180 F°; breasts, 170 F°. Juices  
should run clear and flesh should not be pink.  
Lamb  
Chops ½”  
Medium  
6-12 min  
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°.  
Poultry  
Chicken 2½-3½ lbs.  
Low  
Low  
1 hr, 15 min to 1 hr, 30 min  
40-60 min  
Chicken halved or  
quartered  
NEVER partially grill meat or poultry and finish cooking later.  
Cook food completely to destroy harmful bacteria.  
Low-Medium 18-20 min per lb  
Turkey  
Seafood  
Steaks 1” thick  
Medium-Hot Well: 10-15 min  
Medium-Hot 8-12 min  
Low-Medium 8-12 min  
When reheating takeout foods or fully cooked meats like hot  
dogs, grill to 165 F°, or until steaming hot.  
Fillets 6-8 oz.  
Shrimp large or jumbo  
Storing Your Grill  
Venison  
Steak 1” thick  
Medium  
Medium  
Rare: 8-10 min/Med: 10-12 min  
Rare: 10-12 min/Med: 12-15 min  
Clean cooking grate and discard old briquets.  
Store in dry location.  
Burgers ½”  
Cover grill if stored outdoors. Choose from a variety of grill  
covers offered by Char-Broil.  
Low-Medium Rare: 20-22 min per lb/Med: 22-25 min per lb  
Roast 3-4 lbs.  
Storage of grill indoors is permissible ONLY if gas source is  
disconnected.  
Vegetables  
Wrap vegetables in foil  
When removing grill from storage, follow “Cleaning Burner  
Assembly” instructions before starting grill.  
Low  
55-60 min  
45 min  
Baking potato, whole  
Onions, whole  
Tomatoes, half  
Corn, whole  
Low  
Medium  
Low  
30-40 min  
35-45 min  
15-20 min  
Medium  
Mushrooms  
4638220 • 15  
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Troubleshooting  
Problem  
Possible Cause  
Prevention/Cure  
Burner will not light Wire and/or electrode  
using ignitor.  
Clean wires and/or electrode with rubbing alcohol and clean swab.  
covered with cooking residue.  
Electrode and burner are wet. Wipe dry with cloth.  
Electrode cracked or broken,  
“sparks at crack”.  
Replace electrode.  
Wire is loose or disconnected. Reconnect or replace ignitor wire.  
Wire is shorting (sparking)  
between ignitor and electrode.  
Replace ignitor wire.  
Bad ignitor.  
Replace ignitor.  
Burner(s) will not  
match light.  
No gas flow.  
Turn gas on at source.  
Clean burner tubes.  
Reengage burner and valve.  
Obstruction of gas flow.  
Disengagement of burner to  
valve.  
Is grill assembled correctly?  
High or gusting winds.  
Grease buildup.  
Check assembly steps in manual.  
Turn front of grill to face wind or increase flame height.  
Clean grill.  
Flames blow out.  
Flare-up.  
Excessive fat in meat.  
Trim fat from meat before grilling.  
Excessive cooking temperature. Adjust (lower) temperature accordingly.  
Persistent grease  
fire (can damage  
the appearance of  
steel panels and  
aluminum castings  
on the grill).  
Grease trapped by food Turn knobs to OFF. Turn gas off at gas source. Leave lid in position and  
buildup around burner system. let fire burn out. After grill cools, remove and clean all parts.  
Grease soaked into briquets.  
Replace briquets. If cooking with fatty meats, remove briquets.  
Flashback...  
(fire in burner tube(s)  
Burner and/or burner tubes are Clean burner and/or burner tubes.  
blocked.  
16 • 4638220  
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