ASSEMBLY,USE AND CARE MANUAL
466231203
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.
If you have any questions
or need assistance
during assembly,
please call
CAUTION
Some parts may contain
sharp edges - especially
as noted in the manual!
Wear protective gloves
if necessary.
1-800-241-7548 U.S
1-800-387-6057 CAN
Visit us on the web at:
466231203 / P80112002A (04-15-03)
4
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Table of Contents
Warranty
Char-Broilwarrantstotheoriginalconsumer-purchaserthat
thisproduct shallbefreefromdefectsinworkmanshipand
materialsundernormalandreasonableuseandcorrect
assembly(ifassembledbyconsumer-purchaser),fromdateof
purchase.
For Your Safety ......................................................................... 2
Call Grill Service Center For Help And Parts ........................... 2
Installation Safety Precautions ................................................. 2
Safety Symbols ......................................................................... 2
Table of Contents ..................................................................... 3
Warranty.................................................................................... 3
Before Beginning Assembly ..................................................... 4
Parts List ................................................................................... 4
Exploded View .......................................................................... 5
Assembly ................................................................................ 6-9
Use and Care ........................................................................ 9-14
Storing Your Grill ..................................................................... 13
Indirect Cooking ...................................................................... 14
Food Safety.............................................................................. 14
Troubleshooting ...................................................................... 15
Stainless steel and die cast parts - 99 years
Electronic ignition and burners - 10 years
Remaining parts - 2 years
Char-Broil will, at its option, refinish or replace any
product or part found to be defective during the warranty
period. Char-Broil will require you to return the part(s)
claimed to be defective, for its inspection, freight or postage
prepaid.
Ifyouwishtoobtainperformanceofanyobligationunderthis
limited warranty, you should write to:
CHAR-BROIL
Consumer Warranty / P.O. Box 1240
Columbus, GA 31902-1240
Char-Broilmayrequirereasonableproofofpurchaseand
wesuggestyoukeepyourreceipt. InthestateofCaliforniaonly,
ifrefinishingorreplacementoftheproductisnotcommercially
practicable,theretailersellingthisproductorChar-Broilwill
refundthepurchasepricepaidfortheproduct,lesstheamount
directlyattributabletousebytheoriginalconsumer-purchaser
priortodiscoveryofthenonconformity.Inaddition,inthestateof
Californiaonly,youmaytaketheproducttotheretail
establishmentfromwhichitwaspurchasedortoanyretail
establishmentsellingthisproductinordertoobtainperformance
underthiswarranty.
Thiswarrantydoesnotincludethecostonany
inconvenienceorpropertydamageduetofailureoftheproduct
anddoesnotcoverdamageduetomisuse,abuse,accident,
damagearisingoutoftransportationoftheproduct,ordamage
incurredthroughcommercialuseoftheproduct.Thisexpress
warrantyisthesolewarrantygivenbythemanufacturerandisin
lieuofallotherwarranties,expressorimplied,includingimplied
warrantyofmerchantabilityorfitnessforaparticularpurpose.
NeitherChar-Broildealersnortheretailestablishmentsellingthis
producthasanyauthoritytomakeanywarrantiesortopromise
remediesinadditiontoorinconsistentwiththosestatedabove.
Char-Broil'smaximumliability,inanyevent,shallnotexceedthe
purchasepriceoftheproductpaidbytheoriginalconsumer-
purchaser.Somestatesdonotallowtheexclusionorlimitationof
incidentalorconsequentialdamages.Sotheabovelimitationsor
exclusionsmaynotapplytoyou.Thiswarrantygivesyouspecific
legalrightsandmayalsohaveotherrightswhichvaryfromstate
tostate.
466231203 • 3
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Before Beginning Assembly
Parts List - 466231203
Key Qty Description
Part #
• Necessary tools for assembly of your grill include:
Phillips® screwdriver, pliers and adjustable wrench.
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
1
1
1
1
1
1
1
2
3
1
3
1
3
1
1
1
1
1
1
1
1
1
1
3
1
1
3
3
4
1
1
1
2
1
2
1
2
1
1
2
2
2
1
1
1
1
4
4
1
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
Lid Plate
P00118036A
P00105037K
P00106037K
P00601181A
P00202012A
P00403003H
P01505007E
P01615003E
P01705005E
P05702002E
P02001031E
P02203052B
P02609002B
P02615062A
P02502024C
P00720011A
P00721011A
P00724014A
P00725014A
P00728051A
P02705084B
P02701015B
P05003062A
P03222024B
P03007032B
P02P07501A
P03411111G
P03415041J
P05504017E
P01102013D
P01103012D
P01204004C
P01206003C
P01207002C
P07503001B
P01003006D
P07604002B
P07702002B
P03301001D
P04301002A
P00214006A
P01306002D
P00910005C
P00911005C
P00912005C
P00913005C
P04507003A
P05106003D
P04009005C
P04010006C
P00210004D
P05516003C
P0011508AA
P00201008A
P00814002D
P02614007C
P02002003D
P03218102G
P03401031F
P03702002A
P03601004A
P05301001A
P07502001B
P03408051J
P05507031E
P05515002C
P05515014F
P06004004A
P80112002A
Lid Side Panel, Left
Lid Side Panel, Right
Heat Indicator
Plastic Lid Handle
Logo Plate
Warming Rack
Cooking Grid
Flame Tamer
Griddle
Burner
Burner Support Bracket
Gas Collector Box with Electrode
Electric Wire set
Electric Ignitor (4 port)
Bowl Side Panel, Left
Bowl Side Panel, Right
Bowl Front Panel
Bowl Rear Panel
Rear Wind Shield
Grease Draining Tray
Grease Receptacle
Gas Manifold
Gas Valve for Main Burner
Heat Shield for Control Panel
Control Panel
Control Knob
Control Knob Seat
Spring
Sideburner Frame (Left)
Side Shelf, Right
Bracket for Side Shelf - Left Front
Bracket for Side Shelf - Left Rear, Right Front
Bracket for Side Shelf - Right Rear
Front Panel, Side Shelf, Left
Cart Bottom Shelf
Cart Side Panel
Z
AA
BB
CC
DD
EE
FF
GG
HH
I I
JJ
KK
LL
MM
NN
OO
PP
QQ
RR
SS
TT
UU
VV
WW
XX
YY
ZZ
AAA
BBB
CCC
DDD
EEE
FFF
GGG
HHH
I I I
JJJ
KKK
LLL
Cart Rear Panel
Door Bracket
Door Front Plate
Door Handle
Bowl Support Bracket
Left Side Cart Leg, Front
Left Side Cart Leg, Rear
Right Side Cart Leg, Front
Right Side Cart Leg, Rear
Caster Seat
3" Caster
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 theThermos Company and its affiliates.
Pull-Out Tank Tray
Bracket for Pull-Out Tank Tray
Handle for Pull-Out Tank Tray
Slide Set
Sideburner Lid
Lid Knob for Sideburner
Pot Support
Electrode
Sideburner
Gas Valve for Sideburner
Control Knob
Connection Tube
Regulator with Hose (27")
AA Battery
Front Panel, Side Shelf, Right
Sideburner Control Knob Seat
Match Lighting Stick with Chain
Caster Wrench
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™,
TheTuscan Collection™, andThe Urban Grill™ areTrademarks 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;andD449,492.
Other Patents Pending.
MMM 1
1
1
1
1
Grate Lifter
Hardware Pack
Owner's Manual
4 • 466231203
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Exploded View - 466231203
B
A
D
F
G
C
E
J
H
T
S
P
I
M
K
K
M
R
M
L
Y
Q
BBB
N
AAA
W
CCC
DDD
X
JJJ
EEE
DD
O
BB
GGG
GG
Z
PP
CC
LLL
I I
FF
U
AA
KK
CC
V
HHH
FFF
I I I
RR
VV
QQ
LL
PP
TT
UU
MMM
UU
VV
XX
YY
ZZ
KK
JJ
XX
SS
ZZ
W W
MM
UU
HH
NN
VV
UU
VV
GG
OO
NN
E E
OO
KKK
466231203 • 5
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4. Screw the 4 casters into the caster seats in the bottom of
each cart leg. Turn the threaded caster stem by hand,
clockwise until it stops. Fully tighten with the wrench
provided. See Fig. 2.
Assembly - 466231203
• Unpack and remove all protective packaging.
1. Position bottom shelf with the 4-hole pattern to the left side.
5. Install the two side panels and one rear panel to the cart by
using 4 of the 3/16x3/8" Phillips-head screws on each
panel. Leave rear panel screws loose. See Fig. 2.
See Fig. 1.
VERY IMPORTANT: The labels on the cart legs
indicate their assembly position to the bottom shelf. LF=Left
Front, LR=Left Rear, RF=Right Front, and RR=Right
Rear. Labels should face inward toward each other when
correctly assembled. Remaining components cannot be
assembled if leg positions are incorrect.
FIGURE 2
Side
panel
Rear
panel
2. Install the four cart legs to the indicated corners of the
bottom shelf using 8 of the 1/4x2-1/2" Phillips-head screws
provided. Do not fully tighten screws.
3. Install cross braces, facing inward, to cart legs on both
sides using 8 of the 1/4x1/2" Phillips-head screws. Fully
tighten. See Fig. 1.
FIGURE 1
Caster
Side
panel
Cross
Brace
6. USE CAUTION when handling the pull-out tank tray.
Slide rails have sharp edges. Install the handle on the
pull-out tank using 2 of the 1/4" nuts. Fully tighten. See
Fig. 3.
LR
7. Fully extend the pull-out tank tray and attach the slide rails
to the 4-hole pattern in the bottom shelf using 4 of the
1/4x1/2" Phillips-head screws. Fully tighten. See Fig. 3.
LF
Bottom
Shelf
FIGURE 3
4-hole pattern
toward left side
RR
RF
Handle
Slide
Rail
Pull-out
tank tray
6 • 466231203
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8. Attach the door bracket to the lower holes in the front legs
with the end tabs pointing upward and the flange to the rear,
pointing downward. Use 2 of the 1/4x1/2" Phillips-head
screws. Do not fully tighten. See Fig. 4.
FIGURE 5
13. Attach match lighting stick
and chain to the right rear
leg, below shelf bracket,
using one M4x10mm,
9. Place doors into the hinge holes of the bottom shelf and
door bracket. Push door bracket down until doors are
secure and can open and close freely. Do not fully tighten
door bracket screws. See Fig. 4.
self-tapping, Phillips-head
screw. See Fig. 5.
Match
lighting
stick
10. Remove protective film from doors. Install door handles to
doors using 4 of the 3/16x3/8" Phillips-head screws. See
Fig. 4.
To reduce the weight of the grill head, open the grill lid and
remove the packed components. This step requires 2 people
to lift and position the grill head onto the cart.
11. Attach the 4 side shelf brackets to the tops of the cart legs
using 8 of the 1/4x1/2" Phillips-head screws.
IMPORTANT: Bracket with cut-out installs on front left
leg. Be sure the flat side of each bracket faces outward.
Fully tighten. See Fig. 4.
14. HINT: Slide grill head into cart from the front. Use care to
avoid scratching tops of side shelves. Align the 2 holes
beneath the hang ledge on each side of the grill head with
the 2 holes in the side shelf and cross brace on the cart.
Raise the grill lid and insert 4 of the 1/4x3/4" Phillips-head
screws. Beneath the side shelves, add 1/4" nuts. Do not
fully tighten. See Fig. 6.
12. Place the sideburner shelf over the left brackets and cross
brace. Be sure ignitor wire is hanging loose. Be sure the
inside shelf holes align with cross brace holes. Secure
shelf firmly to the ends of the brackets using 2 of the
1/4x1/2" Phillips-head screws. Repeat this procedure for
the side shelf on the right side of the cart. See Fig. 4.
15. Attach heat indicator to grill lid using nut provided. Make
sure graphics on heat indicator are properly oriented before
tightening nut. See Fig. 6.
FIGURE 4
FIGURE 6
Sideburner
shelf
Grill
head
Side
shelf
Hang
ledge
Align
holes
Heat indicator
Bracket with
cut-out
Hang
Gas hose
ledges
rest on
shelves
Lower
hole
Shelf bracket,
flat side facing
outward
Door
bracket
Hinge
hole
Door
Handle
Remove
Hinge
film
466231203 • 7
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16. Firmly attach ignitor wire from sideburner to the ignitor wire
from the grill head. See Fig. 7a. Beneath left shelf, insert
sideburner valve into sideburner tube. See Fig. 7 for
proper engagement. Attach sideburner valve to shelf using
2 of the M4x10 Phillips-head screws and washers. Place
knob seat, spring, and sideburner knob over valve stem.
20. Place your LP gas tank (not included) onto the pull-out tank
tray and push tray into cart. Be sure the tank valve is facing
forward. See. Fig. 9. READ USE & CARE SECTION
BEFORE ATTACHING REGULATOR TO LP TANK.
FIGURE 9
FIGURE 7
Sideburner
tube
Sideburner
Spring
knob
Valve
Seat
LP gas
tank
FIGURE 7a
21. Unscrew the ignitor cap located on the control panel and
remove the contact and spring from the ignitor slot.
See Fig. 10.
Ignitor
wire
Valve
22. Place the supplied AA battery into the ignitor slot with the
positive pole facing toward you.
23. Place the spring with contact over the battery. Screw the
ignitor cap back onto the control panel.
Wire from Grill head
17. Secure grill head to all cart legs using 4 of the 1/4x2-1/2"
Phillips-head screws and 1/4" nuts. See Fig. 8.
FIGURE 10
18. Fully tighten all leg screws, rear panel screws, door
bracket screws, and grill head screws.
Spring
Contact
19. From the back of the cart, slide the grease draining tray into
the grill head. Place the grease receptacle into the notches
on the bottom of the tray. See Fig. 8.
–
Ignitor
+
cap
AA Battery
FIGURE 8
Grease
draining
tray
24. Attach panel to front of sideburner shelf by placing top lip of
panel ABOVE bottom lip of shelf. Secure using three
3/16"x3/8" Phillips-head screws and 3/16" nuts. Fully
Tighten. See Fig. 11.
FIGURE 11
Grease
receptacle
Panel lip
Shelf
lip
Attach grill head
to all 4 legs
8 • 466231203
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25. Place the 3 flame tamers on the lower ledge above
Use and Care
burners. See Fig. 12. They should meet in the center.
LP Tank
26. Place the cooking grids or griddle on the ledge above the
flame tamers.
• The LP tank used with your grill must meet the following
requirements:
• Purchase LP tanks only with these required measurements:
12" (30.5cm) (diameter) x 18" (45.7 cm) (tall) with 20 lb. (9
kg.) capacity maximum.
• Be constructed and marked in accordance with
specifications for LP tank of the U.S. Department of
Transportation (DOT) or for Canada, CAN/CSA-B339,
cylinders, spheres and tubes for transportation of dangerous
goods, Transport Canada (TC). See LP tank collar for
marking.
27. Place the secondary cooking rack into the slots on the
upper left and upper right of the grill bowl panels.
FIGURE 12
Secondary
cooking
rack
Griddle
• LP tank valve must have:
• Type1outletcompatiblewithregulatororgrill.
• Safetyreliefvalve.
Flame tamer
• ULlistedOverfillProtectionDevice(OPD).
ThisOPDsafetyfeatureisidentifiedbya
Lower
Cooking
ledge
uniquetriangularhandwheel.Useonly
OPD Hand Wheel
grid
tanks equippedwiththis type ofvalve.
• Supply system must be arranged for vapor withdrawal and
include collar to protect LP tank valve.
LP (Liquefied Petroleum Gas)
• Isnontoxic,odorlessandcolorlesswhenproduced.ForYour
Safety, LPgas has beengivenanodor(similartorotten
cabbage)sothatitcanbesmelled.
• LP gas is highly flammable and may ignite unexpectedly
when mixed with air.
Before Your First Cookout
LP Tank Filling
• Useonlylicensedandexperienceddealers.
• LP tank must be purged before filling.
•
Perform the leak test as indicated in the use and care
section.
• Dealer should NEVER fill LP tank more than 80% of LP tank
volume.Volumeofpropaneintankwillvarybytemperature.
• 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.
• 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.
•
Wash the cooking grids, griddle, cooking rack, and all
stainless steel surfaces with warm, soapy water. Rinse and
dry thoroughly.
•
Light burners. Check to make sure they are lit, then close
the lid and warm the grill on HI for 15 minutes. Curing of
paint and parts will produce an odor only on first lighting.
• LP tank Exchange: You may choose to replace your empty LP
tank through an exchange service. Use only those reputable
exchange companies that inspect, precision fill, test and
certify their cylinders. Exchange for OPD safety feature
equipped tank as described in LP Tank
• Always keep LP tank in upright position during use, transit or
storage.
• Leak test LP tank BEFORE connecting to grill.
466231203 • 9
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5. Hold regulator, insert nipple (B) into LP tank valve.
Hand tighten coupling nut, holding regulator in a
straight line (C) with LP tank valve so as not to cross
thread the connection.
LP Tank Leak Test
For your safety
• LeaktestmustberepeatedeachtimeLPtankisexchangedor
refilled.
• Donotsmokeduringleaktest.
B
• Donotuseanopenflametocheckforgas leaks.
• Grillmustbeleakcheckedoutdoorsinwell-ventilatedarea,away
fromignitionsourcessuchasgasfiredorelectricalappliances.
Duringleaktest,keepgrillawayfromopenflamesorsparks.
Nipple has to be
centered into the
LP tank valve
Useacleanpaintbrushand50/50soapandwater
solution.Usemildsoapandwater.
▲Do not use household cleaning agents.
Damagetogastraincomponentscanresult.
C
Brush soapy solution
onto the shaded areas.
Hold coupling nut
and regulator as
shown for proper
connection to LP
tank valve.
If
"growing"
bubbles appear
do not use or move
the LP tank. Contact
an LP gas supplier or
your fire department!
6. Turn the coupling nut clockwise to tighten to a full solid stop.
The regulator will seal on the back-check feature in LP tank
valve, resulting in some resistance. An additional one-half
to three quarters turn is required to complete
Connecting The Regulator To The LP Tank
1. LPtankmustbeproperlysecured ontogrill.
2. Turnallcontrolknobsincludingsideburner(iffeatured)totheOFF
position.
3. Turn LP tank OFF by turning hand-wheel
clockwise to a full stop.
connection. Tighten by hand only - do not use tools.
NOTE: If you cannot complete connection, disconnect regulator and
repeat steps 5 and 6. If you are still unable to complete the
connection, do not use this regulator!
4. Remove the protective cap from
LP tank valve.Always use cap and
strap supplied with valve.
OPD Hand
Wheel
WARNING
Safety Relief Valve
• 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 checked.
• If leak is detected at any time, STOP and call the Fire
Department.
• If you cannot stop a gas leak, immediately close LP
tank valve and call LP gas supplier or your fire
department!
Type 1 outlet with thread on outside
Strap and Cap
Use of this POL transport plug
(A) (plastic part with external
threads) will defeat safety
feature of valve.
A
10 • 466231203
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4. Brush soapy
solution onto
following
DANGER
• NEVER store a spare LP tank under or near grill or in
enclosed areas.
connections:
• Never fill the cylinder beyond 80% full. An overfilled
spare LP tank is hazardous due to possible gas
released from the safety relief valve. The safety relief
valve on a LP tank could activate releasing gas and
cause a fire.
• If you see, smell or hear escaping gas, immediately
get away from the LP tank/grill and call your fire
department.
• All spare LP tanks must have safety caps installed on
the LP tank outlet.
LP Tank Removal, Transport And Storage
• TurnOFFallcontrolknobsandLPtankvalve.Turncouplingnut
counterclockwisebyhandonly-donotusetoolstodisconnect.Lift
LPtankwireupwardoffofLPtankcollar,liftLPtankupandoffof
supportbracket.InstallsafetycapontoLPtankvalve.Alwaysuse
capandstrapsuppliedwithvalve. Failure touse safetycapas
directedmayresultinserious personalinjuryand/or
property damage.
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 U.S. or 1-800-387-6057 CAN.
6. Always close LP tank valve after performing leak test by
turning hand wheel clockwise.
Safety
Cap
LP Tank
Valve
Retainer
Strap
Safety Tips
▲ Before opening LP tank valve, check the coupling nut for
tightness.
▲ When grill is not in use, turn off all control knobs and LP tank
valve.
▲ Never move grill while in operation or still hot.
▲ When moving the grill push it forward, do not pull from
behind.
• 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 a LP tank inside a
vehicle which may become overheated by the sun.
• Do not store LP tank in an area where children play.
▲ Use long-handled barbecue utensils to avoid burns and
splatters.
▲ Do not remove grease receptacle or tray until grill has
completely cooled.
▲ 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, clean and inspect valve, hose
and regulator before continuing. Perform a leak test.
▲ The regulator may make a humming or whistling noise
during operation. This will not affect safety or use of grill.
▲ If you have a grill problem see the "Troubleshooting Section".
Leak Testing Valves, Hoses 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 counter
clockwise. If you hear a rushing sound, turn gas off
immediately. There is a major leak at the connection. Correct
before proceeding.
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Match Lighting
▲ Do not lean over grill while lighting.
WARNING
1. Open lid during lighting.
2. Place lit match into match
lighting stick, then into lighting
hole on right side of grill.
3. Push in and turn far right burner
knob to HI. Be sure burner lights
and stays lit.
For Safe Use Of Your Grill:
• Donotletchildrenoperateorplayneargrill.
• Keepgrillareaclearandfreefrommaterialsthatburn.
• Donotblockholes inbottomorbackofgrill.
• Checkburnerflamesregularly.
• Usegrillonlyinwell-ventilatedspace.NEVERusein
enclosedspacesuchascarport,garage,porch,covered
patio,orunderasurfacethatcancatchfire.
4. Light adjacent burners in sequence by pushing knobs in
and turning to HI.
• Usegrillatleast3ft.fromanywallorsurface.Maintain10ft.
clearancetoobjectsthatcancatchfireorsourcesofignition
suchaspilotlightsonwaterheaters,liveelectricalappliances,
etc.
WARNING
• If burner does not light turn knobs to OFF, wait 5
minutes,tryagain.
• Donotusecharcoal,briquetsorlavarockinthisgrill.
• ApartmentDwellers:
Check with management to learn the requirements and fire
codes for using an LP 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.
Match Lighting
1. To match light SIDEBURNER, open
sideburner cover.
2. Place lit match near burner.
3. Push in and turn sideburner
knob counter-clockwise. Be
sure burner lights and stays lit.
• 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 tank out of correct position.
• Always close LP tank valve and remove coupling nut
before moving LP tank from specified operating
position.
Burner Flame Check
• Remove grates and flametamers. Light burners, rotate knobs
from HI to LOW. You should see a smaller flame in LOW
position than seen on HI. Always check flame prior to each
use. Perform flame check for sideburner. If only low flame is
seen refer to "Sudden drop or low flame" in
CAUTION
• Putting out grease fires by closing the lid is not
possible. Grills are wellventilatedforsafetyreasons.
• Do not use water on a grease fire. Personal injury may
result. If a grease fire develops turn knobs and LP tank
off.
theTroubleshootingSection.
HI
LOW
• Do not leave grill unattended while preheating or
burning off on high. If grill has not been regularly
cleaned a grease fire can occur that may damage the
product.
TurningGrillOff
• Turn all knobs to OFF position. Turn LP tank OFF by turning
hand-wheel clockwise to a full stop.
Ignitor Lighting
▲ Do not lean over grill while lighting.
1. Open lid during lighting
2. To ignite any burner, turn knob to HI, push and hold
ELECTRONIC IGNITOR button for 5 seconds.
3. If ignition does not take place within 5 seconds, turn all
burner knobs to OFF, wait 5 minutes, then repeat lighting
procedure.
4. If IGNITOR does not work, follow match lighting
instructions.
12 • 466231203
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Ignitor Check
General Grill Cleaning
• Turn gas off at LP tank. Push and hold electronic ignitor
button. "Clicks" should be heard and spark seen each time
between collector box or burner and electrode. See
"Troubleshooting" if no click or spark.
• 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.
• Plastic parts: wash with warm soapy water and wipe dry.
▲ Do not use citrisol, abrasive cleaners, degreasers or a
concentrated grill cleaner on plastic parts. Damage to and
failure of parts can result.
Valve Check
• 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 don't spring back, replace valve assembly
before using grill. Turn knobs to LOW position then turn back
to OFF position. Valves should turn smoothly.
Hose Check
CAUTION
• 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.
Clean burners prior to use after storing, at the
beginning of grilling season or a period of
one month not being used. Spiders and insects like to
build nests in burner tubes (especially during colder
months). These nests can cause fires in burner tubes or
under grill.
Cleaning The Burner Assembly
Follow these instructions to clean and/or replace parts of burner
assembly or if you have trouble igniting grill.
1. Turn gas off at control knobs and LP tank.
2. Remove cooking grates, flametamers, grease tray and grease
receptacle.
3. Remove cotter pins from beneath each burner "foot" using a
screwdriver or needle nose pliers.
• 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.
• Painted surfaces: Wash with mild detergent or nonabrasive
cleaner and warm soapy water, wipe dry with a soft
nonabrasive cloth.
• Stainless steel surfaces: To maintain your grill's high-
quality appearance, wash with mild detergent and warm
soapy water, wipe dry with a soft cloth after each use. Baked-
on grease deposits may require the use of an abrasive plastic
cleaning pad.
4. Carefully lift each burner up and away from valve openings.
We suggest three ways to clean the burner tubes. Use the one
easiest for you.
(A) Bend a stiff wire (a light weight coat hanger works well)
into a small hook. Run the hook through each burner tube
and burner several times.
Storing Your Grill
• Clean cooking grates
• Store in dry location.
(B) Use a narrow bottle brush with a flexible handle (do not
use a brass wire brush), run the brush through each burner
tube and burner several times.
• When LP tank is connected to grill, store outdoors in well-
ventilated space and out of reach of children.
• Cover grill if stored outdoors. Choose from a variety of grill
covers offered by Char-Broil.
• 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.
(C) Wear eye protection: Use an air hose to force air into the
burner tube and out the burner ports. Check each port to make
sure air comes out each hole.
5. Wire brush entire outer surface of burner to remove food
residue and dirt.
6. Clean any blocked ports with a stiff wire such as an open paper
clip.
7. Check burner for damage, due to normal wear and corrosion
some holes may become enlarged. If any large cracks or holes
are found replace burner.
VERY IMPORTANT: Burner tubes must reengage valve
openings.
8. Carefully replace burners.
9. Replace cotter pin beneath each burner.
10. Replace grease tray and receptacle, flametamers, and
cooking grates.
466231203 • 13
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Indirect Cooking
Food Safety
Poultry and large cuts of meat cook slowly to perfection on the
grill by indirect heat. The heat from selected burners circulates
gently throughout the grill, cooking meat or poultry without the
touch of a direct flame. This method greatly reduces flare-ups
• 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:
when cooking extra fatty cuts because there is no direct flame to Clean: Wash hands, utensils, and surfaces with hot soapy
ignite the fats and juices that drip during cooking.
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.
Indirect Cooking Instructions
•
Always cook with the lid closed.
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.
•
Due to weather conditions, cooking times may vary. During
cold and windy conditions the temperature setting may
need to be increased to insure sufficient cooking
temperatures.
How To Tell If Meat Is Grilled Thoroughly
• Meat and poultry cooked on a grill often browns very fast on
the outside. Use a meat thermometer to be sure food has
reached a safe internal temperature, and cut into food to
check for visual signs of doneness.
• Whole poultry should reach 1800 F; breasts, 1700 F. Juices
should run clear and flesh should not be pink.
• Hamburgers made of any ground meat or poultry should
reach 1600 F, and be brown in the middle with no pink juices.
Beef, veal and lamb steaks, roasts and chops can be cooked
to 1450 F. All cuts of pork should reach 1600 F.
• NEVER partially grill meat or poultry and finish cooking later.
Cook food completely to destroy harmful bacteria.
• When reheating takeout foods or fully cooked meats like hot
dogs, grill to 1650 F, or until steaming hot.
ON
1 Burner Cooking
Cook with direct or indirect heat.
Best for smaller meals or foods.
Consumes less fuel.
ON
ON
2 Burner Cooking
Great indirect cooking on low.
Produces slow, even heating.
Ideal for slow roasting and baking.
14 • 466231203
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Troubleshooting
Problem
Possible Cause
Prevention/Cure
Clean wires and/or electrode with rubbing alcohol and clean swab.
Burner will not
Wires and/or electrode covered with
light using ignitor.
cooking residue.
Replace electrode(s).
Electrode cracked or broken "sparks at
crack"
MainBurners:Tipofelectrodeshouldbepointingtowardtipofcollector
box. The distance should be 1/8" to 1/4", adjust if necessary.
Electrode tip not in proper position
Wiresarelooseordisconnected.
Sideburner:Tipofelectrode shouldbe pointingtowardgas portopening
on burner. The distance should be 1/8" to 3/16", adjust if necessary.
Reconnectwiresorreplaceelectrode/wireassembly.
Replaceignitorwire/electrodeassembly.
Wireisshorting(sparking)between
ignitorandelectrode.
Replace with a new AA battery.
Deadbattery.
Turn gas on at source.
Clear burner tubes.
Burners will not
match light.
Nogas flow.
Obstructionofgasflow.
Disengagementofburnertovalve.
Reengage burner and valve.
Turnfrontofgrilltofacewindorincreaseflameheight.
Flames blow out.
Flare-up.
Highorgustingwinds.
Cleangrill.
Greasebuildup.
Trimfatfrommeatbeforegrilling.
Adjust(lower)temperatureaccordinglyoruseindirectcooking.
Excessivefatinmeat.
Excessivecookingtemperature.
Turn knobs to OFF. Turn gas off at gas source. Leave lid in position
and let fire burn out. After grill cools, remove and clean all parts.
Persistent grease
fire.
Grease trapped by food buildup around
burnersystem.
Clean burner and/or burner tubes.
Flashback...
Burner and/or burner tubes are blocked.
(fire in burner tubes)
466231203 • 15
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A Division of W.C. Bradley Co.
P. O. Box 1240
Columbus, GA 31902-1240
3
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