Char Broil Gas Grill 466231203 User Manual

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)  
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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  
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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  
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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  
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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
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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.  
466231203 • 11  
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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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