Char-Broil 415.16108 User manual

MODEL 415.16108 • 640-810983-114 • PRODUCT GUIDE
/_ CAUTION:
Read and follow all safety statements, assembly
instructions, and use and care directions before
attempting to assemble and cook.
INSTALLER/ASSEMBLER:
Leave this manual 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.
Printedin China•463721108•463721308 •80013232•09-27-07

if you smell gas:
1. Shut off gas to the appliance.
2. Extinguish any open flame.
3. Open lid.
4. ifodor continues, keep away from the
appliance and immediately call your gas
supplier or your fire department.
1. Do not store or use gasoline or other
flammable liquids or vapors in the vicinity of
this or any other appliance.
2. An LP cylinder not connected for use shall not
be stored in the vicinity of this or any other
appliance.
Call Grill Service Center for Help and Parts
.If you need assistance with your product or warranty parts call
1-800-241-7548. Hours of Service Center Operation are
8:00 A.M. To 6:00 P.M. EST Monday- Friday.
, Toorder non-warranty replacement parts or accessories
pleasevisit uson the web at www.charbroil, com or call
1-800-241-7548 and one of our friendly and knowledgeable
agents will be glad to assist you.
IMPORTANT: Fill out the product record information below.
Model Number
Serial Number See ratinglabelongrillforserialnumber.
Date Purchased
CAUTION
Forresidential use only. Do not use for commercial
cooking.
2 " 463721108"463721308
Installation Safety Precautions
• Use grill only with LP (propane) gas and the regulator/valve
assembly supplied.
• Grill installation must conform with localcodes, or in their
absence with National Fuel Gas Code, NFPA 54 /ANSI
Z223.1 and Natural Gas and Propane Installation Code,
CSA B149.1. Handling and storage of LP cylinders must
conform to LP Gas Code NFPNANSI 58. Grill is notfor use in
or on recreational vehicles and/or boats.
, All electrical accessories (such as rotisserie) must be
electrically grounded in accordance with local codes, or
National Electrical Code, ANSI /NFPA 70 or Canadian
Electrical Code, CSA C22.1. Keep any electrical cords
and/or fuel supply hoses away from any hot surfaces.
.This grill issafety certifiedfor use in the United Statesand/or
Canada only. Do not modify for use in any other location.
Modification will result in a safety hazard.
CALIFORNIA PROPOSITION 65
1. Combustion by-products produced when using
this product contain chemicals known to the
State of California to cause cancer, birth defects,
and other reproductive harm.
2. This product contains chemicals, including lead
and lead compounds, known to the State of
California to cause cancer, birth defects or other
reproductive harm.
Wash your hands after handfinq this product.
Safety Symbols
Thesymbolsandboxesshownbelowexplainwhateachheading
means.Readandfollowallof themessagesfoundthroughout
themanual.
DANGER: Indicatesan imminentlyhazardous situation
which, if not avoided,will result in death or serious injury.
WARNING: Indicatesan potentiallyhazardoussituation
which, if not avoided, could result in death or serious
injury.
__ m
D T,o.
CAUTION: Indicatesa potentially hazardoussituationor
unsafe practicewhich, if not avoided, may resultin minor
or moderateinjury.

For Your Safety...................................... 2
Grill Service Center................................... 2
Product Record Information ............................ 2
Installation Safety Precautions .......................... 2
Safety Symbols...................................... 2
Use and Care .................................... 4-10
Parts List .......................................... 11
Parts Diagram...................................... 12
Assembly ....................................... 13-23
Troubleshooting.................................. 24-25
Limited Warranty.................................... 26
Registration Card ................................... 27
Do notattempt to repair or alter the
hose/valve/regulatorfor any "assumed" defect. Any
modification to this assembly will void your warranty
and create the risk of a gas leak and fire. Use only
authorized replacement partssupplied by
manufacturer.
CertifiedGrill PartsAnd Accessories@,Char-BroilandDesign@,Char-Broil (GasGrill Briquettes)@,Char-Diamonds@,CookingZone and Design@,Diamond Flame@,Executive Chef@,Faststarf@,Flare
Fighter@,FlavorMaster@,GasGrill SilouetteandDesign@,H20 Smoke@,LavaFlame@,MasterFlame@,MasterFlamePrecision CookingSystem@,PowerSpark@,Quantum@,VIP@,PrecisionFlameand
Design@,Sierra@,andTruFlame@are registeredTrademarksoftheW,C. BradleyCompany. TheeT_os@is a registeredtrademarkof the Thermos Companyandits affiliates.
Artisan Collectionby Char-BroilT'_',C3 and DesignTM ,Char-Broiland Design_'_', FlameDesign_'_', FlavorTentsf'_', Grill 2GoT'_', Grillin'Stick_'_',Keeperof the FJame_'_',Keepers of theFlame_'_',NaturalGrip_'_',
OutdoorCookingCollectionand DesignTM, PatioBistroTM, PrecisionFlameTM, Pro-Checkf'_',QuickSetGrills andDesignTM, SmokerTentsT'_',The BigEasyT'_',TheMinuteGdllT'',The EdgeTM, TheTuscan
Collection_'_',and The UrbanGdllT''are Trademarksofthe W.C.BradleyCompany. Universal GrillParts and DesignTM isa trademarkoftheTheeTIosCompanyandits affiliates.
Protectedunder one or moreofthe followingU.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,I32; 6,135,104;
6,173,644B1;6,279,566;6,397,73I; 6,418,923;6,439,222;6,523,461;6,935,327;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,I64; D416,44I; D416,441;D417,587;D422,516;D423,274;D423,876;D428,303;D435,396;
D436,004;D438,059;D438,060;D438,427;D439,II0; D442,505;D443,I79; D443,354;D447,384;D447,385;D447,909;D448,610;D448,614;D448,615;D448,616; D448,975;D449,492; D451,759;D456,202S;
D460,313,D461,359andD504,048, Canada:87743;87744;92607;92608 and1,316,424,OtherPatentsPending.Assemblyinstructions@2006,
463721108°463721308 • 3

LP Tank
• The LP tank used with your grill must meet the following
requirements:
•Use LP tanks only with these required measurements: 12"
(30.5cm) (diameter) x 18" (45.7 cm) (tall) with 20 lb. (9 kg.)
capacity maximum.
.LP tanks must 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.
LP tank valve must have:
, Type 1 outlet compatible with
regulatoror grill.
, Safetyrelief valve.
, ULlisted Overfill Protection OPDHandWheel
Device (OPD). This OPDsafety
feature is identified bya unique triangular hand wheel. Use
only LP tanks equipped with this type of valve.
, LP tank must be arranged for vapor withdrawal and include
collar to protect LP tank valve.
LP Tank Removal, Transport And Storage
,Turn OFF all control knobs and LPtank valve.Turn coupling
nut counterclockwise by hand only - do not use tools to
disconnect. Lift LP tank wire upward off of LP tank collar, then
lift LP tank up and off of support bracket, install safety cap onto
LP tank valve.Always use cap and strap supplied with valve.
Failure to use safety cap as directed may result in serious
personal injury and/or property damage.
LP TankValve
SafetyCap
RetainerStrap
,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 leavean LP tank inside a vehicle
which may become overheated bythe sun.
,Do not store an LP tank in an area where children play.
4 " 463721108"463721308
LP cylinder in upright position for vapor withdrawal
LP (Liquefied Petroleum Gas)
•LP gas is nontoxic, odorless and colorless when produced. For
Your Safety, LP gas has been given an odor (similar to rotten
cabbage) so that it can be smelled.
• LP gas is highlyflammable and may ignite unexpectedly when
mixed with air.
LP Tank Filling
• Useonly licensed and experienced dealers.
• LP dealer must purge tank beforefilling.
• Dealer should NEVERfill LP tank more than 80% of LP tank
volume. Volume of propane in tank will vary by temperature.
• A frosty regulator indicates gas overfill. Immediatelyclose 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.
, Toremove gasfrom 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.

LP Tank Exchange
o Many retailers that sell grills offer you the option of replacing
your empty LPtank through an exchange service. Useonly
those reputable exchange companies that inspect, precision fill,
test and certify their cylinders. Exchange your tank only for
an OPB safety feature-equipped tank as described in the
"LP Tank" section of this manual.
Always keep newand exchanged LP tanks in upright position
during use, transit or storage.
, Leak test new and exchanged LP tanks BEFORE
connecting to grill,
Connecting Regulator To The LP Tank
1. LP tank must be properly secured onto grill. (Refer to
assembly section.)
2. Turnall control knobs to the OFF position.
3. Turn LP tank OFF by turning OPD hand wheel clockwise to a
full stop.
4. Remove the protective cap from LP tank valve.Always use
cap and strap supplied with valve.
LP Tank Leak Test
For your safety
•Leak test must be repeated each time LP tank is exchanged or
refilled.
Do not smoke during leak test.
• Do not use an open flame to check for gas leaks.
Grill must be leak tested outdoors in a well-ventilated area,
away from ignition sources such as gas fired or electrical
appliances. During leak test, keep grill away from open flames
or sparks.
, Usea clean paintbrush and a 50/50 mild soap and water
solution. Brush soapy solution onto areas indicated by arrows
in figure below. Leaks are indicated by growing bubbles.
If "growing" bubbles appear do not use or move the LP tank.
Contact an LP gas supplier or your fire department!
A Do not use household cleaning agents. Damage to gas
train components can result.
Do not use a POL transport plug
(plastic part with external threads)!
itwill defeat the safety feature of
the valve.
5. Hold regulator and insert nipple into LP
tank valve. Hand-tightenthe coupling
nut, holding regulator in a straight line
with LPtank valve so as not to cross-
thread the connection.
O---*
Nipple hasto be centered
intothe LPtankvalve.
463721108•463721308•5

Holdcoupling nutand regulator
asshown for properconnection
to LP tank valve.
Leak TestingValves, Hose and Regulator
1. Turnall grill controlknobs to OFF.
2. Be sure regulator istightly connected to LP tank.
3. Completely open LP tank valve byturning OPD hand wheel
counterclockwise. If you hear a rushing sound, turn gas off
immediately.There is a major leak at the connection. Correct
before proceeding.
4. Brush soapy solution onto areas where bubbles are shown in
picture below:
6. Turn the coupling nutclockwise and tighten to a full stop. The
regulatorwill seal on the back-checkfeature in the LP tank
valve, resulting in some resistance.An additional one-half to
three-quarters turn is required to complete the
connection. Tighten by hand only - do not use tools.
NOTE:
If you cannot complete the connection, disconnect regulator and
repeat steps 5 and 6. If you are still unable to complete the
connection, do not use this regulator!
, Donot insert any tool or foreign objects into the valve outlet
or safety reliefvalve. You may damage the valve and cause
a leak. Leaking propane may result in explosion, fire, severe
personal injury,or death..
, If a leak isdetected at any time, STOPand call the fire
department.
, If you cannot stop a gas leak, immediately close LP tank
valve and call LP gas supplier or yourfire department!
A Neverremovethreaded
orifice atend of valve.
.
if "growing" bubblesappear, there is a leak. Close LP tank
valve immediately and re-tighten connections. If leaks cannot
be stopped do not try to repair, Callfor replacement parts.
Order new parts by giving the serial, model number, name and
part number of items needed (see parts list) to the Grill
Service Center at 1-800-241-7548.
Always close LPtank valve after performing leak test by
turning hand wheel clockwise.
, Never attempt to attach this grill to the self-contained LPgas
system of a camper trailer or motor home.
, Donot usegrill until leak-tested.
6 " 463721108"463721308

For Safe Use Of Your Grill And To Avoid Serious
injury:
•Donot letchildren operate or play near grill.
• Keep grill area clear and free from materials that burn.
• Donot block holes in bottom or back of grill.
• Check burnerflames regularly.
• Use grill only in well-ventilated space. NEVER use in
enclosed space such as carport, garage, porch, covered
patio, or under an overhead structure of any kind.
• Donot usecharcoal or ceramic briquets in a gas grill.
(Unlessbriquets are supplied with your grill.)
•Use grill at least 3ft. from any wall or surface. Maintain
10ft. clearance toobjects that can catch fire or sources of
ignitionsuch as pilot lights on water heaters, live electrical
appliances, etc.
Apartment Dwellers:
Checkwith management to learn the requirements and fire
codes for using an LP gas grill in your apartment complex. If
allowed, use outside on the ground floor with a three (3) foot
clearance from walls or rails. Do not use on or under
balconies.
• NEVER attempt to light burner with lid closed. A buildup
of non-ignited gas inside aclosed grill is hazardous.
• Never operate grill with LP tank out of correct position
specified in assembly instructions,
• Always close LP tank valve and remove coupling nut
before moving LP tank from specified operation
position.
Safety Tips
,A. Beforeopening LP cylinder valve, check the coupling nutfor
tightness.
A When grill is not in use, turn offall control knobs and LP
cylinder valve.
A Never move grill while in operation or still hot.
A Use long-handled barbecue utensils and oven mitts to avoid
burnsand splatters.
A Maximum load for sideburner and side shelf is 10 Ibs.
A The grease tray must be inserted into grill and emptied after
each use. Do not remove grease tray until grill has
completely cooled.
,A. Clean grill often, preferably after eachcookout. Ifa bristle
brush is used to clean any of the grill cooking surfaces,
ensure no loose bristles remain on cooking surfaces prior to
grilling. It is not recommended to clean cooking surfaces
while grill is hot.
,A. Ifyou notice grease or other hot material dripping from grill
onto valve, hose or regulator, turn off gas supply at once.
Determinethe cause, correct it, then clean and inspect valve,
hoseand regulator before continuing. Perform a leaktest.
A Keep ventilation openings in cylinder enclosure (grill cart) free
and clear of debris.
,A. Donot store objects or materials inside the grill cart
enclosure that would block the flow of combustion air to the
undersideof either the control panel or the firebox bowl.
,A. The regulator may make a humming or whistling noiseduring
operation. This will not affect safety or use of grill.
A If you have a grill problem see the "TroubleshootingSection".
,A. If the regulatorfrosts, turn off grill and LP cylinder valve
immediately.This indicates a problem with the cylinder and it
should not be used on any product. Return to supplier!
CAUTION
• Putting out grease fires by closing the lid is not
possible, Grills are well ventilated for safety reasons,
• Do not use water on a grease fire. Personal injury may
result, if a grease fire develops, turn knobs and LP
cylinder off,
• Do not leave grill unattended while preheating or
burning off food residue on Hi. if grill has not been
regularly cleaned, a grease fire can occur that may
damage the product,
463721108"463721308 •7

ignitor Lighting
ADo not lean over grill while lighting.
1. TurnOFF all burner control valves.
2. Turn ON gas source or tank.
3. Open lid during lighting.
4. To ignite, turn LEFT knobto,_ High.
5. Push IGNITOR button rapidly.
6. If ignitiondoes NOT occur in 5 seconds, turn the burner
controls OFF,wait 5 minutes and repeatthe lighting
procedure.
7. Toignite right burner, turn knob to _.
If ignitordoes notwork, follow match lighting instructions.
After Lighting: Turn knobs to HI position for warm-up.
CAUTIO./t
•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 agrease fire develops, turn knobs and LP tank
off.
•Do not leave grill unattended while preheating or
burning off food residue on high. ifgrill has not been
regularly cleaned, a grease fire can occur that may
damage the product. Follow instructions on General
Grill Cleaning and Cleaning The Burner Assembly to
prevent grease fires.
CAUTION
If burner does not light, turn knobs to OFF, wait 5
minutes, and try again. Always close valve during the 5
minute waiting period. If the burner does not ignite with
the valve open, gas will continue to flow out of the burner
and could accidentally ignite with risk of injury.
Match-Lighting
A Do not lean over grill while lighting.
1. Open lid during lighting.
2. Place match into match holder (hanging from side of cart).
3. Push in and turn left knobto _ HIGHposition. Be sure
burner lights and stays lit.
4. Light right burner by pushing knob in and turning to _ HIGH
position.
Before Your First Cookout
,Light burners, check to make sure they are lit, close the lid and
warm up grill on HIGH for 15 minutes. This curing of paint and
parts will produce an odor only on first lighting.
Burner Flame Check
, Light burner, rotate knobs from HIGHto LOW.You should see
a smaller flame in LOW position than seen on HIGH.Always
check flame prior to each use. If only lowflame is seen refer to
"Sudden drop or low flame" in the TroubleshootingSection.
Hose Check
•Beforeeach use, check to see if hoses are cut, worn or kinked.
Replace damaged hoses before using grill. Use only
valve/hose/regulator specified in the Parts List.
Normal Kinked
Hose Hose
8 " 463721108"463721308

Turning Grill Off
, Turn all knobs to OFF position.Turn LP tank off byturning
OPD hand wheel clockwise to afull stop.
ignitorCheck
•Turn gas off at LP tank. Press and hold ignitor button. "Click"
should be heard and spark seen each time between collector
box or burner and electrodes. See "Troubleshooting"if no click
or spark.
Valve Check
• Important: Makesure gas is off at LPtank before checking
valves. Knobs lock in OFF position. Tocheck 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 LO position then turn back to OFF position.
Valves should turn smoothly.
General Grill Cleaning
, Keep the outside of your grill looking new by cleaning it once a
month with warm soap and water or a non-abrasive cleaner. If
you don't have a grill cover,wipe off dust and grime before
starting your grill.
, Coating the cooking grids with spray-on cooking oil will keep the
food from sticking and make clean up easier.After cooking,
scrape the grates with a long handled, brass wire bristle brush.
, Check inside the grill bottomfor grease build up and clean
often, especially after cooking fatty meat.
, Do not mistake brown or black accumulation of grease and
smoke for paint. Apply a strong solution of detergent and water
or use a grill cleaner with scrub brush on insides of grill lid and
bottom. Rinse and allow to completely air dry. Do not apply a
caustic grill/oven cleaner to painted surfaces.
• Plated wire grates: Wash grates with concentrated grill
cleaner or use soap and water solution. Dry thoroughly and
store indoors between cookouts.
, Plastic parts: Wash with warm soapy water and wipe dry.
A Do not usecitrisol, abrasive cleaners, degreasers or a
concentrated grill cleaner on plastic parts. Damage to and
failure of parts can result.
* Porcelain grates: Because of glass-like composition, most
residue can bewiped away with baking soda/water solution or
specially formulated cleaner. Use non-abrasive scouring
powder for stubborn stains.
• Cooking surfaces: If a bristle brush is usedto clean any of
the grill cooking surfaces, ensure no loose bristles remain on
cooking surfaces prior to grilling. It isnot recommended to
clean cooking surfaces while grill is hot.
CAUTION
SPIDER ALERT!
GASCOLLECTOR
VALVE AIR VENTURI
SHUTTER
If you notice thatyour grill is getting hard to light or that the
flame isn't asstrong asit should be,take thetime to checkand
cleanthe venturi's.
LIFT OUT
BURNERASSEMBLY
?
i
6/ CLEAN OUT SPIDERWEBS
VENTURI INSIDEVENTURI
i
REMOVE
BURNER
CLIPS
Insomeareasofthecountry,spidersorsmallinsectshavebeen
knowntocreate"flashback"problems.Thespidersspinwebs,build
nestsand layeggsin thegrill'sventuritube(s)obstructingtheflowof
gastotheburner.Thebacked-upgascanignitein theventuribehind
thecontrolpanel.Thisis knownasa flashbackanditcandamage
yourgrillandevencauseinjury.
Topreventflashbacksandensuregoodperformancetheburnerand
venturiassemblyshouldberemovedfromthegrill andcleaned
beforeusewheneverthegrillhasbeenidleforanextendedperiod.
\J
463721108•463721308• 9

Cleaning the Burner Assembly
Follow these instructions to clean and/or replace partsof burner
assembly or if you have trouble igniting grill.
1. Turn gas off at control knobs and LP cylinder,
2. Removecooking grate and heattent.
3. Undergrill remove grease cup, disconnect ignitorwire from
burner.
4. Insidegrill remove burner assembly (A), clean ceramic
portion of electrode with rubbing alcohol and a swab.
5. Clean outside of burnerwith 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 holeswith 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 holesare found replace burner.
6. Ifgrill is to be stored,coat burner lightly with cooking oil.
Wrap in protective cover to keep insects out.
7. If notstoring grill after cleaning, replace burner intogrill
bottom.
VERY IMPORTANT: Burner tubes must re-engage valve
openings. See illustration (A).
8. Reattach ignitorwire to electrode.
9. Repositionheat tent and cooking grate. Reattach clean
grease cup to grease clip.
10. Before cooking again on grill, perform a "Leak Test'and
"BurnerFlame Check".
Correct burner-to-valveengagement
A
BurnerTube
Valve
10 • 463721108"463721308
Storing Your Grill
o Clean cooking grates.
o Store in dry location.
o When LP tank is connected to grill, store outdoors in well-
ventilated space and out of reachof children.
o Cover grill if stored outdoors.
o Store grill indoors ONLYif LP tank is turned offand
disconnected, removedfrom grill and stored outdoors.
, When removing grill from storage follow "Cleaning Burner
Assembly" instructions before starting grill.
Food Safety
Food safety isa very important part of enjoying the outdoor
cooking experience. Tokeepfood 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.
Cook: Cook meat and poultry thoroughly to kill bacteria. Usea
thermometer to ensure proper internalfood temperatures.
Chill: Refrigerate prepared foods and leftovers promptly.
For more informationcall: USDA Meat and Poultry Hotline at
1-800-535-4555 (In Washington, DC [phone], 10:00 am-
4:00 pm EST).
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 180° F; breasts, 170° F.Juices
should run clear and flesh should not be pink.
•Hamburgersmade of any ground meat or poultry should reach
160° F,and be brown in the middlewith no pinkjuices. Beef,
veal and lamb steaks, roasts and chops can be cooked to 145°
RAll cuts of pork should reach 160° R
• 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 165° F,or until steaming hot.