Char-Broil 415.16120801 User manual

PRODUCT GUIDE
Kenmore Model No. 4t5.16120801
Kmart item No, 640-174093112
IMPORTANT: Fill out the product record information below.
Serial Number Seeratinglabelongrillforserialnumber.
Date Purchased
Forsupportandto registeryour
grill,pleasevisit usat
www.charbroil.com
Ifyouhavequestionsorneed
assistanceduringassembly,
pleasecall1-800-241-7548.
Estimated assembly time: 35-40 minutes
The following are trademarks registered by W.C. Bradley Co. in the U.S. Patent and Trademark Office: Char-Broil®; America's Legendary Barbeque Company®;
American Gourmet®; Banders®; BrushHawg®; CB940®; Char-Diamonds®; Char-Broil Charcoal/Gas®; DiamondFlame®; Everybody Grills®; Everybody Outside®;
FastStart®; Fireball®; Firenzy®; FlavorMaster®; Grill2Go®; Grill2Go® Express®; Grill Lovers®; H20 Smoker@; Keepers of the Flame®; New Braunfels Smoker
Company@; Oklahoma Joe's®; Patio Bistro@; Patio Caddie®; Patio Kitchen®; Precision Flame®; Quantum@; Santa Fe@; Sear and Grill@; Sierra@; Signature
Series@; The Big Easy@; The Minute Grill@; Trentino@; Wild West Tradition@; and the following marks:
TM TM TM TM TM TM
The following are trademarks of W.C. Bradley Co.: Commercial Series ; Designer Series ; Grill2Go@ Advantage ; Longhorn ; Double Chef ; QuickSet ;
TM TM TM TM TM
Ready When YouAre ; Hog and Yard Bird ;You Bring the Party ; SureFire ;Universal Grill Parts
TM
TEC is a trademark of Tec Infrared Grills.
Protected under oneor moreofthe following U.S.Patents:4,989,579; 5,421,319; 5,458,309;5,579,755; 5,996,573;6,114,666; 6,135,104;6,209,533; 6,279,566;6,331,108; 6,484,900; 6,526,876;6,595,197;6,640,799; 6,640,803; 6,729,873;6,739,473; 6,749,424;
6,863,t00; 6,935,327; 6,951,213;6792,935;7,047,590;D364,535;D372,637;D373,70t ;D377,735;D383,035; D397,9t0; D405,643;D4Od,OO5;D4Od,OO9;D413,043;D413,229;D414,982;D4t5,388; D416,164;D4t6,441; D417,587;D417,588;D422,516;D423,876;
D428,303;D430,772;D435,396;D436,004;D438,059; D438,060;Ii)438,427;D439,11O;D442,505;D443,179;D443,354;D443,464;D447,384; D447,385;D447,909;D448,61O;D448,614;D448,6t5; D448,6t6; D448,975; D449,492;D450,544; D451,759;D454,028;
D454,03t; Ii)455,205;D455,206;D456,202;D456,222;D456,223;D457,789;D458,520;D458,760;D458,802; D459,088; D459,148 D459,149;D459,16t; D459,163;D459,586;D459,943;D460,312;D460,313;D460,318;D461,359; D465,123; D465,693;D466,307;
D466,439;D466,752;D473,4t4; Ii)474,371;D477,498;D477,50t; D477,504; D477,506; D477,746;D478,471;D478,472;D480,914;D49t,410; I)494,009; D494,4t3; D498,523;D500,359;D504,048;D530,098;D535,000;Canada:87,743;87,744; 97,504; 99,355;
102,037; 104,2OO;2,315,567;2,336,036;France: O10231 ;0tO,422;0t 0,590; 0t0,849; 1,089,646;Germany:1,089,646;South Korea:384,565;China:99,127,066.5;UnitedKingdom: 2,099,402;1,089,646.OtherPatents Pending.
© 2008W.C.BradleyCompany TM REVISION O0
@2008Char-Broil,LLC Columbus,GA 31902 Printedin China Assemblyinstructions@2008 463611809 • 463612009 • 10/16/08 • 80018007

For Your Safety .................................... 2-3
Use and Care .................................... 4-10
Grilling Guide .................................... 11-14
Limited Warranty.................................... 15
Parts List.......................................... 16
Parts Diagram...................................... 17
Assembly ....................................... 18-25
Troubleshooting.................................. 26-27
Registration Card ................................... 31
Safety Symbols
The symbols and boxes shown below explain what each heading
means. Read and follow all ofthe messages found throughout
the manual.
WARNING: Indicatesan potentially hazardous situation
which, if not avoided, could result in death or serious injury.
CAUTION
CAUTION: Indicatesa potentiallyhazardoussituationor
unsafe practicewhich, if not avoided, may result in minor
or moderateinjury.
DANGER: Indicatesan imminentlyhazardous situation
which, if not avoided,will resultin death or serious injury.
If you smell gas:
1. Shut off gas to the appliance.
2. Extinguish any open flame.
3. Open lid.
4. If odor 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.
CAUTION
For residential use only. Do not use for commercial
cooking.
CAUTION:
Read and follow all safety statements,assembly
instructions,and use and care directions beforeattempting
to assemble and cook.
INSTALLER/ASSEMBLER:
Leavethis manualwith consumer.
CONSUMER:
Keepthis manualfor future reference.
WARNING:
Failureto follow all manufacturer's instructionscould result
in serious personal injuryand/or property damage.
CAUTION:
Some partsmay containsharp edges- especially as noted
in the manual!Wear protectivegloves if necessary.

CALiFORNiAPROPOSiTiON65
1.Combustionby-productsproducedwhenusing
thisproductcontainchemicals 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 handling this product.
Installation Safety Precautions
•Use grill, as purchased, only with LP (propane) gas and the
regulator/valve assembly supplied. A conversion kit must be
purchased for use with naturalgas.
• Grill installation must conform with local codes, or in their
absence of local codes, with either the National Fuel Gas
Code,ANSI Z223.1/NFPA 54, Natural Gas and Propane
Installation Code, CSAB149.1, or Propane Storage and
Handling Code, B149.2, or the Standard for Recreational
Vehicles,ANSI A 119.2/NFPA1192,and CSAZ240 RV Series,
Recreational Vehicle Code,as applicable.
• 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 hotsurfaces.
• This grill issafety certified for use in the United States and/or
Canada only. Donot modifyfor use in any other location.
Modification wilt result in a safety hazard.
CAUTION
Using pots larger than 6 quarts in capacity could
exceed weight limitof the
side burner shelf,
resulting in failure
of grill cart
components.
Do not attempt to repair or alter the
hose/valve/regulator for any "assumed" defect. Any
modification to this assembly will void your warranty
and create the risk of agas leak and fire. Use only
authorized replacement parts supplied by
manufacturer.

• NEVERstore aspare LP cylinder under or near the
appliance or in an enclosed area.
• Never fill a cylinder beyond 80%full.
• If the information in two points above is not
followed exactly, afire causing death or serious
injury may occur.
•An over filled or improperlystored cylinder isa
hazard due to possiblegas release from the safety
relief valve. This could cause an intense fire with
risk of property damage, serious injury or death.
• If you see, smell or hear gas escaping, immediately
get away from the LP cylinderlapplianceand call
your fire department.
LP Cylinder Removal, Transport and Storage
•Turn OFF all control knobs and LPcylinder valve. Turn coupling
nutcounterclockwise by hand only - do not use tools to
disconnect. Loosen cylinder screw beneathbottom shelf, then
lift LP cylinder up and out of cart. Installsafety cap onto LP
cylinder valve.Always use capand strap supplied with valve.
Failure to use safety cap as directed may result in serious
personal injury and/or property damage.
•Adisconnected LP cylinder in LPCylinder
storage or being transported
must have a safety cap installed (as shown).
Do not store an LP cylinder in enclosed spaces
such as a carport, garage, porch, covered
patio or other building. Never leavean LP cylinder Safety
inside a vehicle which may become overheated Cap
by the sun. RetainerStrap
•Do notstore an LP cylinder in an area where children play.
LP Cylinder
•The LP cylinder used with your grill must meet the
following requirements:
*Use LP cylinders only with these required measurements: 12"
(30.5cm) (diameter) x 18" (45.7 cm) (tall) with 20 lb. (9 kg.)
capacity maximum.
•LP cylinders must be constructed and marked in accordance
with specifications for LPcylinders 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 cylinder collar for
marking.
•LP cylinder valve must have:
•Type 1 outlet compatible with
regulatoror grill.
•Safety reliefvalve.
•ULlisted Overfill Protection OPDHandWheel
Device (OPD). This OPD safety
feature is identified by a unique triangular hand wheel. Use
only LP cylinders equipped with this type of valve.
•LPcylinder must be arranged for vapor withdrawal and include
collar to protect LP cylinder valve.Always keep LP cylinders in
upright position during use, transit or storage.
iiii iI
ti!:
LP cylinder in upright position for vapor withdrawal
LP (Liquefied Petroleum Gas)
•LP gas is nontoxic, odorless and colorless when produced. For
Your Safety, LPgas has been given an odor (similar to rotten
cabbage) so that it can be smelled.
•LP gas is highly flammableand may ignite unexpectedly when
mixedwith air.
LP Cylinder Filling
*Useonly licensed and experienced dealers.
•LP dealer must purge new cylinder before filling.
•Dealer should NEVER fill LP cylinder more than 80% of LP
cylinder volume. Volumeof propane in cylinder wilt vary by
temperature.
•Afrosty regulator indicates gas overfill. Immediately close LP
cylinder valve and call local LP gas dealer for assistance.
•Do not releaseliquid propane (LP) gas into the atmosphere.
This is a hazardous practice.
•Toremove gas from LP cylinder,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 Cylinder Exchange
•Many retailers that sell grills offer you the option of replacing
your empty LP cylinder through an exchange service. Use only
those reputable exchange companiesthat inspect, precision fill,
test and certify their cylinders. Exchange your cylinder only
for an OPD safety feature-equipped cylinder as described
in the "LP Cylinder" section of this manual.
•Always keep new and exchanged LP cylinders in upright
position during use, transit or storage.
•Leak test new and exchanged LP cylinders BEFORE
connecting to grill.
Connecting Regulator to the LP Cylinder
1.LP cylinder mustbe properly secured onto grill. (Refer to
assembly section.)
2.Turn all control knobs to the OFF position.
3.Turn LP cylinder OFF by turning hand-wheel clockwise to a
full stop.
4.Remove the protective cap from LP cylinder valve.Always use
cap and strap supplied with valve.
LP Cylinder Leak Test
For your safety
•Leak test must be repeated each time LP cylinder isexchanged
or refilled.
*Do notsmoke during leak test.
*Do notuse an open flame to check for gas leaks.
*Grill must be leak tested outdoors in a well-ventilated area,
away from ignitionsources such as gas fired or electrical
appliances. Duringleak test, keep grill away from open flames
or sparks.
•Use a clean paintbrush and a 50/50 mild soap and water
solution. Brush soapy solution onto areas indicated byarrows
in figure below.
ADo not use household cleaning agents. Damage to gas
train components can result.
Safety Relief Valve
OPD Hand Wheel
jType1outlet with
threadon outside
/
Strapand Cap
Do not use a POL transport plug
(plastic part with external threads)!
It will defeat the safety feature of
the valve.
5.Hold regulatorand insert nipple into LP
cylinder valve. Hand-tightenthe
coupling nut, holding regulator in a
straight line with LP cylinder valve so
as not to cross-thread the connection.
Nipplehasto be centered
intothe LPcylinder valve.
If"growing"bubblesappear do not useor move the LP
cylinder.Contact an LPgas supplieror your fire
department!

Holdcoupling nut and regulator
asshownfor properconnection
to LPcylindervalve.
6.Turn the coupling nut clockwiseand tighten to a full stop. The
regulatorwill seal on the back-checkfeature in the LP cylinder
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 regulatorand
repeat steps 5 and 6. If you are still unable to completethe
connection, do not use this regulator!
Leak Testing Valves, Hose and Regulator
1.Turn all grill control knobs to OFF.
2.Be sure regulator istightly connected to LP cylinder.
3.Completely open LP cylinder valve by turning 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 circled below.
Do not insertanytool or foreignobject intothe valve
outlet or safety relief valve. You maydamage thevalve
and cause a leak. Leaking propane mayresult in
explosion,fire, severepersonal injury,or death.
Outdoorgas appliance is not intendedto beinstalled
in or on a boat.
Outdoorgas appliance is not intendedto beinstalled
in or on an RV.
. Never attemptto attach this grill to the self-contained
LPgas system of a campertrailer or motorhome.
. Do not usegrill until leak-tested.
. If a leak is detectedat any time, STOPand callthe fire
department.
. If you cannot stop a gas leak,immediately close
LPcylindervalve and call LPgas supplieror yourfire
department!
5.If "growing" bubbles appear, there is a leak. Close LP
cylinder valve immediately and retighten connections. If leaks
cannot be stopped do not try to repair. Callfor replacement
parts.
6.Always close LPcylinder valve after performing leak test by
turning hand wheel clockwise.

zL zL
For Safe Use Of Your Grill And To Avoid Serious
Injury:
*Do notlet children operate or play near grill.
•Keep grill area clear and free from materialsthat burn.
•Do notblock holes in bottom or back of grill.
•Check burner flames regularly.
•Use grill only inwell-ventilated space. NEVER use in
enclosed space such as carport, garage, porch, covered
patio, or under an overhead structure of any kind.
•Do notuse charcoal or ceramic briquets in a gas grill.
(Unless briquets are supplied with your grill.)
•Use grillat least 3ft. from any wall or surface. Maintain
10 ft. clearance to objects that can catch fire or sources of
ignitionsuch as pilot lights on water heaters, live electrical
appliances, etc.
•Apartment Dwellers:
Check with 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 floorwith a three (3) foot
clearance from walls or rails. Donot use on or under
balconies.
•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
specified in assembly instructions.
•Always close LP tank valve and remove coupling nut
before moving LP tank from specified operation
position.
Safety Tips
,& Beforeopening LP cylinder valve, check the coupling nutfor
tightness.
,& When grill is not in use, turn off all control knobs and LP
cylinder valve.
,& If the outdoor cooking gas appliance is not in use, the gas
must be turned off at the supply cylinder. Storage of an
outdoor cooking gas appliance indoorsis permissible only if
the cylinder is disconnected and removed from the appliance.
,& Never move grill while in operation or still hot.
,& Use long-handled barbecue utensils and oven mitts to avoid
burnsand splatters.
,& Maximum load for side shelves is 10 Ibs.
,& The grease cup must be inserted into grease clip and
emptied after each use. Do not remove grease cup until grill
has completely cooled.
,& Clean grill often, preferably after each cookout. If a bristle
brush is used to clean any of the grill cooking surfaces,
ensure no loose bristles remain on cooking surfaces prior to
grilling. Itis not recommendedto clean cooking surfaces
while grill is hot.
,& If you notice grease or other hot material dripping from grill
onto valve, hoseor regulator, turn off gas supply at once.
Determinethe cause, correct it, then clean and inspect valve,
hoseand regulator before continuing. Perform a leak test.
,& The regulator may make a humming or whistling noiseduring
operation. This will notaffect safety or use of grill.
,& Onlyuse the pressure regulator and hose assembly supplied
with this grill. Replacement pressure regulator and hose
assemblies must be specified or supplied by Char-Broil, LLC.
,& If you have a grill problem see the "Troubleshooting Section".
,& If the regulator frosts, turn off grill and LP cylinder valve
immediately.This indicatesa problemwith the cylinder and it
should notbe 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 ona 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.

ignitor Lighting
ADo not lean over grill while lighting.
1. TurnOFF gas burner control valves.
2. TurnON gas source or tank.
3. Open lidduring lighting.
4. Toignite, turn left knob to,_ HIGH.
5. Push IGNITOR button rapidly.
6.If ignition does NOT occur in 5 seconds, turn the burner
controls OFF,wait 5 minutes and repeat the lighting
procedure.
7. Toignite right burner,turn knob to _.
If ignitordoes notwork, follow matchlighting instructions.
After Lighting: Turn knobs to HI position for warm-up.
CAUT'O.
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 knob to _: HIGH position. Be sure
burner lights and stays lit.
4.Light right burner by pushing knob in and turning to _ HIGH
position.
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 tank
off.
•Do not leave grill unattended while preheating or
burning off food residue on high. if grill has not been
regularly cleaned, a grease fire can occur that may
damage the product. Follow instructions on General
Grill Cleaning and Cleaning The Burner Assembly to
prevent grease fires.
Before Your First Cookout
•Light burners, check to make sure they are lit, close the lid and
warm up grill on HIGHfor 15 minutes. This curing of paint and
partswill produce an odor only on first lighting.
Burner Flame Check
•Light burner, rotateknobs 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 Troubleshooting Section,
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

Turning Grill Off
•Turn all knobs to OFF position.Turn LP tank off byturning
OPD handwheel clockwise to a full stop.
Ignitor Check
•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: Make sure gas is off at LP tank 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
•Keepthe 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 havea grill cover, wipe off dust and grime before
starting your grill.
• Coating the cooking gridswith 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 bottom for 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 cleanerwith scrub brush on insides of grill lid and
bottom. Rinse and allow to completely air dry. Do not apply a
caustic grill/oven cleanerto 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 use citrisol, 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 be wiped away with baking soda/water solution or
specially formulated cleaner. Use non-abrasive 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: Tomaintain your grill's high quality
appearance, wash with mild detergent and warm soapy water
and wipe drywith a soft cloth after each use. Baked-ongrease
deposits may require the use of an abrasive plastic cleaning
pad. Use only in direction of brushed finish toavoid damage.
Do not use abrasive pad on areas with graphics.
• Cooking surfaces: If a bristle brush isused to cleanany of
the grill cooking surfaces, ensure no loose bristles remain on
cooking surfaces prior to grilling. It is not recommendedto
clean cooking surfaces while grill is hot.
Iz ! cAuT,o.Iz !
SPIDER ALERT!
GAS COLLECTOR
VALVE AIR VENTURI
SHUTTER
If you notice that your grill is getting hard to light orthat the
flame isn't asstrong as itshould be,take the time to checkand
clean theventuri's.
LIFTOUT
BURNERASSEMBLY
REMOVE
BURNER
CLIPS
CLEAN OUT SPIDER WEBS
VENTURI INSIDEVENTURI
Insomeareasofthecountry,spidersor smallinsectshavebeen
knowntocreate"flashback"problems.Thespidersspinwebs,build
nestsandlayeggsin thegrill'sventuritube(s)obstructingtheflowof
gastotheburner.Thebacked-upgascanignitein theventuribehind
thecontrolpanel.Thisis knownasa flashbackanditcandamage
yourgrilland evencauseinjury.
Topreventflashbacksandensuregoodperformancetheburnerand
venturiassemblyshouldberemovedfromthegrilland cleaned
beforeusewheneverthegrillhasbeenidleforanextendedperiod.
,,. j

Cleaning the Burner Assembly
Follow these instructions to clean and/or replace partsof burner
assembly or if you have trouble ignitinggrill.
1. Turn gas off at control knobs and LP cylinder.
2. Remove cooking grate and heattent.
3. Under grill remove grease cup, disconnect ignitorwire from
burner.
4. Inside grill remove burner assembly (A), clean ceramic
portion of electrode with rubbing alcohol and a swab.
5. Clean outside of burner with soap andwater. Lay burner
upside down on flat surface, insert garden hose to force
water through tubes. Make sure water comes out of all
burner holes. Open clogged holes with a thinwire. Shake
out excess water and examine holes. Due to normal wear
and corrosion some holes may become enlarged. Ifany
large cracks or holesare found replace burner.
6. If grill 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. Reposition heat tent and cooking grate. Reattach clean
grease cup to grease clip.
10. Before cooking again on grill, perform a "Leak Test"and
"Burner Flame Check".
Correctburner-to-valveengagement
A
BurnerTube
Valve
B
10