Char-Broil 463234703 User manual

463234703 • 1
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463234703 / P80116074A (041503)
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463234703

2 • 463234703
CallGrillServiceCenterForHelpAndParts
• Ifyouneedhelporwarrantypartscall ! 18002417548,or
sendaFAXto17065766355.
Businesshours:Open24hoursSevendaysaweek.
• To ordernonwarrantyreplacement partsor accessories(grill
cover,cleaners,paint)call18009932677orsendaFAXto
17065652121.
Important:FilloutWarrantyInformationbelow
WarrantyInformation
Model Number _______________________________
Lot Number (oncartonlabel) _____________________
Serial Number _______________________________
Date Purchased ______________________________
• Forresidentialuseonly.Donotuseforcommercial
cooking.
CA CA
CA CA
CAUTION UT ION
UT ION UT ION
UT ION
FORYOURSAFETY
1.Donotstoreorusegasolineorother
flammablevaporsandliquidsinthe
vicinityofthisoranyotherappliance.
2.AnLPTanknotconnectedforuse
shallnotbestoredinthevicinityof
thisoranyotherappliance.
FORYOURSAFETY
Ifyousmellgas:
1. Shutoffgastotheappliance.
2. Extinguishanyopenflame.
3. Openlid.
4. Ifodorcontinues,immediatelycall
yourgassupplieroryourfire
department.
WARNING WARNING
WARNING WARNING
WARNING
• DANGER: Indicatesanimminentlyhazardous
situationwhich,ifnotavoided,willresultindeathor
serious injury.
D D
D D
DANG ER ANG ER
ANG ER ANG ER
A NG E R
• CAUTION:Indicatesapotentiallyhazardous
situationwhich,ifnotavoided,mayresultinminor
ormoderateinjury.
CA CA
CA CA
CAUTION UT ION
UT ION UT ION
UT ION
• WARNING:Bealerttothepossibilityofserious
bodilyinjuryiftheinstructionsarenotfollowed.Be
suretoreadandcarefullyfollowallofthemessages.
WARNING WARNING
WARNING WARNING
WARNING
InstallationSafetyPrecautions
• Thisgrillisdesignedfornaturalgasuseat7inchwater
columnsupplypressure.Verifysupplypressurewithyour
localgascompany. Not for use with LP gas.
• Grillinstallationmustconformwithlocalcodes,orintheir
absence,with National Fuel Gas Code, NFPA 54 / ANSI
Z223.1.HandlingandstorageofLPcylindersmust
conformtoLPGasCode NFPA/ANSI 58.Grillisnotfor
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.Keepany
electricalcordsand/orfuelsupplyhosesawayfromany
hotsurfaces.
• ThisgrillissafetycertifiedforuseintheUnitedStatesonly.
Donotmodifyforuseinanyotherlocation.Modification
willresultinasafetyhazard.
SafetySymbols
• Thesymbolsandboxesshownbelowexplainwhateach
headingmeans.Readandfollowallofthemessagesfound
throughoutthe manual.

463234703 • 3
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
CharBroilwarrantstotheoriginalconsumerpurchaserthat
thisproduct shallbefreefromdefectsinworkmanshipand
materialsundernormalandreasonableuseandcorrect
assembly(ifassembledbyconsumerpurchaser),fromdateof
purchase.
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.
Ifyouwishtoobtainperformanceofanyobligationunderthis
limitedwarranty,youshouldwriteto:
CHARBROIL
Consumer Warranty / P.O. Box 1240
Columbus, GA 319021240
CharBroilmayrequirereasonableproofofpurchaseand
wesuggestyoukeepyourreceipt.InthestateofCaliforniaonly,
ifrefinishingorreplacementoftheproductisnotcommercially
practicable,theretailersellingthisproductorCharBroilwill
refundthepurchasepricepaidfortheproduct,lesstheamount
directlyattributabletousebytheoriginalconsumerpurchaser
priortodiscoveryofthenonconformity.Inaddition,inthestateof
Californiaonly,youmaytaketheproducttotheretail
establishmentfromwhichitwaspurchasedortoanyretail
establishmentsellingthisproductinordertoobtainperformance
underthiswarranty.
Thiswarrantydoesnotincludethecostonany
inconvenienceorpropertydamageduetofailureoftheproduct
anddoesnotcoverdamageduetomisuse,abuse,accident,
damagearisingoutoftransportationoftheproduct,ordamage
incurredthroughcommercialuseoftheproduct.Thisexpress
warrantyisthesolewarrantygivenbythemanufacturerandisin
lieuofallotherwarranties,expressorimplied,includingimplied
warrantyofmerchantabilityorfitnessforaparticularpurpose.
NeitherCharBroildealersnortheretailestablishmentsellingthis
producthasanyauthoritytomakeanywarrantiesortopromise
remediesinadditiontoorinconsistentwiththosestatedabove.
CharBroil'smaximumliability,inanyevent,shallnotexceedthe
purchasepriceoftheproductpaidbytheoriginalconsumer
purchaser.Somestatesdonotallowtheexclusionorlimitationof
incidentalorconsequentialdamages.Sotheabovelimitationsor
exclusionsmaynotapplytoyou.Thiswarrantygivesyouspecific
legalrightsandmayalsohaveotherrightswhichvaryfromstate
tostate.
WarrantyTable of Contents

4 • 463234703
Key Qty Description Part #
A 1 Lid P00119106A
B 1 Heat Indicator P00601181A
C 1 Curved Stainless Steel Handle P00205013B
D 1 Name Plate  Professional Series P00414034G
E 1 Warming Rack P01507009B
F 2 Cooking Grid  Stainless Steel P01602006B
G 4 Flame Tamer P01705005E
H 4 Burner P02001032E
I 1 Burner Bracket P02204114A
J 4 Gas Collector Box with Electrode P02609002B
K 1 Electric Wire Set P02615063A
L 1 Electric Ignitor (4 port) P02502145C
M 1 Back Burner P02007033D
N 1 Back Burner Frame P03305005H
O 1 Bowl Side Panel, Left P00720033C
P 1 Bowl Side Panel, Right P00721033C
Q 1 Bowl Front Panel P00724066C
R 1 Bowl Rear Panel P00725066C
S 1 Grease Draining Tray P02706374A
T 1 Grease Receptacle P02701041A
U 1 Gas Manifold P05006082B
V 3 Gas Valve for Main Burner P03222053B
W 1 Gas Valve for Back Burner P03222095B
X 1 Spark Electrode P02610005B
Y 1 Gas Tube P03701003A
Z 1 Heat Shield for Control Panel P03009042B
AA 1 Control Panel P02909421A
BB 4 Control Knob (Main Burner) P03419031B
CC 1 Control Knob (Back Burner) P03411142H
DD 5 Control Knob Seat P03413011A
EE 1 Bracket for Side Burner, LF P01211010A
FF 1 Side Burner Frame P01108035B
GG 1 Side Shelf, Right P01107036B
HH 2 Bracket for Side Shelf, LR/RF P01213005A
I I 2 Bracket for Side Shelf, RR P01211005A
JJ 1 Shelf Trim Plate, Right P07502002A
KK 1 Shelf trim Plate, Left P07513014A
LL 2 Side Shelf Handle P00205016B
MM 1 Bottom Shelf P01010010C
NN 2 Bowl Support Bracket P01303002B
OO 1 Side Cart Leg, LF P00917005B
PP 1 Side Cart Leg, LR P00918051B
QQ 1 Side Cart Leg, RF P00912005B
RR 1 Side Cart Leg, RR P00920005B
SS 2 Cart Side Panel P07601001A
TT 1 Cart Rear Panel P07701003A
UU 1 Front Door, Left P04302004A
VV 1 Front Door, Right P04303004A
WW 1 Door Bracket P03302002C
XX 2 Door Curved Handle P00211004B
YY 1 Door Stop P05510009E
ZZ 4 Caster Seat P04507003A
AAA 4 "3" Industry Caster P05106003D
BBB 1 Regulator (4" WC) P03614002B
CCC 1 AA Battery P05301001A
DDD 1 Motor P07101002B
EEE 1 Motor Bracket P05508005A
FFF 2 Fork P05508006A
GGG 1 Collar P05508007A
HHH 1 Bushing P05508008A
I I I 1 Handle P05508004E
JJJ 1 Spit P05508012A
KKK 3 Tool Hook P05514130A
LLL 1 Basket
MMM Griddle P05702014E
NNN 1 Brass Fitting (Manifold) P03901004A
OOO 1 Connection Tube P03702002A
PPP 1 NG Regulator Rubber Hose P03705037A
QQQ 1 NG Regulator Bracket P03311029D
RRR 1 SS Towel Bar P05212013A
SSS 1 Side Burner Lid P01127029B
TTT 1 Pot Support P00805010B
UUU 1 Electrode P02614007C
VVV 1 Side Burner P02002003D
WWW 1 Gas Valve for Side Burner P03218094I
XXX 1 Side Burner Control Knob P03401352J
YYY 1 Side Burner Control Knob Seat P03425364A
ZZZ 1 Connection Tube P03702002A
AAAA 1 Orifice Support Bracket for Side Burner P03317034F
BBBB 1 Match Lighting Stick with Chain P05507031E
1 Caster Wrench P05515002C
1 Hardware Pack P06004054A
1 Owners Manual P80116074A
Parts List  463234703
• Necessarytoolsforassemblyofyourgrillinclude:
Phillips
®screwdriver,pliersandadjustablewrench.
Before Beginning Assembly
CertifiedGrillPartsAndAccessories®,CharBroilandDesign®,CharBroil(GasGrillBriquettes)®,
CharDiamonds®,CookingZoneandDesign®,DiamondFlame®,ExecutiveChef®,Faststart®,
FlareFighter®,FlavorMaster®,GasGrillSilouetteandDesign®,H2OSmoker®,LavaFlame®,
MasterFlame®,MasterFlamePrecisionCookingSystem®,PowerSpark®,Quantum®,VIP®,
PrecisionFlameandDesign®,Sierra®,andTruFlame®areregisteredTrademarksoftheW.C.Bradley
Company.Thermos®isaregisteredtrademarkoftheThermosCompanyanditsaffiliates.
ArtisanCollectionbyCharBroil™,C3andDesign™,CharBroilandDesign™,FlameDesign™,
FlavorTents™,Grill2Go™,Grillin’Stick™,KeeperoftheFlame™,KeepersoftheFlame™,
NaturalGrip™,OutdoorCookingCollectionandDesign™,PatioBistro™,PrecisionFlame™,ProCheck™,
QuickSetGrillsandDesign™,SmokerTents™,TheBigEasy™,TheMinuteGrill™,TheEdge™,
TheTuscanCollection™,andTheUrbanGrill™areTrademarksoftheW.C.BradleyCompany.Universal
GrillPartsandDesign™isatrademarkoftheThermosCompanyanditsaffiliates.
ProtectedunderoneormoreofthefollowingU.S.Patents:4,598,692;4,624,240;4,747,391;4,747,391;
4,817,583;4,924,846;4,989,579;5,003,960;5,076,256;5,076,257;5,090,398;5,109,834;5,224,676;
5,277,106;5,421,319;5,441,226;5,452,707;5,458,309;5,566,606;5,566,606;5,579,755;5,582,094;
5,613,486;5,649,475;5,706,797;5,711,663;5,765,543;5,931,149;5,996,573;6,095,132;6,135,104;
6,279,566;D282,619;D339,714;D341,292;D343,337;D358,059;D361,466;D364,535;D372,637;
D373,701;D377,735;D383,035;D397,910;D405,643;D405,643;D406,005;D406,009;D413,043;D413,229;
D413,229;D414,982;D415,388;D416,164;D416,441;D416,441;D417,587;D422,516;D423,274;D423,876;
D428,303;D435,396;D436,004;D438,059;D438,060;D438,427;D439,110;D442,505;D443,179;D443,354;
D447,384;D447,385;D447,909;D448,610;D448,614;D448,615;D448,616;D448,975;andD449,492.
OtherPatentsPending.

463234703 • 5
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6 • 463234703
Assembly  463234703
• Unpack and remove all protective packaging.
1. Positionbottomshelfwiththetopholestowardyou.Thisis
thefront.See Fig. 1.
VERY IMPORTANT:Thelabelsonthecartlegs
indicatetheirassemblypositiontothebottomshelf.LF LF
LF LF
LF=Left
Front, LR LR
LR LR
LR=Left Rear, RF RF
RF RF
RF=Right Front, and RR RR
RR RR
RR=Right
Rear.Labelsshouldfaceinwardtowardeachotherwhen
correctly assembled. Remaining components cannot be
assembled if leg positions are incorrect.
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bowlsupportbrackets,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
Bowl
support
bracket
Bottom
shelf
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.
5. Installthetwosidepanelsandonerearpaneltothecartby
using4ofthe 3/16x1/2"Phillipsheadscrewsoneach
panel.Leaverearpanelscrewsloose.See Fig. 2.
FIGURE 2
Caster
Rear
panel
Side
panel
Side
panel
6. 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. 3.
7. Attachthedoorstoptothebottomshelf,withtheflange
facingthefront,using2ofthe 3/16x3/8"Phillipshead
screws.Fullytighten.See Fig. 3.
8. 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. 3.
9. Removeprotectivefilmfromdoors.Installdoorhandlesto
doorsusing4ofthe 3/16x3/8" Phillipsheadscrewsand
washers.See Fig. 3.
10. Attachthe4sideshelfbracketstothetopsofthecartlegs
using8ofthe 1/4x1/2"Phillipsheadscrews.Besurethe
flatsideofeachbracketfacesoutward.Fullytighten.
See Fig. 3.
ÔÚ
ÔÎ
ÎÎ
ÎÚ
Top holes
11. Placethesideshelvesovertheshelfbracketsandbowl
supportbracketswiththewiderspacedshelfholestothe
outside(shelfwithtrimplateonrightside).Besurethe
insideshelfholesalignwithholesinbowlsupportbracket.
See Fig. 3.

463234703 • 7
12. Toinstallthesideshelfhandle,removetheboltandwasher
fromonesideofthehandle(capremainswithhandle).
Frombeneathshelf,placewasherontoboltandinsertbolt
throughendofshelfbracket,sideshelf,andintohandle.
Leaveboltlooseuntilothersideofhandleisattached,then
fullytightenbothsides.Repeatforothersideshelf.
Assemblethematchlightstickandchainon
theRightrearlegusing3/16"x1/2"selftapping
Phillip’sheadscrew.See Fig. 3.
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.
15. 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bowlsupportbracketon
thecart.Raisethegrilllidandinsert4ofthe 1/4x1/2"
Phillipsheadscrews.Beneaththesideshelves,add
1/4" nuts.Donotfullytighten.See Fig. 5.
Basket
FIGURE 4
Tool
hooks
13. Installbaskettorightsidepanelby
placingbaskethooksintopanel
ventsandsecuringbottomof
baskettopanelusing2ofthe
3/16x3/8" Phillipshead screws
and 3/16" lock nuts.Fully
tighten.See Fig. 4.
14.
Note: Some previously
assembled components not
shown for clarity.
Slidetoolhooksontotowel
bar.Assemblethetowelrodwith
thehookstothefrontoftheright
shelfwithtwo,3/16"nuts
provided.See Fig. 4.
FIGURE 3 Shelf
handle
Side
shelf
Shelf bracket,
flat side facing
outward
Lower
hole
Do or
bracket
Do or
Handle
Hinge
Hinge
hole
Align
holes
Do or
stop
Remove
film
Side Burner
frame
Side Burner
Lid
Screw with
washer
FIGURE 5
Grill
head
Hang
ledge
Hang
ledges
rest on
shelves
Match light
stick & chain

8 • 463234703
16. Securegrillheadtoallcartlegsusing4ofthe 1/4x21/2"
Phillipsheadscrewsand 1/4" nuts.(Nutsmaybewelded
inplace) See Fig. 6.
17. Fully tighten all leg screws, rear panel screws, door
bracket screws, and grill head screws.
18. 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. 6.
20. Unscrewtheignitorcaplocatedonthecontrolpaneland
removethecontactandspringfromtheignitorslot.(Ignitor
Postionmayvaryfromillustration)
See Fig. 7.
21. PlacethesuppliedAAbatteryintotheignitorslotwiththe
positivepolefacingtowardyou.
22. Placethespringwithcontactoverthebattery.Screwthe
ignitorcapbackontothecontrolpanel.
FIGURE 6 Grease
draining
tray
Grease
receptacle
Attach grill head
to all 4 legs
23. Assembletheregulatormountedonthe"L"bracketonto
theLeftrearlegwith3/16"X1/2"Phillip'sheadscrew.
See Fig. 9.
FIGURE 9
Contact
Spring
AA Battery
FIGURE 8
Ignitor
cap +
–
19.InserttheorificethroughtheOrificeSupport
Bracketandintotheairshutterofsideburner.See Fig. 7.
Attachthefrontpanelwiththevalvestemgoingthroughthe
frontpanel.Fixthefrontpanelusingscrewsandnuts.
Assemblebothvalveandcontrolknobseattofrontpanel
usingthesamescrews.Connectthewirefromgrillheadto
theotherwireofelectrodeassembly.See Fig. 7a.
FIGURE 7
Orifice Support
Bracket
Sideburner
Valve
FIGURE 7a
Control
Kn ob
Control
Knob Seat
Front
Panel
Regulator
with "L"
bracket
Electrode & wire
Assembly
Wire from Grill
head
Valve
Orifice
Air Shutter

463234703 • 9
24. Placethe3flametamersonthelowerledgeabove
burners.See Fig. 10.Theyshouldmeetinthecenter.
25. Placethecookinggridsontheledgeabovetheflame
tamers.See Fig. 10.
26. Placethewarmingrackintotheslotsontheupperleftand
upperrightofthegrillbowlpanels.See Fig. 10.
FIGURE 10 Warming
rack
FIGURE 11
Handle
Bushing and collar
Forks
Spit rod
Motor
Bracket
Flame tamer
Cooking
grid
Lower
ledge
27. Attachrotisseriemotorbrackettobowlsidepanelusing
screws,washers,andnutsprovided,thenslidemotoronto
bracket.See Fig. 11.
28. Twisthandleontothreadedendofspitrod,thenadd
bushing,collar,andforkstospit.Insertspitintomotorand
restcollaringrooveofoppositeside.
BeforeYourFirstCookout
• Performtheleaktestasindicatedintheuseandcare
section.
• 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.
29. Threadthenaturalgashose(soldseparately)ontothe
regulator fitting and wrenchtighten the connection.
See Fig. 12. Please read"ConnectingYourGrilltothe
NaturalGasSource" and"LeakTesting", in the Use
and Care section, before using your grill.
FIGURE 12
Natural gas
quick connect
hose
Regulator
fitting

10 • 463234703
ConnectingYourGrilltothe
NaturalGasSource
1. Coatpipenipplewithgasresistantdope.Screwsocketontogas
manifoldatgassource(A).
2. Connectunattachedendofnaturalgashosetosocket.Pushsleeve
backonsocket(B)andinsertpluguntilsleevesnapsforward,locking
plugintosocket.
Whensocketandplugareconnected,valveinsocketopensautomati
callytopermitfullgasflow.Whencouplingisdisconnected,valvein
socketinstantlyandpositivelyshutsoffflowofgas.Becausevalvein
socketpositivelyshutsoffflowofgas,grillcanbedisconnectedfromgas
sourcebydisconnectinghosefromsocket.Socketcanbelefton
manifoldofgassourceifsodesired.
With proper assembly, plug cannot be removed without
pushing sleeve back. Todisconnect,pushsleevebackandpullplug
outofsleeve(thisautomaticallyshutsoffgas).
Please Note: Hose and assembly are A.G.A. certified and C.G.A.
listed for natural gas, manufactured gas, mixed gas and for
liquefied petroleum and for LP GasAir mixtures on basis of 0.64
specific gravity for 1000 BTU's per cubic foot of gas at 0.3 in.
water column pressure drop. Only ANSI Z21.54 approved hoses
should be used with this grill.
The appliance and its individual shut off valve must be discon
nected from the gas supply piping system during any pressure
testing of that system at test pressures in excess of
1/2 psig (3.5kPa).
The appliance must be isolated from the gas supply piping
system by closing its individual manual shutoff valve during
any pressure testing of the gas supply piping system at test
pressures equal to or less than 1/2 psi (3.5 kPa).
Use and Care
Gas
Flow
Pipe Nipple
Gas Manifold
Socket
Sleeve
Insert cover in socket
when hose is removed
Plug
Hose
Socket
Push sleeve back to attach
Hose
Plug
B B
B B B
A A
A A
A
WARNING WARNING
WARNING WARNING
WARNING
• Connection to gas source must be done by a
certified plumber.
IMPORTANT: IMPORTANT:
IMPORTANT: IMPORTANT: IMPORTANT: Regulator supplied with grill MUST be
utilized for natural gas connection.
WARNING WARNING
WARNING WARNING
WARNING
• Do not use hard metal piping of any kind to
connect this type of grill to natural gas source. Use
ONLY hose specified by CharBroil. Using hard
metal piping or convoluted metal tubing is an
unsafe practice. Movement of the grill can cause
breakage of metal pipe.