Char-Broil 463320108 User manual

MODEL 463320108 ,, PRODUCT GUIDE
/_ CAUTION:
Read and follow all safety statements, assembly
instructions,and useand care directions before
attempting to assemble and cook.
INSTALLER/ASSEMBLER:
Leave this manualwith consumer.
CONSUMER:
Keep this manual for future reference.
/_ WARNING:
Failure tofollow all manufacturer's instructions could
result in serious personalinjury and/or property
damage.
CAUTION:
Some partsmay contain sharpedges- especiallyas
noted inthe manual! Wearprotectivegloves if
necessary.
463320108,80015846,11-16-07

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 us on 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.
CALIFORNIA PROPOSITION65
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 handling this product.
installation Safety Precautions
•Use grill, as purchased, only with LP (propane) gas and the
regulator/valve assembly supplied. A conversion kit mustbe
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 Standardfor Recreational
Vehicles,ANS/ A 119.2/NFPA1192,and CSAZ240 RV Series,
Recreational VehicleCode, as applicable.
• All electrical accessories (such as rotisserie) must be
electrically grounded in accordance with local codes, or
National Electrical Code,ANSI / NFPA 70or Canadian
Electrical Code, CSA C22.1. Keep any electrical cords and/or
fuel supply hoses away from any hot surfaces.
• This grill issafety certified for use in the United States and/or
Canada only. Donot modify for use in any other location.
Modification wilt result in a safety hazard.
Safety Symbols
The symbols and boxes shownbelow explain what each heading
means. Read and follow all of the messagesfound throughout
the manual.
iMPORTANT: Fill out the product record information below.
Model Number
Serial Number
Date Purchased
Seeratinglabelongrillforserialnumber.
CAUT,o.
For residential use only. Do not use for commercial
cooking.
DANGER: Indicatesan imminentlyhazardous situation
which, if not avoided,will result in death or serious injury.
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.
2•463320108

For Your Safety...................................... 2
Grill Service Center................................... 2
Product Record Information ............................ 2
Installation Safety Precautions .......................... 2
Safety Symbols...................................... 2
Use and Care..................................... 4-11
Parts List.......................................... 12
Parts Diagram...................................... 13
Assembly ....................................... 14-22
Troubleshooting.................................. 23-25
Warranty .......................................... 26
Registration Card ................................... 27
463320108 •3

•NEVERstore a spare LP cylinder under or near
the appliance or in an enclosed area.
•Never fill a cylinder beyond 80% full.
•An over filled or improperlystored cylinder is a
hazard due to possible gas release from the
safety relief valve.
• If you see, smell or hear gas escaping,
immediatelyget away from the LP
cylindedappliance and call your fire department.
• This could cause an intense fire with risk of
property damage, serious injury or death.
LP Cylinder Removal, Transport and Storage
•Turn OFF all control knobsand 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 injuryand/or property damage.
• Adisconnected LP cylinder in LPCylinder
storage or being transported
must havea 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 LP cylinders 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 compatiblewith
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.
• LP cylinder 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.
LP cylinder in upright position for vapor withdrawal
LP (Liquefied Petroleum Gas)
•LPgas 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.
• LPgas is highly flammable and may ignite unexpectedly when
mixedwith air.
LP Cylinder Filling
•Use only licensed and experienced dealers.
•LPdealer must purge new cylinder before filling.
• Dealershould NEVER fill LP cylinder more than 80% of LP
cylinder volume. Volumeof propane in cylinder wilt vary by
temperature.
• A frosty regulator indicates gas overfill. Immediately close LP
cylinder valve and call local LP gas dealer for assistance.
• Donot 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.
4•463320108

LP CylinderE×change
• 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 OPB 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 must be properlysecured onto grill. (Refer to
assembly section.)
2. Turnall control knobs to the OFF position.
3. Turn LP cylinder OFF by turning hand-wheel clockwise to a
full stop.
4, Remove the protective capfrom 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 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 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.
A Do not use household cleaning agents. Damage to gas
train components can result.
SafetyReliefValve
OPD Hand Wheel
//- Type1outlet 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 regulator and 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.
Nipplehas to be centered
intothe LP cylinder valve.
If"growing"bubblesappear do not useor move theLP
cylinder.Contact an LPgas supplier oryour fire
department!
463320108 •5

Holdcoupling nut and regulator
asshownfor properconnection
to LPcylindervalve.
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 byturning 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. Turnthe 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 and6. If you are still unableto completethe
connection, do not use this regulator!
A Neverremovethreaded
orificeatend of valve.
Do not insertany tool or foreignobject into thevalve
outlet or safety relief valve. You maydamage the valve
and cause a leak. Leaking propane mayresult in
explosion,fire, severepersonal injury,or death.
Outdoorgas appliance isnot intendedto be installed
in or on a boat.
Outdoorgas appliance isnot intendedto be installed
in oron an RV.
, Never attemptto attach this grill to theself-contained
LPgas system of a campertrailer or motor home.
, Do not use grill until leak-tested.
, If a leak isdetected at any time, STOPand call the fire
department.
, If you cannotstop a gas leak, immediately close
LPcylindervalve and call LPgas supplier oryour fire
department!
.
.
If "growing" bubblesappear, 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. Order new parts by giving the serial, model number and
name and part numberof items needed (see parts list) to the
Grill Service Center at 1-800-241-7548.
Always close LP cylindervalve after performing leak test by
turning hand wheel clockwise.
6•463320108

For SafeUse of Your Grill and to Avoid Serious
Injury:
•Do not letchildren operateor play near grill.
• Keepgrill area clear and freefrom materials that burn.
• Do not blockholes in sidesor back of grill.
• Check burnerflames regularly.
• Use grill only inwell-ventilated space. NEVERuse in
enclosedspace suchas carport, garage, porch,
covered patio,or under anoverhead structure of any
kind.
Do not use charcoal or ceramic briquetsin a gas grill.
(Unlessbriquets aresupplied with your grill.)
Usegrill at least 3ft. from any wall or surface.
Maintain 10ft. clearanceto objects that cancatch fire
or sources of ignition such as pilot lightsonwater
heaters,live electrical appliances,etc.
• Apartment Dwellers:
Checkwith managementto learnthe requirements
and fire codes for using an LPgasgrill in your
apartmentcomplex.If allowed, useoutside on the
ground floorwith a three (3)foot clearance fromwalls
or rails. Donot useonor under balconies.
•NEVERattempt to light burner with lid closed.A
buildup of non-ignited gas inside a closed grill is
hazardous.
•Never operategrill with LP cylinderout of correct
position specified in assembly instructions.
•Always close LP cylinder valve and remove
coupling nut before moving LP cylinder from
specified operation position.
Safety Tips
A Beforeopening LP cylinder valve, check the coupling nutfor
tightness.
A When grill is not in use, turn off all 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 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. It is not recommendedto clean cooking surfaces
while grill is hot.
A 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.
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 noise during
operation. This will notaffect safety or use of grill.
,A, If you have a grill problem see the "Troubleshooting Section".
A If the regulator frosts, turn off grill and LP cylinder valve
immediately.This indicates a problemwith the cylinder and it
should not be used on any product. Return to supplier!
CAuT,oN
•Putting out grease fires by closingthe 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
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
A Do not lean over grill while lighting.
1. Turn OFF gas burner control valves.
2 Turn ONgas source or tank
3. Open lid during lighting..
4. To ignite, turn the IGNITION BURNER knob to_ HIGH.
5. Push and hold ELECTRONIC IGNITOR button.
6. If ignition does NOT occur in 5 seconds, turn the burner
controls OFF,wait 5 minutes, and repeat lighting procedure.
7. Ignite remaining burners byturning to _, startingwith the
burners closest to the IGNITION BURNER first.
if ignition still does not occur, follow match-lighting
instructions.
Lighting instructionscontinued on nextpage.
463320108 •7

Turn controls and gas source or tank OFF when not
in use. CAUTIo.
If ignitiondoes NOT occur in 5seconds, turn the
burner controls OFF,wait 5 minutes and repeat the
lighting procedure. If the burner does not ignitewith
the valve open, gas will continue to flow out of the
burner and could accidently ignite with risk of injury.
Match-Lighting
ADo not lean over grill while lighting.
1. Open lid. Turnon gas at LP cylinder.
2. Place lit match into match holder (hangingfrom cartside
panel), light burner on right or leftside of grill.
3. Push in and turn far right or far left burner knob to HIGH. Be
sure burner lights and stays lit.
4. Light adjacent burners in sequence by pushing knobs in and
turning to HIGH.
Sideburner ignitor Lighting
,& Do not lean over grill while lighting.
1. Top cover must be open when burner is operational.
2. Toignite SIDEBURNER, open sideburner cover.
3. Turnsidebumer knobto HIGH, pushand hold ELECTRONIC
IGNITOR button.
4. If sideburner does NOT light in 5 seconds, turn knob to OFF,
wait 5 minutes, then repeat lighting procedure.
Sideburner Match Lighting
1. Open sideburner cover.
2. Place lit match near burner.
3. Turnsideburner knobto HIGH. Besure burner lights and
stays lit.
8•463320108
Burner Flame Check
• Removecooking grates and flame tamers. Light burners, rotate
knobsfrom HIGHto LOW.You should see a smaller flame in
LOW position than seen on HIGH. Perform burner flame check
on sideburner, also.Always check flame prior to each use. If
only low flame is seen refer to "Suddendrop or low flame" in
the TroubleshootingSection.
Turning Grill Off
• Turn all knobs to OFF position. Turn LP cylinderoff by turning
hand-wheel clockwise to a full stop.
Ignitor Check
• Turn gas off at LP cylinder. Press and hold electronic ignitor
button. "Click" should be heard and spark seen each time
between collector box or burner and electrode. See
"Troubleshooting" if no click or spark.
Valve Check
• Important: Makesure gas is off at LP cylinder before
checking valves. Knobs lock in OFF position.To check
valves, first push in knobs and release, knobs should spring
back. If knobsdo not 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
, Before each use, check to see if hoses are cut or worn.
Replace damaged hoses before usinggrill. Use only
valve/hose/regulator specified by manufacturer.
General Grill Cleaning
• Donot mistake brown or black accumulation of grease and
smoke for paint. Apply a strong solution of detergent and water
or usea 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 cleaner to painted surfaces.
• Plastic parts: Wash with warm soapy water and wipe dry.
,A.Donot use citrisol, abrasive cleaners, degreasers or a
concentrated grill cleaner on plastic parts. Damage to and
failure of parts can result.
• 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.
• Paintedsurfaces: Wash with milddetergent 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 dry with a soft cloth after each use. Baked-on grease
deposits may requirethe use of an abrasive plastic cleaning
pad. Use only in direction of brushed finish to avoid damage.
Do not use abrasive pad on areas with graphics.
•Cooking surfaces: If a bristle brushis usedto clean any 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.

cAuTioN
/SPIDER ALERT!
If you notice that your grill is getting hard to light or that the
flameisn't as strongas it should be, takethe time to checkand
cleanthe venturi's.
SPIDERWEBS
CONTROLPANEL INSIDE VENTURI
Insomeareasofthecountry,spidersor smallinsectshavebeen
knowntocreate"flashback"problems.Thespidersspinwebs,build
nestsandlayeggsinthegrill'sventuritube(s)obstructingtheflowof
gastotheburner.Thebacked-upgascanigniteintheventuribehind
thecontrolpanel.Thisisknownasaflashbackand itcandamage
yourgrillandevencauseinjury.
Topreventflashbacksandensuregoodperformancetheburnerand
venturiassemblyshouldbe removedfromthegrillandcleaned
beforeusewheneverthegrill hasbeenidleforan extendedperiod./
\ J
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 cylinder.
2. Remove cooking grates and heat tents.
3. Remove screws and carryover tubes from rear of burners.
4. Remove screw and washers to disengage burner from
bracket on firebox,
5. Remove screws to detach electrode from burner,Electrode
should remain in firebox,
6. 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 hangerworks well)
into a small hook. Run the hook through each burner
tube several times.
r,,_,,,,, _- ,..D
(B) Use a narrow bottle brushwith a flexible handle (do not
use a brass wire brush), run the brush through each
burner tube several times.
(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.
7. Wire brush entire outer surface of burner to remove food
residue and dirt.
8. Clean any blocked ports with a stiff wire such as an open
paper clip.
9. Check burner fordamage, 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 re-engage valve
openings. See illustrations at right.
10. Attach electrode to burner. Correct
burner-to-valve \_
11. Carefully replace burners, engagement
12. Attach burners to brackets on firebox.
13. Reposition carryover tubes and attach
to burners. Replace heat tents and
cooking grates.
Storing Your Grill
• Clean cooking grates.
• Store in dry location.
• When LP cylinder tsconnected to grill, store outdoors in a well-
ventilated space and out of reach of children.
• Cover grill ifstored outdoors. Choose from a variety of grill
covers offered by manufacturer.
• Store grill indoors ONLY if LP cylinder isturned off and
disconnected, removed from grill and stored outdoors.
• When removing grill from storage, follow "Cleaning the Burner
Assembly' instructions before starting grill.
Firebox
burner
bracket Electrode
463320108 • 9

Indirect Cooking
Poultry and large cuts of meatcook 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 when cooking extra fatty cuts because there is no direct
flame to ignitethe fats and juices that drip during cooking.
Indirect Cooking Instructions
• Always cook with the lid closed.
• 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.
1Burner Cooking
Cook with direct or indirect heat.
Best for smaller meals or foods.
Consumes less fuel.
Food Safety
Food safety isa very important part of enjoying the outdoor
cooking experience. To keep foodsafe from harmful bacteria,
follow these four basic steps:
Clean: Wash hands, utensils, and surfaces with hot soapy water
beforeand 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 kilt bacteria. Use a
thermometer to ensure proper internalfood temperatures.
Chill: Refrigerate prepared foods and leftovers promptly.
For more information call: USDA Meatand Poultry Hotlineat
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.
•Hamburgers madeof any ground meat or poultry should reach
160° F, and be brown in the middle with no pinkjuices. Beef,
veal and lamb steaks, roasts and chops can be cooked to 145°
F.All cuts of pork should reach 160° 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 165° F,or until steaming hot.
2 BurnerCooking
Great indirect cooking on low.
Produces slow, even heating.
Ideal for slow roasting and baking.
10 •463320108