Char-Broil 463820208 User manual

MODEL 463820208 ,, 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 manual7 Wear
protective gloves if necessary.
463820208•80016427•12_04_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 tank not connected for use shall not
er not connected for use shall not
be stored in the vicinity of this or any other
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.
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 natural gas.
•Grill installation must conform with local codes, orin 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 forRecreational
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 70or Canadian
Electrical Code, CSAC22.1. Keep any electrical cords and/or
fuel supply hoses away from any hot surfaces.
• Grill is not for use in or on recreational vehicles and/or boats.
• This grill issafety certified for use in the United States and/or
Canadaonly. Do not modifyfor use inany other location.
Modification wilt result in a safety hazard.
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.
Safety Symbols
The symbols and boxes shown below explain what each heading
means. Read and follow all of the messages found 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: Indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
WARNING: Indicatesan potentiallyhazardous situation
which, if not avoided, could result in death or serious injury.
CAUTION
CAUTION: Indicatesa potentially hazardoussituationor
unsafe practicewhich, if notavoided, may result in minor
or moderateinjury.
2•463820208

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 ....................................... 13-19
Troubleshooting.................................. 20-21
Limited Warranty.................................... 22
Registration Card ................................... 23
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 a gas leak and fire. Use only
authorized replacement parts supplied by
manufacturer.
463820208 • 3

• NEVERstore aspare LP tank under or near the
appliance or in anenclosed area.
• Never fill a tank beyond 80%full.
• An over filled or improperlystored tank 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 tank/appliance
and call your fire department.
• If the above is not followed exactly, a fire causing
death or serious injurymay occur.
LP tank Removal, Transport and Storage
•Turn OFF all control knobs and LP tankvalve. Turn coupling
nutcounterclockwise by hand only - do not use tools to
disconnect .Loosen tank screw beneath bottom shelf, then lift
LP tank up and out of cart. Placedust cap on tank valve outlet
whenever the tank is not in use. Only install the type of dust
cap on the tank valve outlet that is provided with the tank
valve. Always use cap and strap supplied with valve. Other
types of caps or plugs may result in leakage of propane.
Failure to use dust cap as directed may result in serious
personal injuryand/or property damage.
• A disconnected LP tank in LPtank Valve
storage or being transported
must havea dust cap installed (as shown).
Do not store an LPtank in enclosed spaces
such as a carport, garage, porch, covered
patio or other building. Never leavean LP tank
inside a vehicle which may becomeoverheated
by the sun.
• Do notstore an LPtank in an area where children play.
Dust
Cap
RetainerStrap
LP tank
• The LP tank used with your grill must meet the following
requirements:
• Use LP s only with these required measurements: 12" (30.5cm)
(diameter) x 18" (45.7 cm) (tall) with 20 lb. (9 kg.) capacity
maximum.
• LPtanks must be constructed and marked in accordance with
specifications for LP tanks of the U.S. Department of
Transportation (DOT) or for Canada, CAN/CSA-B339, tanks,
spheres and tubes for transportation of dangerous goods.
Transport Canada (TC). See LP tank collarfor marking.
• LPtank valve must have:
• Type 1 outlet compatiblewith
regulatoror grill.
• Safety reliefvalve.
• ULlisted Overfill Protection
Device (OPD). This OPD safety OPDHandWheel
feature is identified by a unique triangular hand wheel. Use
only LP tanks equipped with this type of valve.
• LPtank must be arranged for vapor withdrawal and include
collar to protect LP tank valve.Always keep LP tanks in upright
positionduring use, transit or storage.
LP tank in upright position for vaporwithdrawal
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 flammable and may ignite unexpectedly when
mixed with air.
LP tank Filling
•Use only licensed and experienced dealers.
•LPdealer must purge new tank before filling.
• Dealershould NEVER fill LP tank more than 80% of LP tank
volume. Volume of propane in tank wilt vary by temperature.
• A frosty regulator indicates gas overfill. Immediatelyclose LP
tank 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 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.
4•463820208

LP tank Exchange
• Many retailers that sell grills offer you the option of replacing
your empty LP tank through an exchange service. Use only
those reputable exchange companiesthat inspect, precision fill,
test and certify their tanks. Exchange your tank only for an
OPB safety feature-equipped tank as described in the "LP
tank" section of this manual.
• Always keep new and 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 tankOFF by turning hand-wheel clockwise to a full
stop.
4. Remove the protective capfrom LP tank valve.Always use
cap and strap supplied with valve.
LP tank Leak Test
For your safety
•Leak test mustbe repeated each time LPtank 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.
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 regulator and insert nipple into LP
tank valve. Hand-tightenthe coupling
nut, holding regulator in a straight line
with LP tank valve so as not to cross-
thread the connection.
Continued on nextpage.
If"growing"bubblesappear do not useor move the LP
tank, Contact an LPgas supplieror your fire department!
Nipplehasto be centered
intothe LPtankvalve.
463820208 •5

Holdcoupling nut and regulator
asshown for properconnection
to LP tank valve.
Leak Testing Valves, Hose and Regulator
1. Turn all grill control knobs to OFF.
2. Be sure regulator istightly connected to LP tank.
3. Completely open LP tank 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.
A Neverremovethreaded
orifice atend of valve.
6. Turnthe coupling nut clockwiseand 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 regulatorand
repeat steps 5 and 6. If you are still unable to completethe
connection, do not use this regulator!
Do not insertany tool or foreignobject into thevalve
outlet or safety relief valve. You may damagethe valve
and cause a leak. Leakingpropane may result in
explosion,fire, severepersonal injury,ordeath.
Outdoorgas appliance is not intendedto beinstalled
in or on a boat.
Outdoorgas appliance is not intendedto beinstalled
in oron 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 cannotstop a gas leak, immediately close
Lptankvalve and call LPgas supplier oryour fire
department!
.
.
If "growing" bubblesappear, there is a leak. Close LP tank
valve immediately and retighten connections. If leaks cannot
be stopped do not try to repair. Call for replacement parts.
Order newparts 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 tankvalve after performing leak test by
turning hand wheel clockwise.
6•463820208

For Safe Use of Your Grill and to Avoid Serious
Injury:
•Do not letchildren operate or play near grill.
• Keepgrill area clear and freefrom materials that burn.
• Do not blockholes in sidesor backof 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 orceramic 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,liveelectrical appliances,etc..
• Apartment Dwellers:
Checkwith managementto learnthe requirements
and fire codes for using an LPgasgrill in your
apartmentcomplex. If allowed, useoutside onthe
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 aclosed grill is
hazardous.
•Never operate grillwith LP tank out of correct
positionspecified in assembly instructions.
• Always close LP tank valve and remove coupling
nut before movingLP tank from specified
operationposition.
Safety Tips
A Beforeopening LP tank valve, check the coupling nutfor
tightness.
A When grill is not in use, turn off all control knobs and LP tank
valve.
A If the outdoor cooking gas appliance is not in use, the gas
must be turned off at the supply tank. Storage of an outdoor
cooking gas appliance indoors ispermissible only ifthe tank
isdisconnected and removed from the appliance.
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 side shelves is 10 Ibs.
A The grease cup must be inserted into grease clip and
emptied after each use. Do not remove grease cup 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 The regulator may make a humming or whistling noiseduring
operation. This will notaffect safety or use of grill.
A 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.
A If you have a grill problem see the "Troubleshooting Section".
A If the regulator frosts, turn off grill and LP tank valve
immediately.This indicatesa problemwith the tank 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 on a grease fire. Personalinjury
may result. If a grease fire develops, turn knobs
and LP tank off.
Do not leavegrill unattendedwhile 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.
463820208 •7

Ignitor Lighting
ADo not lean over grill while lighting.
1. TurnOFF gas burner control valves.
2. Turn ON gas source or tank.
3. Open lid during lighting.
4. Toignite, turn ignition left knob to PRE-HEAT_I:,Go to step 3.
5. Push IGNITORbutton rapidly.
6. If ignition doe NOT occur in 5 seconds, turn the burner
controls OFF,wait 5 minutes and repeat the lighting
procedure.
7. Toignite right burner,turn right knobto PRE-HEAT.
CAUTION
If ignitiondoes NOToccur 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
,& Do not lean over grill while lighting.
1. Open lid during lighting. Turn on gas at LP tank.
2. Place lit match into match holder,then into side of grill bottom
(as shown below).
3. Push in and turn IGNITION BURNER knob toJt: HI. Be sure
burner lights and stays lit.
4. Toignite right burner,turn right knobto HI.
Burner Flame Check
• Removecooking grates and flametamers. Light burners, rotate
knobsfrom HI to LO. Youshould see a smaller flame in LO
position than seen on HI.Always check flame priorto each use.
If only low flame is seen referto "Sudden drop or low flame" in
the TroubleshootingSection.
Turning Grill Off
• Turn all knobs to OFF position. Turn LPtank off by turning
hand-wheelclockwise to a full stop.
Ignitor Check
•Turn gas off at LP tank. Press ignitor button rapidly. "Click"
should be heardand spark seen each time between collector
boxor burner and electrode. See "Troubleshooting" if no click
or spark.
Valve Check
•important: Makesure gas is off at LPtank before checking
valves. Knobslock in OFF position. Tocheck valves, first
pushin knobs and release, knobs should spring back. If knobs
do notspring back, replace valve assembly before using grill.
Turn knobs to LO position then turn back to OFF position.
Valves should turn smoothly.
Hose Check
•Beforeeach 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. Interiorsof gas grills are not painted at the
factory (and should never be painted). 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
residuecan be wiped away with baking soda/water solution or
specially formulated cleaner. Use nonabrasive scouring powder
for stubborn stains.
•Painted surfaces: Wash with milddetergent or nonabrasive
cleaner and warm soapy water. Wipe dry with a soft
nonabrasive cloth.
•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.
8•463820208

fSPIDER ALERT!
CONTROLPANEp
GAS COLLECTOR
BOX & IGNITOR
,f BURNER
SPIDERWEBS
INSIDEVENTURI
VALVE AIR VENTURI
SHUTTER
Ifyou notice thatyour grill is getting hard to light or that the
flameisn't as strong asit should be,take thetime to check and
cleanthe venturi's.
LIFT OUT
BURNERASSEMBLY
REMOVE
BURNER
CLIPS
CLEANOUT SPIDERWEBS
VENTURI INSIDE VENTURI
Insomeareasofthecountry,spidersor smallinsectshavebeen
knowntocreate"flashback"problems.Thespidersspinwebs,build
nestsandlayeggsinthegrill'sventuritube(s)obstructingtheflowof
gastotheburner.Thebacked-upgascanigniteintheventuribehind
thecontrolpanel.Thisisknownasa flashbackand itcandamage
yourgrillandevencauseinjury.
Topreventflashbacksandensuregoodperformancetheburnerand
venturiassemblyshouldbe removedfromthegrillandcleaned
beforeusewheneverthegrill hasbeenidleforan extendedperiod.
,,. j
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 tank.
2. Remove cooking grate and vaporiser bar.
3. Under grill remove grease cup, disconnect ignitorwire and
clips from burner.To remove clips pull down on large end of
clip attached to the valve, turn away from valve, rotate
upward and remove smallend of clip from burner tube (A).
4. Insidegrill remove burner assembly (B), clean ceramic
portion of electrode with rubbing alcohol and a swab.
5. Clean outsideof burner with 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. Ifany
large cracks or holes are 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.
8. Toreattach clips hold large curved end away from burner
tube, insert small curved end into hole under burner tubes,
turn clip towards valve, snap into place.
VERY IMPORTANT: Burner tubes must reengage valve
openings. See illustration (A).
9. Reattach ignitorwire toelectrode.
10. Reposition vaporiser bar and cooking grate. Reattach clean
grease cup to grease clip.
11. Before cooking again on grill, perform a "Leak Test'and
"BurnerFlame Check".
............. Valve
S
Z
Storing Your Grill
• Clean cooking grates.
• Store in dry location.
• Cover grill if stored outdoors. Choose from a variety of grill
covers offered by manufacturer.
• When LPtank is connected to grill, store outdoors in a well-
ventilated space and out of reachof children.
• Ifthe outdoor cooking gas appliance is not in use, thegas must
be turned off at the supply tank. Storage of an outdoor cooking
gas appliance indoors is permissibleonly ifthe tank is
disconnected and removed from the appliance.
• Store grill indoors ONLYif LPtank is turned off and
disconnected, removed from grill and stored outdoors.
• When removing grill from storage, follow "Cleaning the Burner
Assembly" instructions before starting grill.
B
A
Correct burner-to-valveengagement
463820208 •9

Food Safety
Food safety isa very important part of enjoying the outdoor
cooking experience. To keepfood 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 meatsand poultry from ready-to-eat
foods to avoid cross contamination. Usea clean platter and
utensils when removing cooked foods.
Cook: Cook meat and poultry thoroughly to kill bacteria. Use a
thermometer to ensure proper internalfood temperatures.
Chill: Refrigerate prepared foods and leftovers promptly.
For more information call: USDA Meatand 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.
• Hamburgers madeof any ground meat or poultry should reach
160° F, andbe brown in the middle with no pinkjuices. Beef,
veal and lamb steaks, roasts and chops can be cookedto 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.
10 • 463820208