Char-Broil 463860108 User manual

THIS GRILL IS FOR OUTDOOR USE ONLY.
If you have any questions or need assistance during assembly, please call 1-800-241-7548.
To insure your satisfaction and for follow-up service, register your grill online at www.grillregistration.com
463860108 • 80016566 • 01-10-08
CAUTION:
Read and follow all safety statements, assembly
instructions, and use and care directions before
attempting to assemble and cook.
INSTALLER/ASSEMBLER:
Leave this manual with consumer.
CONSUMER:
Keep this manual for future reference.
WARNING:
Failure to follow all manufacturer’s instructions
could result in serious personal injury and/or
property damage.
CAUTION:
Some parts may contain sharp edges –
especially as noted in the manual! Wear
protective gloves if necessary.
MODEL 463860108 • PRODUCT GUIDE

2 • 463860108
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
WARNING
CAUTION
For residential use only. Do not use for commercial
cooking.
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.
• To order non-warranty replacement parts or accessories
please visit 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.
WARNING
CALIFORNIA PROPOSITION 65
1. Combustion by-products produced when using
this product contain chemicals known to the State of
California to cause cancer, birth defects, and other
reproductive harm.
2. This product contains chemicals, including lead
and lead compounds, known to the State of
California to cause cancer, birth defects or other
reproductive harm.
Wash your hands after handling this product.
DANGER
Safety Symbols
The symbols and boxes shown below explain what each heading
means. Read and follow all of the messages found throughout
the manual.
DANGER: Indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
WARNING
WARNING: Indicates an potentially hazardous situation
which, if not avoided, could result in death or serious injury.
CAUTION
CAUTION: Indicates a potentially hazardous situation or
unsafe practice which, if not avoided, may result in minor
or moderate injury.
Model Number
Serial Number
Date Purchased
IMPORTANT: Fill out the product record information below.
See rating label on grill for serial number.
DANGER
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.
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, 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, CSA B149.1, or Propane Storage and
Handling Code, B149.2, or the Standard for Recreational
Vehicles, ANSI A 119.2/NFPA 1192, and CSA Z240 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 hot surfaces.
• Grill is not for use in or on recreational vehicles and/or boats.
• This grill is safety certified for use in the United States and/or
Canada only. Do not modify for use in any other location.
Modification will result in a safety hazard.

TABLE OF CONTENTS
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.......................................13-22
Troubleshooting..................................23-25
Limited Warranty....................................24
Registration Card...................................27
463860108 • 3
To insure your satisfaction
and for follow-up service,
register your grill
online at:
www.grillregistration.com
WARNING
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.

• NEVER store a spare LP tank under or near the
appliance or in an enclosed area.
• Never fill a tank beyond 80% full.
• An over filled or improperly stored tank is a
hazard due to possible gas release from the
safety relief valve.
• If you see, smell or hear gas escaping,
immediately get away from the LP tank/appliance
and call your fire department.
• If the above is not followed exactly, a fire causing
death or serious injury may occur.
DANGER
USE AND CARE
LP tank Removal, Transport and Storage
• Turn OFF all control knobs and LP tank valve. Turn coupling
nut counterclockwise by hand only - do not use tools to
disconnect .Loosen tank screw beneath bottom shelf, then lift
LP tank up and out of cart. Place dust 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 injury and/or property damage.
• A disconnected LP tank in
storage or being transported
must have a dust cap installed (as shown).
Do not store an LP tank in enclosed spaces
such as a carport, garage, porch, covered
patio or other building. Never leave an LP tank
inside a vehicle which may become overheated
by the sun.
• Do not store an LP tank in an area where children play.
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.
• LP tanks 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 collar for marking.
•LP tank valve must have:
• Type 1 outlet compatible with
regulator or grill.
• Safety relief valve.
• UL listed Overfill Protection
Device (OPD). This OPD safety
feature is identified by a unique triangular hand wheel. Use
only LP tanks equipped with this type of valve.
• LP tank must be arranged for vapor withdrawal and include
collar to protect LP tank valve. Always keep LP tanks in upright
position during use, transit or storage.
OPD Hand Wheel
LP (Liquefied Petroleum Gas)
•LP gas is nontoxic, odorless and colorless when produced. For
Your Safety, LP gas has been given an odor (similar to rotten
cabbage) so that it can be smelled.
•LP gas is highly flammable and may ignite unexpectedly when
mixed with air.
LP tank Filling
•Use only licensed and experienced dealers.
•LP dealer must purge new tank before filling.
•Dealer should NEVER fill LP tank more than 80% of LP tank
volume. Volume of propane in tank will vary by temperature.
•A frosty regulator indicates gas overfill. Immediately close LP
tank valve and call local LP gas dealer for assistance.
• Do not release liquid propane (LP) gas into the atmosphere.
This is a hazardous practice.
• To remove 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 • 463860108
LP tank Valve
Retainer Strap
Dust
Cap
LP tank in upright position for vapor withdrawal

WARNING
If “growing” bubbles appear do not use or move the LP
tank. Contact an LP gas supplier or your fire department!
Connecting Regulator to the LP tank
1. LP tank must be properly secured onto grill. (Refer to
assembly section.)
2. Turn all control knobs to the OFF position.
3. Turn LP tank OFF by turning hand-wheel clockwise to a full
stop.
4. Remove the protective cap from LP tank valve. Always use
cap and strap supplied with valve.
Safety Relief Valve
Nipple has to be centered
into the LP tank valve.
OPD Hand Wheel
Type 1 outlet with
thread on outside
c k w
o
l
i
s
C
e
f
f
O
Do not use a POL transport plug
(plastic part with external threads)!
It will defeat the safety feature of
the valve.
Strap and Cap
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 companies that inspect, precision fill,
test and certify their tanks. Exchange your tank only for an
OPD 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.
LP tank Leak Test
For your safety
•Leak test must be repeated each time LP tank is exchanged or
refilled.
•Do not smoke during leak test.
•Do not use an open flame to check for gas leaks.
•Grill must be leak tested outdoors in a well-ventilated area,
away from ignition sources such as gas fired or electrical
appliances. During leak test, keep grill away from open flames
or sparks.
• Use a clean paintbrush and a 50/50 mild soap and water
solution.
s Do not use household cleaning agents. Damage to gas
train components can result.
Brush soapy solution onto areas indicated by arrows
in figure below.
5. Hold regulator and insert nipple into LP
tank valve. Hand-tighten the coupling
nut, holding regulator in a straight line
with LP tank valve so as not to cross-
thread the connection.
Continued on next page.
463860108 • 5

6. Turn the coupling nut clockwise and tighten to a full stop. The
regulator will seal on the back-check feature in the LP tank
valve, resulting in some resistance. An additional one-half to
three-quarters turn is required to complete the
connection. Tighten by hand only – do not use tools.
NOTE:
If you cannot complete the connection, disconnect regulator and
repeat steps 5 and 6. If you are still unable to complete the
connection, do not use this regulator!
Straight
Hold coupling nut and regulator
as shown for proper connection
to LP tank valve.
DANGER
• Do not insert any tool or foreign object into the valve
outlet or safety relief valve. You may damage the valve
and cause a leak. Leaking propane may result in
explosion, fire, severe personal injury, or death.
Leak Testing Valves, Hose and Regulator
1. Turn all grill control knobs to OFF.
2. Be sure regulator is tightly 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.
5. If “growing” bubbles appear, 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 new parts by giving the serial, model number and name
and part number of items needed (see parts list) to the Grill
Service Center at 1-800-241-7548.
6. Always close LP tank valve after performing leak test by
turning hand wheel clockwise.
6 • 463860108
• Outdoor gas appliance is not intended to be installed
in or on a boat.
• Outdoor gas appliance is not intended to be installed
in or on an RV.
• Never attempt to attach this grill to the self-contained
LP gas system of a camper trailer or motor home.
• Do not use grill until leak-tested.
• If a leak is detected at any time, STOP and call the fire
department.
• If you cannot stop a gas leak, immediately close
Lptank valve and call LP gas supplier or your fire
department!
WARNING
s Never remove threaded
orifice at end of valve.

For Safe Use of Your Grill and to Avoid Serious
Injury:
•Do not let children operate or play near grill.
•Keep grill area clear and free from materials that burn.
•Do not block holes in sides or back of grill.
•Check burner flames regularly.
•Use grill only in well-ventilated space. NEVER use in
enclosed space such as carport, garage, porch,
covered patio, or under an overhead structure of any
kind.
•Do not use charcoal or ceramic briquets in a gas grill.
(Unless briquets are supplied with your grill.)
• Use grill at least 3 ft. from any wall or surface.
Maintain 10 ft. clearance to objects that can catch fire
or sources of ignition such 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 floor with a three (3) foot clearance from walls
or rails. Do not use on or under balconies.
• NEVER attempt to light burner with lid closed. A
buildup of non-ignited gas inside 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.
WARNING
Safety Tips
sBefore opening LP tank valve, check the coupling nut for
tightness.
sWhen grill is not in use, turn off all control knobs and LP tank
valve.
sIf 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 is permissible only if the tank
is disconnected and removed from the appliance.
sNever move grill while in operation or still hot.
sUse long-handled barbecue utensils and oven mitts to avoid
burns and splatters.
sMaximum load for side shelves is 10 lbs.
sThe grease cup must be inserted into grease clip and
emptied after each use. Do not remove grease cup until grill
has completely cooled.
s 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 recommended to clean cooking surfaces
while grill is hot.
sIf you notice grease or other hot material dripping from grill
onto valve, hose or regulator, turn off gas supply at once.
Determine the cause, correct it, then clean and inspect valve,
hose and regulator before continuing. Perform a leak test.
sThe regulator may make a humming or whistling noise during
operation. This will not affect safety or use of grill.
sOnly use 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.
sIf you have a grill problem see the "Troubleshooting Section".
sIf the regulator frosts, turn off grill and LP tank valve
immediately. This indicates a problem with the tank and it
should not be used on any product. Return to supplier!
CAUTION
• Putting out grease fires by closing the lid is not
possible. Grills are well ventilated for safety
reasons.
• Do not use water on a grease fire. Personal injury
may result. If a grease fire develops, turn knobs
and LP tank 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.
463860108 • 7

CAUTION
If ignition does NOT occur in 5 seconds, turn the
burner controls OFF, wait 5 minutes and repeat the
lighting procedure. If the burner does not ignite with
the valve open, gas will continue to flow out of the
burner and could accidently ignite with risk of injury.
Burner Flame Check
• Remove cooking grates and flame tamers. Light burners, rotate
knobs from HI to LO. You should see a smaller flame in LO
position than seen on HI. Always check flame prior to each use.
If only low flame is seen refer to "Sudden drop or low flame" in
the Troubleshooting Section.
HI
LO
Turning Grill Off
• Turn all knobs to position. Turn LP tank off by turning
hand-wheel clockwise to a full stop.
Ignitor Check
• Turn gas off at LP tank. Press ignitor button rapidly. "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: Make sure gas is off at LP tank before checking
valves. Knobs lock in position. To check 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 position.
Valves should turn smoothly.
Hose Check
•Before each use, check to see if hoses are cut or worn.
Replace damaged hoses before using grill. Use only
valve/hose/regulator specified by manufacturer.
General Grill Cleaning
• Do not mistake brown or black accumulation of grease and
smoke for paint. Interiors of gas grills are not painted at the
factory (and should never be painted). Apply a strong solution
of detergent and water or use a grill cleaner with scrub brush
on insides of grill lid and bottom. Rinse and allow to completely
air dry. Do not apply a caustic grill/oven cleaner to painted
surfaces.
• Plastic parts: Wash with warm soapy water and wipe dry.
s Do not 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.
• Painted surfaces: Wash with mild detergent or nonabrasive
cleaner and warm soapy water. Wipe dry with a soft
nonabrasive cloth.
• Cooking surfaces: 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 recommended to
clean cooking surfaces while grill is hot.
OFF
OFF
OFF
Match-Lighting
s 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 to HI. Be sure
burner lights and stays lit.
4. To ignite right burner, turn right knob to HI.
8 • 463860108
Ignitor Lighting
s Do not lean over grill while lighting.
1. Turn OFF gas burner control valves.
2.Turn ON gas source or tank.
3. Open lid during lighting.
4. To ignite, turn ignition left knob to PRE-HEAT ,Go to step 3 .
5. Push IGNITOR button rapidly.
6. If ignition doe NOT occur in 5 seconds, turn the burner
controls OFF, wait 5 minutes and repeat the lighting
procedure.
7. To ignite right burner, turn right knob to PRE-HEAT.
If ignitor does not work, follow match lighting instructions.

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 tank.
2. vaporiser b
3.
4.
5.
6.
7.
8.
VERY IMPORTANT: Burner tubes must reengage valve
openings. See illustration (A).
9. electrode
10. vaporiser
grease cup
11.
Remove cooking grate and ar.
Under grill remove grease cup, disconnect ignitor wire 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 small end of clip from burner tube (A).
Inside grill remove burner assembly (B), clean ceramic
portion of electrode with rubbing alcohol and a swab.
Clean outside of 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 holes with a thin wire. Shake
out excess water and examine holes. Due to normal wear
and corrosion some holes may become enlarged. If any
large cracks or holes are found replace burner.
If grill is to be stored, coat burner lightly with cooking oil.
Wrap in protective cover to keep insects out.
If not storing grill after cleaning, replace burner into grill
bottom.
To reattach 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.
Reattach ignitor wire to .
Reposition bar and cooking grate. Reattach clean
to grease clip.
Before cooking again on grill, perform a “Leak Test” and
“Burner Flame Check”.
CAUTION
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 LP tank is connected to grill, store outdoors in a well-
ventilated space and out of reach of children.
• 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 is permissible only if the tank is
disconnected and removed from the appliance.
• Store grill indoors ONLY if LP tank 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.
463860108 • 9
SPIDER ALERT!
GAS COLLECTOR
BOX & IGNITOR
VALVE
CONTROL PANEL BURNER
VENTURI
LIFT OUT
BURNER ASSEMBLY
AIR
SHUTTER
SPIDER WEBS
INSIDE VENTURI
SPIDER WEBS
INSIDE VENTURI
CLEAN OUT
VENTURI
REMOVE
BURNER
CLIPS
If you notice that your grill is getting hard to light or that the
flame isn’t as strong as it should be, take the time to check and
clean the venturi’s.
In some areas of the country, spiders or small insects have been
known to create “flashback” problems. The spiders spin webs, build
nests and lay eggs in the grill’s venturi tube(s) obstructing the flow of
gas to the burner. The backed-up gas can ignite in the venturi behind
the control panel. This is known as a flashback and it can damage
your grill and even cause injury.
To prevent flashbacks and ensure good performance the burner and
venturi assembly should be removed from the grill and cleaned
before use whenever the grill has been idle for an extended period.
A
Burner Tube
Valve
Correct burner-to-valve engagement
B

Food Safety
Food safety is a very important part of enjoying the outdoor
cooking experience. To keep food safe from harmful bacteria,
follow these four basic steps:
Clean: Wash hands, utensils, and surfaces with hot soapy water
before and after handling raw meat and poultry.
Separate: Separate raw meats and poultry from ready-to-eat
foods to avoid cross contamination. Use a clean platter and
utensils when removing cooked foods.
Cook: Cook meat and poultry thoroughly to kill bacteria. Use a
thermometer to ensure proper internal food temperatures.
Chill: Refrigerate prepared foods and leftovers promptly.
For more information call: USDA Meat and Poultry Hotline at
1-800-535-4555 In Washington, DC [phone], 10:00 am-
4:00 pm EST.
How To Tell If Meat Is Grilled Thoroughly
•Meat and poultry cooked on a grill often browns very fast on the
outside. Use a meat thermometer to be sure food has reached
a safe internal temperature, and cut into food to check for
visual signs of doneness.
•Whole poultry should reach 180° F; breasts, 170° F. Juices
should run clear and flesh should not be pink.
•Hamburgers made of any ground meat or poultry should reach
160° F, and be brown in the middle with no pink juices. 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.
10 • 463860108