Char-Broil Front Avenue User manual

1
463230703 / G408-001-000802 (06-17-03)

2
Call Grill Service Center For Help And Parts
•If you need help or warranty parts call !1-800-241-7548 U.S.
or 1-800-387-6057 CAN, 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
WarrantyInformation
ModelNumber_______________________________
LotNumber(oncartonlabel) _____________________
SerialNumber_______________________________
DatePurchased______________________________
Installation Safety Precautions
•Use grill only with LP (propane) gas and the regulator/valve
assembly supplied.
•Grill installation must conform with local codes, or in their
absence with National Fuel Gas Code, NFPA 54 / ANSI
Z223.1 or CAN/CGA-B149.2 Propane Installation
Code. 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 or Canadian
Electrical Code, CSA C22.1. 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 and
Canada 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.
•For residential use only. Do not use for commercial
cooking.
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. Openlid.
4. If odor continues, immediately call
your gas supplier or your fire
department.
• DANGER: Indicates an imminently hazardous
situation which, if not avoided, will result in death or
serious injury.
• CAUTION: Indicates a potentially hazardous
situation which, if not avoided, may result in minor
or moderate injury.
• 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.

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ForYourSafety .........................................................................2
Call Grill Service Center For Help And Parts...........................2
Installation Safety Precautions.................................................2
SafetySymbols .........................................................................2
Table of Contents.....................................................................3
Warranty....................................................................................3
Use and Care ......................................................................... 4-8
Storing Your Grill ......................................................................8
Indirect Cooking .......................................................................8
Food Safety...............................................................................9
Troubleshooting..................................................................10-11
Manufacturer 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
Manufacturer will, at its option, refinish or replace any
product or part found to be defective during the warranty
period. Manufacturer will require you to return the part(s)
claimed to be defective, for its inspection, freight or postage
prepaid.
Ifyouwishtoobtainperformanceofanyobligationunderthis
limited warranty, you should write to:
Consumer Warranty / P.O. Box 1240
Columbus, GA 31902-1240
Manufacturer 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 Manufacturer 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.
Thiswarrantydoesnotincludethecostonany
inconvenienceorpropertydamageduetofailureoftheproduct
anddoesnotcoverdamageduetomisuse,abuse,accident,
damagearisingoutoftransportationoftheproduct,ordamage
incurredthroughcommercialuseoftheproduct.Thisexpress
warrantyisthesolewarrantygivenbythemanufacturerandisin
lieuofallotherwarranties,expressorimplied,includingimplied
warrantyofmerchantabilityorfitnessforaparticularpurpose.
Neither Manufacturer 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. Manufacturer'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
varyfromstatetostate.
WarrantyTable of Contents

4
LP Tank
• TheLPtankusedwithyourgrillmustmeetthefollowing
requirements:
•Purchase LP tanks only with these required measurements:
12" (30.5cm) (diameter) x 18" (45.7 cm) (tall) with 20 lb. (9
kg.) capacity maximum.
•Be constructed and marked in accordance with
specifications for LP tank 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 tank collar for
marking.
•LPtank valvemusthave:
• Type1outletcompatiblewithregulatororgrill.
• Safetyreliefvalve.
• ULlistedOverfillProtectionDevice(OPD).
ThisOPDsafetyfeatureisidentifiedbya
uniquetriangularhandwheel.Useonly
tanksequippedwiththistypeofvalve.
• Supply system must be arranged for vapor withdrawal and
include collar to protect LP tank valve.
LP (Liquefied Petroleum Gas)
•Isnontoxic,odorlessandcolorlesswhenproduced.ForYour
Safety,LPgashasbeengivenanodor(similartorotten
cabbage)sothatitcanbesmelled.
•LP gas is highly flammable and may ignite unexpectedly
when mixed with air.
LP Tank Filling
•Useonlylicensedandexperienceddealers.
•LP tank must be purged before filling.
•Dealer should NEVER fill LP tank more than 80% of LP tank
volume.Volumeofpropaneintankwillvarybytemperature.
•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.
• LP tank Exchange: You may choose to replace your empty LP
tank through an exchange service. Use only those reputable
exchange companies that inspect, precision fill, test and
certify their cylinders. Exchange for OPD safety feature
equipped tank as described in LP Tank
•Always keep LP tank in upright position during use, transit or
storage.
•Leak test LP tank BEFORE connecting to grill.
OPD Hand Wheel
Use and Care
Use of this POL transport plug
(A) (plastic part with external
threads) will defeat safety
feature of valve.
AA
AA
A
LP Tank Leak Test
Foryoursafety
•LeaktestmustberepeatedeachtimeLPtankisexchangedor
refilled.
•Donotsmokeduringleaktest.
•Donotuseanopenflametocheckforgasleaks.
•Grillmustbeleakcheckedoutdoorsinwell-ventilatedarea,away
fromignitionsourcessuchasgasfiredorelectricalappliances.
Duringleaktest,keepgrillawayfromopenflamesorsparks.
Use a clean paint brush and 50/50 soap and
water solution. Use mild soap and water.
▲▲
▲▲
▲Do not use household cleaning agents.
Damagetogastraincomponentscanresult.
Brush soapy solution
ontotheshadedareas.
Connecting The Regulator To The LP Tank
OPD Hand
Wheel
Type 1 outlet with thread on outside
1. LP tank must be properly secured onto grill.
2. Turn all control knobs including sideburner (if featured) to the
OFF position.
3. TurnLPtankOFFbyturninghand-wheel
clockwisetoafullstop.
4. Removetheprotectivecapfrom
LPtankvalve.Alwaysusecapand
strapsuppliedwithvalve.
Strap and Cap
Safety Relief Valve
Off
Clockwise
If
"growing"
bubbles appear
do not use or move
the LP tank. Contact
an LP gas supplier or
your fire department!

5
Nipple has to be
centered into the
LP tank valve
5. Hold regulator, insert nipple (B) into LP tank valve.
Hand tighten coupling nut, holding regulator in a
straight line (C) with LP tank valve so as not to cross
thread the connection.
6. Turn the coupling nut clockwise to tighten to a full solid stop.
The regulator will seal on the back-check feature in LP tank
valve, resulting in some resistance. An additional one-half
to three quarters turn is required to complete
connection. Tighten by hand only - do not use tools.
NOTE: Ifyoucannotcompleteconnection,disconnectregulatorand
repeatsteps5and6.Ifyouarestillunabletocompletethe
connection,donotusethisregulator!
Hold coupling nut
and regulator as
shown for proper
connection to LP
tank valve.
• Do not insert any foreign objects into the valve
outlet. You may damage the valve and cause a leak.
Leaking propane may result in explosion, fire, severe
personal injury, or death.
• 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 checked.
• If leak is detected at any time, STOP and call the Fire
Department.
• If you cannot stop a gas leak, immediately close LP
tank valve and call LP gas supplier or your fire
department!
BB
BB
B
CC
CC
C
•A disconnected LP tank in storage or being transported must
have a safety 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 a LP tank inside a
vehicle which may become overheated by the sun.
•Do not store LP tank in an area where children play.
Leak Testing Valves, Hoses 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 counter
clockwise. If you hear a rushing sound, turn gas off
immediately. There is a major leak at the connection. Correct
before proceeding.
LP Tank Removal, Transport And Storage
•TurnOFFallcontrolknobsandLPtankvalve.Turncouplingnut
counterclockwisebyhandonly-donotusetoolstodisconnect.Lift
LPtankwireupwardoffofLPtankcollar,liftLPtankupandoffof
supportbracket.InstallsafetycapontoLPtankvalve.Alwaysuse
capandstrapsuppliedwithvalve.Failuretousesafetycapas
directedmayresultinseriouspersonalinjuryand/or
property damage.
LP Tank
Valve Safety
Cap
Retainer
Strap
• NEVER store a spare LP tank under or near grill or in
enclosed areas.
• Never fill the cylinder beyond 80% full. An overfilled
spare LP tank is hazardous due to possible gas
released from the safety relief valve. The safety relief
valve on a LP tank could activate releasing gas and
cause a fire, resulting in serious injury, property
damade or death.
• If you see, smell or hear escaping gas, immediately
get away from the LP tank/grill and call your fire
department.
• All spare LP tanks must have safety caps installed on
the LP tank outlet.

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4. Brush soapy
solution onto
following
connections:
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 of items needed to the Grill Service
Center at !1-800-241-7548 U.S. or 1-800-387-6057 CAN.
6. Always close LP tank valve after performing leak test by
turning hand wheel clockwise.
Safety Tips
▲▲
▲▲
▲Before opening LP tank valve, check the coupling nut for
tightness.
▲▲
▲▲
▲When grill is not in use, turn off all control knobs and LP tank
valve.
▲▲
▲▲
▲Never move grill while in operation or still hot.
▲▲
▲▲
▲When moving the grill push it forward, do not pull from
behind.
▲▲
▲▲
▲Use long-handled barbecue utensils to avoid burns and
splatters.
▲▲
▲▲
▲Do not remove grease receptacle or tray until grill has
completely cooled.
▲▲
▲▲
▲If 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, clean and inspect valve, hose
and regulator before continuing. Perform a leak test.
▲▲
▲▲
▲The regulator may make a humming or whistling noise
during operation. This will not affect safety or use of grill.
▲▲
▲▲
▲If you have a grill problem see the "Troubleshooting Section".
For Safe Use Of Your Grill:
•Donotletchildrenoperateorplayneargrill.
•Keepgrillareaclearandfreefrommaterialsthatburn.
•Donotblockholesinbottomorbackofgrill.
•Checkburnerflamesregularly.
•Usegrillonlyinwell-ventilatedspace.NEVERuseinenclosed
spacesuchascarport,garage,porch,coveredpatio,orundera
surfacethatcancatchfire.
•Usegrillatleast3ft.fromanywallorsurface.Maintain10ft.
clearancetoobjectsthatcancatchfireorsourcesofignitionsuchas
pilotlightsonwaterheaters,liveelectricalappliances,etc.
•Donotusecharcoal,briquetsorlavarockinthisgrill.
• ApartmentDwellers:
Checkwithmanagementtolearntherequirementsandfirecodes
forusinganLPGasGrillinanapartmentcomplex.Ifalloweduse
outsideonthegroundfloorwithathree(3)footclearancefrom
wallsorrails.Donotuseonorunderbalconiesmadeofwood.
• 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.
• Always close LP tank valve and remove coupling nut before
moving LP tank from specified operating position.
• Putting out grease fires by closing the lid is not
possible.Grillsarewellventilatedforsafetyreasons.
• Donotusewateronagreasefire.Personalinjurymay
result.IfagreasefiredevelopsturnknobsandLP tank
off.
• Donotleavegrillunattendedwhilepreheatingor
burningoff on high.If grill hasnot been regularly
cleanedagreasefirecanoccurthatmaydamagethe
product.
IgnitorLighting
▲▲
▲▲
▲Donotleanovergrillwhilelighting.
1. Open lid during lighting
2. To ignite, turn center knob to HI,
push and hold ELECTRONIC IGNITOR button.
3. If ignition does NOT take place within 5 seconds,
turn all burner valve knobs to OFF,
wait 5 minutes, then repeat lighting procedure.
4. To ignite left burner, turn left knob to HI.
5. To ignite right burner, turn right knob to HI.

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Burner Flame Check
• Remove grates and flametamers. Light burners, rotate knobs
from HI to LOW. You should see a smaller flame in LOW
position than seen on HI. Always check flame prior to each
use. Perform flame check for sideburner. If only low flame is
seen refer to "Sudden drop or low flame" in
theTroubleshootingSection.
TurningGrillOff
• Turn all knobs to OFF position. Turn LP tank OFF by turning
hand-wheel clockwise to a full stop.
HI
LOW
Match Lighting
▲▲
▲▲
▲ Donot leanovergrillwhile lighting.
1.Open lid during lighting.
2.Place lit match into match
lighting stick, then into lighting
hole on right side of grill.
3.Push in and turn far right burner
knob to HI. Be sure burner lights
andstays lit.
4.Light adjacent burners in sequence by pushing knobs in
and turning to HI.
Sideburner Ignitor Lighting
▲▲
▲▲
▲Do not lean over grill while lighting.
1. To ignite side burner, open side burner cover.
2. Turn side burner knob to HI,
push and hold ELECTRONIC IGNITOR button.
3. If side burner does NOT light, turn knob to OFF,
wait 5 minutes, then repeat lighting procedure or use match.
Match Lighting
1. To match light SIDEBURNER, open
sideburner cover.
2. Place lit match near burner.
3. Push in and turn sideburner
knob counter-clockwise. Be
sure burner lights and stays lit.
• If burner does not light turn knobs to OFF, wait 5
minutes,tryagain.
Ignitor Check
• Turn gas off at LP tank. Push and hold electronic ignitor
button or push in and turn sideburner knob counter-
clockwise. "Clicks" 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 OFF position. To check
valves, first push in knobs and release, knobs should spring
back. If knobs don't 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 using grill. Use only valve/
hose/regulator specified by manufacturer.
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. Remove cooking grates, flametamers, grease tray and grease
receptacle.
3. Remove cotter pins from beneath each burner "foot" using a
screwdriver or needle nose pliers.
4. Carefully lift each burner up and away from valve openings.
We suggest three ways to clean the burner tubes. Use the one
easiestforyou.
(A) Bend a stiff wire (a light weight coat hanger works well)
into a small hook. Run the hook through each burner tube
and burner several times.
(B) Use a narrow bottle brush with a flexible handle (do not
use a brass wire brush), run the brush through each burner
tube and burner 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.
5. Wire brush entire outer surface of burner to remove food
residue and dirt.
6. Clean any blocked ports with a stiff wire such as an open paper
clip.
7. Check burner for damage, 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 reengage valve
openings.

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Clean burners prior to use after storing, at the
beginning of grilling season or a period of
one month not being used. Spiders and insects like to
build nests in burner tubes (especially during colder
months). These nests can cause fires in burner tubes or
under grill.
8. Carefully replace burners.
9. Replace cotter pin beneath each burner.
10. Replace grease tray and receptacle, flametamers, and
cooking grates.
GeneralGrillCleaning
• 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 to 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.
▲▲
▲▲
▲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.
• Stainless steel surfaces: To maintain your grill's high-
quality appearance, wash with mild detergent and warm
soapy water, wipe dry with a soft cloth after each use. Baked-
on grease deposits may require the use of an abrasive plastic
cleaning pad.
StoringYourGrill
• Clean cooking grates
• Store in dry location.
• When LP tank is connected to grill, store outdoors in well-
ventilated space and out of reach of children.
• Cover grill if stored outdoors. Choose from a variety of grill
covers offered by Manufacturer.
• 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.
Indirect Cooking
Poultry and large cuts of meat cook 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
ignite the 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.
1 Burner Cooking
Cook with direct or indirect heat.
Best for smaller meals or foods.
Consumes less fuel.
2 Burner Cooking
Great indirect cooking on low.
Produces slow, even heating.
Ideal for slow roasting and baking.
ON
ON
ON

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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.
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 1800F; breasts, 1700F. Juices
should run clear and flesh should not be pink.
•Hamburgers made of any ground meat or poultry should
reach 1600F, and be brown in the middle with no pink juices.
Beef, veal and lamb steaks, roasts and chops can be cooked
to 1450F. All cuts of pork should reach 1600F.
•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 1650F, or until steaming hot.

10
Problem
Burner will not
light using
ignitor.
Burners will not
match light.
Sudden drop in
gas flow or low
flame.
Flames blow out.
Flare-up.
Persistent grease
fire.
Flashback...
(fireinburner
tubes)
Possible Cause
- Wiresand/orelectrodecoveredwith
cookingresidue.
- Electrodecrackedorbroken"sparks
atcrack"
- Electrodetipnotinproperposition
- Wiresarelooseordisconnected.
- Wireisshorting(sparking)between
ignitorandelectrode.
- Deadbattery.
- Nogasflow.
- Obstructionofgasflow.
- Disengagementofburnertovalve.
- Outofgas.
- Excessflowvalvetripped.
- Highorgustingwinds.
- Greasebuildup.
- Excessivefatinmeat.
- Excessivecookingtemperature.
- Greasetrappedbyfoodbuildup
aroundburnersystem.
- Burnerand/orburnertubesare
blocked.
Prevention/Cure
-Cleanwiresand/orelectrodewithrubbingalcoholandcleanswab.
-Replaceelectrode(s).
-MainBurners:Tipofelectrodeshouldbepointingtowardtipofcollectorbox.
Thedistanceshouldbe1/8"to1/4",adjustifnecessary.
Sideburner:Tipofelectrodeshouldbepointingtowardgasportopeningon
burner.Thedistanceshouldbe1/8"to3/16",adjustifnecessary.
-Reconnectwiresorreplaceelectrode/wireassembly.
-Replaceignitorwire/electrodeassembly.
-ReplacewithanewAAbattery.
-Turngasonatsource.
-Clearburnertubes.
-Reengage burner and valve.
-CheckforgasinLPtank.
-Turnoffknobs,wait30secondsandlightgrill.Ifflamesarestilllow,turnoff
knobsandLPtankvalve.Disconnectregulator.Reconnectregulatorandleak
check.TurnonLPtankvalve,wait30secondsandthenlightgrill.
-Turnfrontofgrilltofacewindorincreaseflameheight.
-Cleangrill.
-Trimfatfrommeatbeforegrilling.
-Adjust(lower)temperatureaccordinglyoruseindirectcooking.
-TurnknobstoOFF.Turngasoffatgassource.Leavelidinpositionandlet
fireburnout.Aftergrillcools,removeandcleanallparts.
-Cleanburner and/orburner tubes.
Troubleshooting