Char-Broil Professional Series 463233503 User manual

463233503 • 1
ASSEMBLY,USE AND CARE MANUAL
CAUTION:
Read and follow
all safety statements,
assembly instructions,
and use and care
directions before
attempting to
assemble and cook.
INSTALLER/
ASSEMBLER:
Leave these instructions
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.
THIS GRILL IS
FOR OUTDOOR
USE ONLY
If you have any questions
or need assistance
during assembly,
please call
1-800-241-7548.
Visit us on the web at:
www.charbroil.com
4632235
463233503/P8012066A(06-18-03)
®
463233503

2 • 463233503
Call Grill Service Center For Help And Parts
•If you need help or warranty parts call !1-800-241-7548, or
send a FAX to 1-706-576-6355.
Business hours: Open 24 hours - Seven days a week.
• To order non-warranty replacement parts or accessories (grill
cover, cleaners, paint) call 1-800-993-2677 or send a FAX to
1-706-565-2121.
Important: Fill out Warranty Information below
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. Handling and storage of LP cylinders must
conform to LP Gas Code NFPA/ANSI 58. Grill is not for
use in or on recreational vehicles and/or boats.
• All electrical accessories (such as rotisserie) must be
electrically grounded in accordance with local codes, or
National Electrical Code, ANSI / NFPA 70. Keep any
electrical cords and/or fuel supply hoses away from any
hot surfaces.
• This grill is safety certified for use in the United States only.
Do not modify for use in any other location. Modification
will result in a safety hazard.
Safety Symbols
• The symbols and boxes shown below explain what each
heading means. Read and follow all of the messages found
throughout the manual.
•For residential use only. Do not use for commercial
cooking.
CACA
CACA
CAUTIONUTION
UTIONUTION
UTION
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.
WARNINGWARNING
WARNINGWARNING
WARNING
• DANGER: Indicates an imminently hazardous
situation which, if not avoided, will result in death or
serious injury.
DD
DD
DANGERANGER
ANGERANGER
ANGER
• CAUTION: Indicates a potentially hazardous
situation which, if not avoided, may result in minor
or moderate injury.
CACA
CACA
CAUTIONUTION
UTIONUTION
UTION
• 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.
WARNINGWARNING
WARNINGWARNING
WARNING

463233503 • 3
ForYour Safety .........................................................................2
Call Grill Service Center For Help And Parts...........................2
Installation Safety Precautions.................................................2
SafetySymbols .........................................................................2
Table of Contents.....................................................................3
Warranty....................................................................................3
Before Beginning Assembly .....................................................4
Parts List ...................................................................................4
Exploded View..........................................................................5
Assembly ................................................................................ 6-9
Use and Care ........................................................................9-14
Storing Your Grill .....................................................................13
Indirect Cooking ......................................................................14
Food Safety..............................................................................14
Troubleshooting..................................................................15-16
Char-Broilwarrantstotheoriginalconsumer-purchaserthat
thisproductshallbefreefromdefectsinworkmanshipand
materialsundernormalandreasonableuseandcorrect
assembly(ifassembledbyconsumer-purchaser),fromdateof
purchase.
Stainless steel and die cast parts - 99 years
Electronic ignition and burners - 10 years
Remaining parts - 2 years
Char-Broil will, at its option, refinish or replace any
product or part found to be defective during the warranty
period. Char-Broil will require you to return the part(s)
claimed to be defective, for its inspection, freight or postage
prepaid.
Ifyouwishtoobtainperformanceofanyobligationunderthis
limited warranty, you should write to:
CHAR-BROIL
Consumer Warranty / P.O. Box 1240
Columbus, GA 31902-1240
Char-Broilmayrequirereasonableproofofpurchaseand
wesuggestyoukeepyourreceipt. InthestateofCaliforniaonly,
ifrefinishingorreplacementoftheproductisnotcommercially
practicable,theretailersellingthisproductorChar-Broilwill
refundthepurchasepricepaidfortheproduct,lesstheamount
directlyattributabletousebytheoriginalconsumer-purchaser
priortodiscoveryofthenonconformity.Inaddition,inthestateof
Californiaonly,youmaytaketheproducttotheretail
establishmentfromwhichitwaspurchasedortoanyretail
establishmentsellingthisproductinordertoobtainperformance
underthiswarranty.
Thiswarrantydoesnotincludethecostonany
inconvenienceorpropertydamageduetofailureoftheproduct
anddoesnotcoverdamageduetomisuse,abuse,accident,
damagearisingoutoftransportationoftheproduct,ordamage
incurredthroughcommercialuseoftheproduct.Thisexpress
warrantyisthesolewarrantygivenbythemanufacturerandisin
lieuofallotherwarranties,expressorimplied,includingimplied
warrantyofmerchantabilityorfitnessforaparticularpurpose.
NeitherChar-Broildealersnortheretailestablishmentsellingthis
producthasanyauthoritytomakeanywarrantiesortopromise
remediesinadditiontoorinconsistentwiththosestatedabove.
Char-Broil'smaximumliability,inanyevent,shallnotexceedthe
purchasepriceoftheproductpaidbytheoriginalconsumer-
purchaser.Somestatesdonotallowtheexclusionorlimitationof
incidentalorconsequentialdamages.Sotheabovelimitationsor
exclusionsmaynotapplytoyou.Thiswarrantygivesyouspecific
legalrightsandmayalsohaveotherrightswhichvaryfromstate
tostate.
WarrantyTable of Contents

4 • 463233503
Key Qty Description New Part #
A 1 Lid P00119096A
B 1 Heat Indicator P00601181A
C 1 Curved Stainless Steel Handle P00205015B
D 1 Name Plate - Professional Series P00414034G
E 1 Warming Rack P01505007B
F 2 Cooking Grid - Stainless Steel P01602005B
G 3 Flame Tamer P01705005E
H 3 Burner P02001031E
I 1 Burner Bracket P02203055A
J 3 Gas Collector Box with Electrode P02609002B
K 1 Electric Wire Set P02615033A
L 1 Electric Ignitor (4 port) P02502024C
M 1 Back Burner P02007027D
N 1 Back Burner Frame P03305006H
O 1 Bowl Side Panel, Left P00720033C
P 1 Bowl Side Panel, Right P00721033C
Q 1 Bowl Front Panel P00724046C
R 1 Bowl Rear Panel P00725044A
S 1 Grease Draining Tray P02705364A
T 1 Grease Receptacle P02701041A
U 1 Gas Manifold P05004072B
V 3 Gas Valve for Main Burner P03222024B
W 1 Gas Valve for Back Burner P03222095B
X 1 Spark Electrode P02610005B
Y 1 Gas Tube P03701003A
Z 1 Heat Shield for Control Panel P03007051B
AA 1 Control Panel P02907121A
BB 3 Control Knob (Main Burner) P03419031B
CC 1 Control Knob (Back Burner) P03411142H
DD 4 Control Knob Seat P03413011A
EE 1 Griddle P05702002E
FF 1 Side Shelf, Left P01102009B
GG 1 Side Shelf, Right P01107010B
HH 2 Bracket for Side Shelf, LR/RF P01213005A
I I 2 Bracket for Side Shelf, LF/RR P01211005A
JJ 1 Shelf Trim Plate, Right P07502001A
KK 1 Shelf trim Plate, Left P07503001A
LL 2 Side Shelf Handle P00205016B
MM 1 Bottom Shelf P01008005C
NN 2 Bowl Support Bracket P01303002B
OO 1 Side Cart Leg, LF P00917005B
PP 1 Side Cart Leg, LR P00918005B
QQ 1 Side Cart Leg, RF P00912005B
RR 1 Side Cart Leg, RR P00920005B
SS 2 Cart Side Panel P07601001A
TT 1 Cart Rear Panel P07701002A
UU 1 Front Door, Left P04302003A
VV 1 Front Door, Right P04303003A
WW 1 Door Bracket P03302001C
XX 2 Door Curved Handle P00211004B
YY 1 Door Stop P05510009E
ZZ 4 Caster Seat P04507003A
AAA 4 "3" Industry Caster P05106003D
BBB 1 Regulator with Hose (27") P03601004A
CCC 1 AA Battery P05301001A
DDD 1 Motor P07101002B
EEE 1 Motor Bracket P05508005A
FFF 2 Fork P05508006A
GGG 1 Collar P05508007A
HHH 1 Bushing P05508008A
I I I 1 Handle P05508004E
JJJ 1 Spit P05508011A
KKK 1 Tool Hooks P05514013A
LLL 1 Match Lighting Stick with Chain P05507031E
MMM 1 Retention Screw for Tank P06222019B
1 Caster Wrench P05515002C
1 Hardware Pack P06004045A
1 Owners Manual P80112066A
Parts List - 463233503
• Necessary tools for assembly of your grill include:
Phillips®screwdriver,pliersandadjustablewrench.
Before Beginning Assembly
CertifiedGrillPartsAndAccessories®,Char-BroilandDesign®,Char-Broil(GasGrillBriquettes)®,
Char-Diamonds®,CookingZoneandDesign®,DiamondFlame®,ExecutiveChef®,Faststart®,
FlareFighter®,FlavorMaster®,GasGrillSilouetteandDesign®,H2OSmoker®,LavaFlame®,
MasterFlame®,MasterFlamePrecisionCookingSystem®,PowerSpark®,Quantum®,VIP®,
PrecisionFlameandDesign®,Sierra®,andTruFlame®areregisteredTrademarksoftheW.C.Bradley
Company. Thermos®isaregisteredtrademarkoftheThermosCompanyanditsaffiliates.
ArtisanCollectionbyChar-Broil™,C3andDesign™,Char-BroilandDesign™,FlameDesign™,
FlavorTents™,Grill2Go™,Grillin’Stick™,KeeperoftheFlame™,KeepersoftheFlame™,
NaturalGrip™,OutdoorCookingCollectionandDesign™,PatioBistro™,PrecisionFlame™,Pro-Check™,
QuickSetGrillsandDesign™,SmokerTents™,TheBigEasy™,TheMinuteGrill™,TheEdge™,
TheTuscanCollection™,andTheUrbanGrill™areTrademarksoftheW.C.BradleyCompany. Universal
GrillPartsandDesign™isatrademarkoftheThermosCompanyanditsaffiliates.
ProtectedunderoneormoreofthefollowingU.S.Patents: 4,598,692;4,624,240;4,747,391;4,747,391;
4,817,583;4,924,846;4,989,579;5,003,960;5,076,256;5,076,257;5,090,398;5,109,834;5,224,676;
5,277,106;5,421,319;5,441,226;5,452,707;5,458,309;5,566,606;5,566,606;5,579,755;5,582,094;
5,613,486;5,649,475;5,706,797;5,711,663;5,765,543;5,931,149;5,996,573;6,095,132;6,135,104;
6,279,566;D282,619;D339,714;D341,292;D343,337;D358,059;D361,466;D364,535;D372,637;
D373,701;D377,735;D383,035;D397,910;D405,643;D405,643;D406,005;D406,009;D413,043;D413,229;
D413,229;D414,982;D415,388;D416,164;D416,441;D416,441;D417,587;D422,516;D423,274;D423,876;
D428,303;D435,396;D436,004;D438,059;D438,060;D438,427;D439,110;D442,505;D443,179;D443,354;
D447,384;D447,385;D447,909;D448,610;D448,614;D448,615;D448,616;D448,975;andD449,492.
OtherPatentsPending.

463233503 • 5
Exploded View - 463233503 A
B
C
D
E
F
F
GHHH
I
JJJ
KK
K
L
M
N
O
P
Q
R
S
T
U
V
W
V
V
X
Y
Z
AA
BB
BB
DD
DD
FF
GG
HH
HH
I I
I I
JJ
KK
LL
LL
MM
NN
NN
OO
PP
QQ
RR
SS
SS TT
UU
VV
WW
XX
YY
ZZ
ZZ
ZZ
ZZ
AAA
AAA
AAA
AAA
BBB
CCC
DDD
EEE
FFF
HHH GGG
I I I
JJJ
CC
BB
LLL
EE
KKK
MMM

6 • 463233503
LF
LR
RR
RF
Assembly - 463233503
• Unpack and remove all protective packaging.
1. Position bottom shelf with the tank hole toward the left side.
See Fig. 1.
VERY IMPORTANT: The labels on the cart legs
indicate their assembly position to the bottom shelf. LFLF
LFLF
LF=Left
Front, LRLR
LRLR
LR=Left Rear, RFRF
RFRF
RF=Right Front, and RRRR
RRRR
RR=Right
Rear. Labels should face inward toward each other when
correctly assembled. Remaining components cannot be
assembled if leg positions are incorrect.
2. Install the four cart legs to the indicated corners of the
bottom shelf using 8 of the 1/4x2-1/2" Phillips-head screws
provided. Do not fully tighten screws.
3. Install bowl support brackets, facing inward, to cart legs on
both sides using 8 of the 1/4x1/2" Phillips-head screws.
Fully tighten. See Fig. 1.
FIGURE 1
Bowl
Support
Bracket
Bottom
Shelf
4. Screw the 4 casters into the caster seats in the bottom of
each cart leg. Turn the threaded caster stem by hand,
clockwise until it stops. Fully tighten with the wrench
provided. See Fig. 2.
5. Install the two side panels and one rear panel to the cart by
using 4 of the 3/16x1/2" Phillips-head screws on each
panel. Leave rear panel screws loose. See Fig. 2.
FIGURE 2
Caster
Rear
panel
Side
panel
Side
panel
6. Attach the door bracket to the lower holes in the front legs
with the end tabs pointing upward and the flange to the rear,
pointing downward. Use 2 of the 1/4x1/2" Phillips-head
screws. Do not fully tighten. See Fig. 3.
7. Attach the door stop to the bottom shelf, with the flange
facing the front , using 2 of the 3/16x3/8" Phillips head
screws. Fully tighten. See Fig. 3.
8. Place doors into the hinge holes of the bottom shelf and
door bracket. Push door bracket down until doors are
secure and can open and close freely. Do not fully tighten
door bracket screws. See Fig. 3.
9. Remove protective film from doors. Install door handles to
doors using 4 of the 3/16x3/8" Phillips-head screws and
washers. See Fig. 3.
10. Attach the 4 side shelf brackets to the tops of the cart legs
using 8 of the 1/4x1/2" Phillips-head screws. Be sure the
flat side of each bracket faces outward. Fully tighten.
See Fig. 3.
Tank Hole
FIGURE 3 ON NEXT PAGE

463233503 • 7
11. Place the side shelves over the brackets and cross braces
with the wider-spaced shelf holes to the outside (shelf with
trim plate on right side). Be sure the inside shelf holes align
with holes in bowl support bracket. See Fig. 3.
12. To install the side shelf handle, remove the bolt and washer
from one side of the handle (cap remains with handle).
From beneath shelf, place washer onto bolt and insert bolt
through end of shelf bracket, side shelf, and into handle.
Leave bolt loose until other side of handle is attached, then
fully tighten both sides. Repeat for other side shelf.
See Fig. 3.FIGURE 5
Side
shelf
Shelf bracket,
flat side facing
outward Lower
hole
Door
bracket
Door
Handle
Hinge
Hinge
hole
Align
holes
To reduce the weight of the grill head, open the grill lid and
remove the packed components. This step requires 2 people
to lift and position the grill head onto the cart.
14. HINT: Slide grill head into cart from the front. Use care to
avoid scratching tops of side shelves. Align the 2 holes
beneath the hang ledge on each side of the grill head with
the 2 holes in the side shelf and bowl support bracket on
the cart. Raise the grill lid and insert 4 of the 1/4x1/2"
Phillips-head screws. Beneath the side shelves, add
1/4" nuts. Do not fully tighten. See Fig. 5.
Grill
head
Hang
ledge
Gas hose
Hang
ledges
rest on
shelves
FIGURE 3
Door
stop
Remove
film
Shelf
handle
13. Attach match lighting stick
and chain to the right rear
leg, below shelf bracket,
using one M4 X 10mm,
self-tapping, Phillips-head
screw. See Fig. 4.
Match
lighting
stick
FIGURE 4
Screw& washer

8 • 463233503
23. Place the 3 flame tamers on the lower ledge above
burners. See Fig. 10. They should meet in the center.
24. Place the cooking grids on the ledge above the flame
tamers. See Fig. 10.
25. Place the warming rack into the slots on the upper left and
upper right of the grill bowl panels. See Fig. 10.
FIGURE 6
15. Secure grill head to all cart legs using 4 of the 1/4x2-1/2"
Phillips-head screws and 1/4" nuts. See Fig. 6.
16. Fully tighten all leg screws, rear panel screws, door
bracket screws, and grill head screws.
17. From the back of the cart, slide the grease draining tray into
the grill head. Place the grease receptacle into the notches
on the bottom of the tray. Assemble the 3 tool hooks
provided to the front panel on the right shelf by inserting the
thin end of the hook first into the holes provided and sliding
all thru. See Fig. 6.Grease
draining
tray
Grease
receptacle
Attach grill head
to all 4 legs
18. Place your LP gas tank (not included) into the tank hole in
the bottom shelf. Be sure the tank valve is facing forward.
Secure tank by tightening the wing screw at the rear
of the bottom shelf. See. Fig. 7.
READ USE & CARE SECTION BEFORE ATTACHING
REGULATOR TO LP TANK.
Contact Spring
AA Battery
19. Unscrew the ignitor cap located on the control panel and
remove the contact and spring from the ignitor slot.
See Fig. 8.
20. Place the suppliedAAbattery into the ignitor slot with the
positive pole facing toward you.
21. Place the spring with contact over the battery. Screw the
ignitor cap back onto the control panel.
FIGURE 8
Ignitor
cap +–
FIGURE 7
LP gas
tank
22. Attach trim plate to front of left shelf by placing top lip of
plate ABOVE bottom lip of shelf. Secure using three
3/16"x3/8" Phillips-head screws and 3/16" nuts.
Fully Tighten. See Fig. 9.
Plate lip
Shelf
lip
FIGURE 9
FIGURE 10 ON NEXT PAGE
Tool Hooks

463233503 • 9
FIGURE 10
Flame tamer
Cooking
grid
Warming
rack
Lower
ledge
Before Your First Cookout
• Perform the leak test as indicated in the use and care
section.
• Wash the cooking grids, griddle, cooking rack, and all
stainless steel surfaces with warm, soapy water. Rinse and
drythoroughly.
• Light burners. Check to make sure they are lit, then close
the lid and warm the grill on HI for 15 minutes. Curing of
paint and parts will produce an odor only on first lighting.
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). See LP tank collar for marking.
•LPtankvalvemusthave:
• 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
FIGURE 11
26. Attach rotisserie motor bracket to bowl side panel using
screws, washers, and nuts provided, then slide motor onto
bracket. See Fig. 11.
27. Twist handle onto threaded end of spit rod, then add
bushing, collar, and forks to spit. Insert spit into motor and
rest collar in groove of opposite side.
Handle
Bushing and collar
Forks
Spit rod
Motor
Bracket

10 • 463233503
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.
Nipple has to be
centered into the
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!
WARNINGWARNING
WARNINGWARNING
WARNING
BB
BB
B
CC
CC
C
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
Foryour safety
•LeaktestmustberepeatedeachtimeLPtankisexchangedor
refilled.
•Donotsmokeduringleaktest.
•Donotuseanopenflametocheckforgasleaks.
•Grillmustbeleakcheckedoutdoorsinwell-ventilatedarea,away
fromignitionsourcessuchasgasfiredorelectricalappliances.
Duringleaktest,keepgrillawayfromopenflamesorsparks.
Useacleanpaintbrushand50/50soapandwater
solution.Usemildsoapandwater.
▲▲
▲▲
▲Donotusehouseholdcleaningagents.
Damagetogastraincomponentscanresult.
Brushsoapysolution
ontotheshadedareas.
Connecting The Regulator To The LP Tank
OPD Hand
Wheel
Type 1 outlet with thread on outside
1. LPtankmustbeproperlysecuredontogrill.
2. Turnallcontrolknobsincludingsideburner(iffeatured)totheOFF
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!

463233503 • 11
•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
•Turn OFF all control knobs and LP tank valve. Turn coupling
nut counter clockwise by hand only - do not use tools to
disconnect. Lift LP tank wire upward off of LP tank collar, lift
LP tank up and off of support bracket. Install safety cap onto
LP tank valve. Always use cap and strap supplied with valve.
Failure to use safety cap as directed may result in
serious personal injury and/or property damage.
LP Tank
Valve Safety
Cap
Retainer
Strap
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.
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".
• 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
damage 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.
DD
DD
DANGERANGER
ANGERANGER
ANGER

12 • 463233503
Rotisserie Ignitor Lighting
▲▲
▲▲
▲Donotleanovergrillwhilelighting.
1. Open lid during lighting
2. To ignite rotisserie burner, turn knob to HI, push and hold
ELECTRONIC IGNITOR button for 5 seconds.. If burner
does not light, repeat lighting procedure up to 5 times.
3. If IGNITOR does not work, follow match lighting
instructions.
Match Lighting
▲▲
▲▲
▲ Do not lean over grill while lighting.
1.Open lid during lighting.
2.Place lit match near rotisserie spark electrode wire.
3.Push in and turn rotisserie knob to ON. Be sure burner
lights and stays lit.
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. If only low flame is seen refer to "Sudden drop or low
flame" in the Troubleshooting Section.
TurningGrillOff
• Turn all knobs to OFF position. Turn LP tank OFF by turning
hand-wheel clockwise to a full stop.
HI
LOW
Match Lighting
▲▲
▲▲
▲ Donotlean overgrillwhilelighting.
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
andstayslit.
4.Light adjacent burners in
sequence by pushing knobs in and turning to HI.
• If burner does not light turn knobs to OFF, wait 5
minutes,tryagain.
WARNINGWARNING
WARNINGWARNING
WARNING
For Safe Use Of Your Grill:
•Donotletchildrenoperateorplayneargrill.
•Keepgrillareaclearandfreefrommaterialsthatburn.
•Donotblockholesinbottomorbackofgrill.
•Checkburnerflamesregularly.
•Usegrillonlyinwell-ventilatedspace.NEVERusein
enclosedspacesuchascarport,garage,porch,covered
patio,orunderasurfacethatcancatchfire.
•Usegrillatleast3ft.fromanywallorsurface.Maintain10ft.
clearancetoobjectsthatcancatchfireorsourcesofignition
suchaspilotlightsonwaterheaters,liveelectricalappliances,
etc.
•Donotusecharcoal,briquetsorlavarockinthisgrill.
•ApartmentDwellers:
Checkwithmanagementtolearntherequirementsandfire
codesforusinganLPGasGrillinanapartment.Ifallowed
useoutsideonthegroundfloorwithathree(3)footclearance
fromwallsorrails.Donotuseonorunderbalconiesmadeof
wood.
• NEVERattempttolightburnerwithlidclosed.A
buildupofnon-ignitedgasinsideaclosedgrillis
hazardous.
• NeveroperategrillwithLPtankoutofcorrectposition.
• AlwayscloseLPtankvalveandremovecouplingnut
beforemovingLPtankfromspecifiedoperating
position.
WARNINGWARNING
WARNINGWARNING
WARNING
• Putting out grease fires by closing the lid is not
possible.Grillsarewellventilatedforsafetyreasons.
• Donotusewateronagreasefire.Personalinjurymay
result.Ifagreasefiredevelopsturn knobsandLPtank
off.
• Donotleavegrillunattendedwhilepreheatingor
burningoffon high.If grill hasnot been regularly
cleanedagreasefirecanoccurthatmaydamagethe
product.
CACA
CACA
CAUTIONUTION
UTIONUTION
UTION
IgnitorLighting
▲▲
▲▲
▲Donotleanovergrillwhilelighting.
1. Open lid during lighting
2. To ignite any burner, turn knob to HI, push and hold
ELECTRONIC IGNITOR button for 5 seconds.
3. If ignition does not take place within 5 seconds, turn all
burner knobs to OFF, wait 5 minutes, then repeat lighting
procedure.
4. If IGNITOR does not work, follow match lighting
instructions.

463233503 • 13
Ignitor Check
• Turn gas off at LP tank. Push and hold electronic ignitor
button. "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.
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 Char-Broil.
• 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.
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.
CACA
CACA
CAUTIONUTION
UTIONUTION
UTION

14 • 463233503
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.
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
ONON

463233503 • 15
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...
(firein burner
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/or burnertubesare
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.
-Cleanburnerand/orburner tubes.
Troubleshooting

16 • 463233503
A Division of W.C. Bradley Co.
P.O.Box 1240
Columbus,GA 31902-1240
Problem
No sparks appear
at any electrodes
when ignition
button is pushed;
no noise can be
heard from spark
module.
No sparks appear
at any electrodes
when ignition
switch is pushed;
noise can be heard
from spark module.
Sparks are present
but not at all
electrodes and/or
not at full strength
Possible Cause
- Batterynotinstalled
properly.
- Deadbattery.
- Buttonassemblynot
installedproperly.
- Faultysparkmodule.
- Outputlead
connectionsnot
complete.
- Outputlead
connectionsnot
complete.
- Arcingtogrillaway
fromburner(s).
- Weakbattery.
- Electrodesarewet.
- Electrodescrackedor
broken"sparksat
crack".
Check Procedure
- Checkbatteryorientation.
- Hasbatterybeenused
previously?
- Checktoinsurethreadsare
properlyengaged.Buttonshould
travelupanddownwithout
binding.
- Ifnosparksaregeneratedwith
newbatteryandgoodwire
connections,moduleisfaulty.
- Areoutputconnectionsonand
tight?
- Areoutputconnectionsonand
tight?
- Ifpossible,observegrillindark
location.Operateignitionsystem
andlookforarcingbetween
outputwiresandgrillframe.
- Allsparkspresentbutweakorat
slowrate.
- Hasmoistureaccumulatedon
electrodeand/orinburnerports?
- Inspectelectrodesforcracks.
Solution
- Installbattery(makesurethat"+"and"–"
connectorsareorientedcorrectly,with"+"end
down and "–" end up.)
- ReplacebatterywithnewAA-sizealkalinebattery.
- Unscrewbuttoncapassemblyandreinstall,making
surethreadsarealignedandengagedfully.
- Replacesparkmoduleassembly.
- Removeandreconnectalloutputconnectionsat
moduleandelectrodes.
- Removeandreconnectalloutputconnectionsat
moduleandelectrodes.
- Ifsparksareobservedotherthanfromburner(s),
wireinsulationmaybedamaged. Replacewires.
- ReplacebatterywithanewAA-sizealkaline
battery.
- Usepapertoweltoremovemoisture.
- Replacecrackedorbrokenelectrodes.
Troubleshooting - Electronic Ignition