Thermos 461262006 User manual

THERMOs
STAINLESS
MODEL 461262006 • PRODUCT GUIDE
DPCl# 009-07-0225
CgHVERSIOH-REAgY
Easily converts from (LP) Gquid
propane to (NG) natural gas
purchase your ING)
natural gss conversion kit. Go to
www.charbroil.com
/_ CAUTION:
Readandfollowallsafetystatements,assembly
insb'uctions,anduseandcaredirectionsbefore
attemptingtoassembleandcook.
INSTALLER/ASSEMBLER:
Leavethismanualwithconsumer.
CONSUMER:
Keepthismanualforfuturereference.
/_ WARNING:
Failuretofollowallmanufacturer'sins_uctionscould
resultinseriouspersonalinjuryand/orproperty
damage.
/_ CAUTION:
Somepartsmaycontainsharpedges- especiallyas
notedinthemanual!Wearprotectiveglovesif
necessary.
461262006• 80005671.02-15-06

FORYOUR SAFETY
1. Donot store or usegasoline or other flammable
vapors and liquidsinthe vicinity ofthis or any
other appliance.
2. An LP cylindernot connectedfor use shall not
bestored in the vicinity of this or anyother
appliance.
FORYOUR SAFETY
Ifyou smell gas:
1. Shut off gas tothe appliance.
2. Extinguishany open flame.
3. Open lid.
4. Ifodor con6nues, immediatelycall your gas
supplier or your fire department.
Call Grill Service Centerfor Help and Parts
•Ifyouneedhelporwarrantypartscall1-888-473-1238.
Businesshours:8AM-6PMEST,Monday-Friday.
•Toordernon-warrantyreplacementpartsoraccessories(gd//
cover,c/eaners,pain_)call1-800-993-2677orsenda FAXto
1-706-565-2121.
IMPORTANT: Fill out the product record information below.
InstallationSafety Precautions
• Usegrill,aspurchased,onlywithLP(propane)gasandthe
regulator/valveassemblysupplied.Aconversionkitmustbe
purchasedfor usewithnaturalgas.
•Grillinstallationmustconformwithlocalcodes,orintheir
absencewithNationalFuelGasCode,NFPA541ANSI
Z223.t.HandlingandstorageofLPcylindersmustconformto
LPGasCodeNFPA/ANS158.Grillisnotforuseinoron
recreationalvehiclesand/orboats.
Allele_ical accessories(suchasrotisserie)mustbe
eleckicallygroundedinaccordancewithlocalcodes,or
NationalElec_icalCode,ANSI/NFPA70. Keepany
elec_calcordsand/orfuelsupplyhosesaway_m anyhot
surfaces.
•Thisgrillissafetycertifiedfor useintheUnitedStatesonly.Do
notmodifyforusein anyotherlocation.Modificationwill result
in asafetyhazard.
Safety Symbols
Thesymbolsandboxesshownbelowexplainwhateachheading
means,Reedandfollowallofthemessagesfoundthroughout
themanual.
DANGER:Indicatesanimminentlyhazardoussituation
which,ifnotavoided,willresultindeathorseriousinjury.
WARNING:Indicatesanpotentiallyhazardoussituation
which,ifnotavoided,couldresultindeathorserious
injury.
ModelNumber
SerialNumber Seeratinglabelongrillforserialnumber.
DatePurchased
For residentialuse only. Do not usefor commercial
cooking.
CAUTION CAUTION
CAUTION:Indicatesa potentiallyhazardoussituationor
unsafepracticewhich,ifnotavoided,mayresultinminor
ormoderateinjury.
CALIFORNIA PROPOSITION65
Combustionby-productsproduced when usingthis
productcontain chemicalsknown to the State of
Californiato cause cancer, birthdefects, and other
reproductive harm.
2• 461262006

ForYourSafety...................................... 2
GrillServiceCenter................................... 2
ProductRecordInformation............................ 2
InstallationSafetyPrecautions.......................... 2
SafetySymbols...................................... 2
LimitedWarranty..................................... 3
UseandCare..................................... 4-11
PartsList.......................................... 12
PartsDiagram...................................... 13
Assembly....................................... 14-23
Troubleshooting.................................. 24-26
RegistrationCard................................... 27
CHNVERSIOH-REAgY
Easily converts from (LP) liquid
propane to (NG) natural gas
Find out how to purchase your (NG)
natural gas _onversion kit, Go to
www.charbroiLcom
Do not attempt to repair or alter the
hose/valve/regulatorfor any "assumed" defect,Any
modificationto this assemblywill void your warranty
and createthe risk of a gas leakand fire, Useonly
authodzed replacement parts suppliedby
manufacturer,
Manufacturerwarrantstotheork:Jinalconsumer-purchaseronlythat
thisproductshallbefreefromdefectsinworkmanshipandmaterialsafter
correctassemblyandundernormalandreasonablehomeusefarthe
pe_odsindicatedbelowbeginningwiththedateofpurchase.Uponproof
ofpurchaseasprovidedherein,Manufacturerwillrepairorreplacethe
partslistedbelowwhichareprovendefestivaduringtheapplicable
warrantyperiod.Suchrepairorreplacementshallbefreeofchargetoyou
exceptforshippingcosts.
Stainlesssteelburners• 3years
Fireboxandlid- LimitedLifetimeagainstperforation
Electronicignition(excludingbattery)-3years
Remainingparts(excludingbattery)- I year
ThislimitedwarrantyisapplicableintheUnitedStatesandCanada
only,isonlyavailabletotheoriginalowneroftheproductandisnot
transferable.Manufacturerrequiresreasonableproofofyourdateof
purchase.Therefore,youshouldretainyoursalessliporinvoiceand
reglstsryournewproductimmediately.Defactivepartssubjecttothis
limitedwarrantywillnotbereplacedwithoutregistrationorproofof
purchase.Registsrenliceatwww.grillregis_aiton.cemorcompleteand
returnviamailtheProductRegistrationCardindudedwiththisproductand
retainyoursalesreceiptfarproofofpurchase..Ifregls_tioninformationis
notavailable,theproofofpurchasewillberequired.
Repairorreplacementofdefectivepartsisyourexclusiveremedy
underthetermsofthislimitedwarranty.Manufacturerwillnotbe
responsibleforanyconsequentialorincidentaldamagesarisingfromthe
breachofeitherthislimitedwarrantyoranyapplicableimpliedwarranty,or
forfailureordamageresultingfromactsofGOd,impropercareand
maintenance,greasetire,accident,alteration,replacementofpartsby
anyoneotherthanManufacturer,misuse,transportation,commercialuse,
abuse,hostileenvironments(inclementweather,actsofnature,animal
tampering),improperinstallationorinstallationnotinaccordancewithlocal
codes.Thislimitedwarrantydoesnotcoverscratches,dents,corrosions
ordiscoloringbyheat,abrasiveandchemicalcleanersoranytoolsusedin
theassemblyorinstallationoftheappliance,surfacerust,orthe
discolorationofstainlesssteelsurfaces.Thislimitedwarrantywillnot
reimburseyoufarthecostofanyinconvenience,foodreimbursement,
personalinjuryorpropertydamage.Ifanoriginalreplacementpartisnot
available,a comparablereplacementpartwillbesent.Youwillbe
responsibleforallshippingchargesofpartsreplacedunderthetermsof
thislimitedwarranty.
THISLIMITEDWARRANTYISTHESOLEEXPRESSWARRANTY
GIVENBYTHEMANUFACTURER.NOPRODUCTPERFORMANCE
SPECIFICATIONORDESCRIPTIONWHEREVERAPPEARINGIS
WARRANTEDBYMANUFACTUREREXCEPTTOTHEEXTENTSET
FORTHINTHISLIMITEDWARRANTY.ANYIMPLIEDWARRANTY
PROTECTIONARISINGUNDERTHELAWSOFANYSTATE,
INCLUDINGIMPLIEDWARRANTYOFMERCHANTABILITYORFITNESS
FORAPARTICULARPURPOSEORUSE,ISHEREBYLIMITEDIN
DURATIONTOTHEDURATIONOFTHISLIMITEDWARRANTY.
Neitherdealersnortheretailestablishmentsellingthisproducthas
anyauthoritytomakeanyadditionalwarrantiesortopromiseremediesin
additiontoorinconsistentwiththosestatedabove.Manufacturer's
maximumliability,inanyevent,shallnotexceedthepurchasepriceofthe
productpaidbytheoriginalconsumer.Thiswarrantyonlyappliestounits
purchasedfromanauthorizedretailer.
NOTE:Somestatesdonotallowanaxdusionorlimitationof
incidentalorconsequenitaldamages,sosomeoftheabovelimitationsor
exclusionsmaynotapplytoyou.Thislimitedwarrantygivesyouspedfic
legalrk:Jhtsassetfarherein.Youmayalsohaveotherrightswhichvary
fromstatetostate.InthestateofCaliforniaonly,ifrefinishingor
replacementoftheproductisnotcommerciallypracticable,theretailer
sellingthisproductortheManufacturerwillrefundthepurchaseprisepaid
fortheproduct,leestheamountdirectlyattributabletousebytheoriginal
consumer-purcheserpriortodiscoveryofthenonconfarmity.Inaddiiton,in
thestateofCaliforniaonly,youmaytaketheproducttotheretail
establishmentsellingthisproductinordertoobtainperformanceunderthis
limitedwarranty.
Ifyouwishtoobtainperformanceofanyoblig=ionunderthislimited
warranty,youshouldwriteto:
ConsumerWarrantyService/P.O.Box1240
Columbus,GA31902-1240
461262006 • 3

• NEVERstoreaspareLPcylinderunderornear
theapplianceor inanenclosedarea.
•Neverfilla cylinderbeyond80%full.
•Anoverfilledorimproperlystoredcylinderisa
hazardduetopossiblegasreleasefromthe
safetyreliefvalve. Thiscouldcauseanintense
firewithriskofpropertydamage,seriousinjuryor
death.
•Ifyou see, smell or hear gasescaping,
immediatelyget away from the LP
cylinder/applianceand call your fire department.
LP Cylinder Removal,Transport and Storage
•TurnOFFallcontrolknobsandLPcylindervalveTumcoupling
nutcounterclockwisebyhandonly-donotusetoolsto
disconnectLoosencylinderscrewbeneathbottomshelf,then
liftLPcylinderupandoutofcart.InstalsafelycapontoLP
cylindervalve.Alwaysusecapandstrapsuppliedwithvalve.
Failuretousesafetycapasdirectedmay resultineadous
peraonalinjuryand/orpropertydamage.
•AdisconnectedLPcylinderin LPCylinderValve,,_
storageorbeingtransported [_
musthaveasafetycapinstalod(asshown).
DonotstoreanLPcylinderinenclosedspaces\",-_,_
suchasa carport,garage,porch,covered
paUoorotherbuilding.NeverleaveanLPcylinder Safety
insideavehiclewhichmaybecomeoverheated Cap
bythesun. RetainerStrap
•DonotstoreanLPcylinderinanareawherechildrenplay.
LPCylinder
• TheLPcylinderusedwithyourgrillmustmeetthe
followingrequirements:
•UseLPcylindersonlywiththesereqLdredmeasurements:12"
(305cm)(diameter)x 18"(45.7cm)(tall)with20 Ib (9 kg)
capacitymaximum
•LPcylindersmustbeconstructedandmarkedinaccordance
withspecificationsforLPcylindersoftheUS Departmentof
Transportation(DOT) SeeLPcylindercollarformarking
•LPcylindervalvemusthave:
•Type1outletcompaUblewith
regulatororgrill
•Safetyraliefvelve
•ULlistedOverfillProtection OPDHandWheel
Device(OPD)ThisOPDsafely
featureisidentifiedbya uniquetnengularhandwheelUse
onlyLPcylindersequippedwiththistypeofvalve.
•LPcylindermustbearrangedforvaporwithdrawalandinclude
collartoprotectLPcylindervalveAlwayskeepLPcylindersin
uprightpositionduringuse,transitorstorage
LP (Liquefied Petroleum Gas)
•LPgasisnontoxic,ododessandcolorlesswhenproducedFor
YourSafety,LPgashasbeengivenanodor(similartorotten
cabbage)sothatitcanbesmelled
•LPgasishighlyflammableandmayigniteunexpectedlywhen
mixedwithair
LP Cylinder Filling
•Useonlylicensedandexperienceddealers
•LPdealermustpurgenewcylinderbeforefilling
•DealershouldNEVERfillLPcylindermorethan80%ofLP
cylindervolumeVolumeofpropaneincylinderwillvaryby
temperature
•AfrostyregulatorindicatesgasoverfillImmediatelycloseLP
cylindervalveandcalllocalLPgasdealerforassistance
•Donotreleaseliquidpropane(LP)gasintothea_osphere
Thisisa hazardouspractice
•ToremovegasfromLPcylinder,contactanLPdealerorcalla
localfiredepar_entforassistanceCheckthetelephone
directoryunder=GasCompanies"fornearestcertifiedLP
dealers
4 • 461262006

LP Cylinder Exchange
•Manyretailersthatsellgrillsofferyoutheoptionofreplacing
youremptyLPcylinderthroughanexchangeservice.Useonly
thosereputableexchangecompaniesthatinspect,precisionfill,
tastandcertifytheircylinders.Exchangeyourcylinderonly
foran OPDsafetyfeature-equippedcylinderasdescribed
in the"LP Cylinder"sectionofthismanual,
• AlwayskeepnewandexchangedLPcylindersinupright
posiUonduringuse,transitorstorage.
•LeaktestnewandexchangedLPcylindersBEFORE
connectingto grill.
ConnectingRegulatortotheLPCylinder
1. LPcylindermustbepropedysecuredontogrill.(Referto
assemblysection.)
2.TurnallcontrolknobstotheOFFposition.
,
4.
TumLPcylinderOFFbyturninghand-wheelclockwisetoa
full stop.
Removethe protectivecapfromLPcylindervalve.Alwaysuse
capandstrapsuppliedwithvalve.
LP Cylinder Leak Test
Foryoursafety
•LeaktestmustberepeatedeachtimeLPcylinderisexchanged
orrefilled.
•Donotsmokeduringleaktest.
•Donotuseanopenflametocheckforgasleaks.
•Grillmustbeleaktestedoutdoorsina well-ventilatedarea,
away_m ignitionsourcessuchasgasfiredorele_ical
appliances.Duringleaktest,keepgrillawayfromopenflames
orsparks.
•Usea deanpaintbrushanda 50/50mildsoapandwater
solution.Brushsoapysolutionontoareasindicatedbyarrows
infigurebelow.
•Donotusehouseholdcleaningagents.Damagetogas
traincomponentscanresult.
If"growing"bubblesappeardonotuseormovetheLP
cylinder.ContactanLPgassupplieroryourfire
department!
Donotusea POLtransportplug
(plasticpartwithexternalthreads)!
Itwill defeatthe safetyfeatureof
thevalve,
5. HoldregulatorandinsertnippleintoLP
cylindervalve.Hand-_ghtenthe
couplingnut,holdingregulatorina
straightlinewithLPcylindervalveso
asnottocross-threadtheconnection.
Nipplehasto becentered
intothe LPcylindervalve.
461262006 • 5

Holdcouplingnutand regulator
asshownfor properconnection
to LPcylindervalve.
Leak TestingValves, Hose and Regulator
,
2.
3.
Tum all grillcontrol knobsto OFF.
Besureregulatorislightlyconnectedto LPcylinder.
CompletelyopenLPcylindervalvebyturninghandwheel
counterclockwise.Ifyouheara rushingsound,turngasoff
immediately.Thereisamajorleakattheconnection.Correct
beforeproceeding.
4. Brushsoapysolutionontoareascirdedbelow.
6. Turnthecouplingnutclockwiseandlightentoafullstop.The
regulatorwill sealontheback.checkfeaturein theLPcylinder
valve,resultinginsomeresistance.Anadditionalone-halfto
three-quartereturnisrequiredto completethe
connection,Tightenbyhandonly- donotusetools,
NOTE:
Ifyoucannotcompletethecomection,disconnectregulatorand
repeatsteps5and6. Ifyouarestillunabletocompletethe
connection,donotusethis regulatod
•Donotinsertanytoolorforeignobjectintothevalve
outletor safetyreliefvalve.Youmaydamagethevalve
andcausealeak.Leakingpropanemayresultin
explosion,fire,severepersonalinjury,or death.
•Neverattempttoattachthisgrilltotheself-contained
LPgassystemofa campertrailerormotorhome.
• Donotusegrilluntilleak-tested.
• Ifaleakisdetectedatanytime,STOPandcallthefire
department.
• Ifyoucannotstopagasleak,immediatelyclose
LPcylindervalveandcallLPgassupplieroryourfire
department!
,
,
ff"growing" bubblesappear,thereisa leak.CloseLP
cylindervalveimmediatelyandretightenconnections.If leaks
cannotbestoppeddonottryto repair.Callforreplacement
parts.Ordernewpartsbygivingtheserial,modelnumberand
nameandpartnumberofitemsneeded(seepartslist)tothe
GrillServiceCenterat 1-888-473-1238.
AlwayscloseLPcylindervalveafterperformingleaktestby
turninghandwheelclockwise.
6 • 461262006

ForSafe Use of Your Grill and toAvoid Serious
Injury:
•Do notletchildrenoperateor playneargrill.
•Keepgrillarea clearandfreefrommaterialsthatbum
(i.e. gasoline,propane,or anyotherflammableliquid
or gas).
• Do notblockholesin sidesor backof grill.
•Checkburnerflamesregularly.
•Usegrillonlyinwell-ventilatedspace.NEVER usein
enclosedspacesuchascarport,garage,porch,
coveredpatio,or underan overheadstructureofany
kind.
• Donotusecharcoalorceramicbriquetsin agasgrill.
(Unlessbriquetsaresuppliedwithyourgrill.)
•Usegrillat least3ft.fromanywallorsurface.
Maintain10ft.clearancetoobjectstha_cancatchfire
or sourcesofignitionsuchas pilotlightsonwater
heaters,liveelectricalappliances,etc..
J
f
•ApartmentDwellers:
Checkwithmanagementtolearntherequirements
andfirecodesforusingan LPgasgrillinyour
apartmentcomplex.Ifallowed,useoutsideonthe
groundfloorwithathree(3)footclearancefromwalls
orrails.Donotuseonorunderbalconies.
•NEVERattemptto lightburnerwithlidclosed.A
buildupofnon-ignitedgasinsideaclosedgrillis
hazardous
•Never operategrillwith LP cylinder out of correct
positionspecified in assemblyinstructions.
•Always close LPcylinder valve and remove
coupling nut beforemoving LP cylinderfrom
specified operation position.
Safety Tips
•BeforeopeningLPcylindervalve,checkthecouplingnutfor
tighthess.
• Whengrillisnotinuse,tumoffallconb'olknobsandLP
cylindervalve.
• Nevermovegrillwhileinoperationor stillhot.
• Uselong-handledbarbecueutensilsandovenmittstoavoid
bumsandsplatters.
• Maximumloadforsideburnerandsideshelfis 10Ibs.
• Thegreasetraymustbeinsertedintogrillandempf_edafter
eachuse.Donotremovegreasetrayuntilgrillhas
completelycoded.
• Ifyounoticegreaseor otherhotmetedaldripping_omgrill
ontovalve,hoseorregulator,turnoffgassupplyatonce.
Determinethecause,correctit,thancleanandinspectvalve,
hoseandregulatorbeforecontinuing.Performa leaktest.
• Keepventilationopeningsincylinderenclosure(grillcart)free
andclearofdebris.
• Donotstoreobjectsor materialsinsidethegrillcart
enclosurethatwouldblocktheflowof combustionairtothe
undersideofeitherthecobol panelor thefireboxbowl.
• Theregulatormaymakea hummingorwhistlingnoiseduring
operation.Thiswill notaffectsafetyor useofgrill.
• Ifyou havea gnllproblemseethe "TroubleshcctingSection".
• Ifthe ragulator_ests,turnoffgrillandLPcylindervalve
immediately.Thisindicatesa problemwiththecylinderandit
shouldnotbeusedonanyproduct.Returntosupplied
CAUTION1!I
•Puttingoutgreasefiresbyclosingthelidisnot
possible.Grillsarewellventilatedforsafety
reasons.
Do not use water on a greasefire. Personalinjury
may result.If a greasefire develops, turn knobs
and LP cylinderoff.
Do not leave grill unattended while prehesting or
buming off food residue on HI. If grill has not been
regularlycleaned, a greasefire can occurthat may
damage the product.
IgnitorLighting
•Donotleanovergrillwhilelighting.
1.Openlidduringlighting.
2.TurnONgassourceortank.
3.Toignite,turntheIGNITIONBURNERknobtoIGNITE_.
4. PushandholdELECTRONICIGNITORbutton.
5. IfignitiondoesNOToccurwithin5 seconds,tumtheburner
controlsOFF_), wait5 minutes,andrepeatlighting
procedure.
6. Igniteremaining_mers byturningtoHIGH_j), startingwith
theburnersclosesttotheIGNITIONBURNERfirst.
If ignitionstill does not occur, follow match-lighting
instructions.
Lightinginstructionscontinuedonnextpage.
461262006 • 7

TurncontrolsandgassourceortankOFFwhennot
in use. 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 con6nue to flow out of the
burner and could acddently ignite with risk of injury.
Match-Lighting
•Donotleanovergrillwhilelighting.
1. Openlid.TurnongasatLPcylinder,
2. Placelitmatchintomatchholder(hangingfromcartside
panel),thenintolightingholeonrightorleftsideofgrill.
3. PushinandtomfarrightorfarleftburnerknobtoHIGH_j_.
Besurebumerlightsandstayslit.
4. Lightadjacentburnersinsequencebypushingknobsinand
turningtoHIGH(_j_.
Sidebumer IgnitorLighting
•Donotleanovergrillwhilelighting.
t. Opensidebumerlid.TurnongasatLPcylinder,
2. TurnsidebumerknobtoHIGH_j), pushandhold
ELECTRONICIGNITORbutton.
3. IfsidebumerdoesNOTlight,tom knobtoOFF_, wait5
minutes,thenrepeatlightingprocedure.
Sidebumer Match Lighting
1. Opensidebumerlid.TurnongasatLPcylinder.
2. Placelitmatchnearbumer.
3. TurnsidebumerknobtoHIGH_.
Besurebumerlightsand
stayslit.
8 • 461262006
Burner Flame Check
• Removecookingg_atasandflametamers.Lightbumers,rotate
knobsfromHIGH_toLOW_. Youshouldseea smaller
flameinLOWpositionthanseenonHIGH.Performburner
flamecheckonsideburner,also.Alwayscheckflamepriorto
eachuse.Ifonlylowflameisseenreferto "Suddendroporlow
flame"inthe TroubleshootingSection.
Turning Grill Off
• Turnallknobsto OFF_) position.TurnLPcylinderoffby
turninghand-wheelclockwisetoafullstop.
IgnitorCheck
• Turngasoffat LPcylinder.Pressandholdelec_onicignitor
button."Click"shouldbeheardandsparkseeneachtime
betweencollectorboxorburnerandelectrode.See
"Troubleshooting"if noclickorspark.
Valve Check
•Important:Makesuregasisoffat LPcylinderbefore
checldngvalves. Knobslockin OFF position.Tocheck
valves,firstpushinknobsandrelease,knobsshouldspring
back.Ifknobsdonotspringback,replacevalveassembly
beforeusinggdll.TurnknobstoLOWpositionthentombackto
OFF position.Valvesshouldtomsmoothly.
Hose Check
•Beforeeachuse,checktoseeif hosesarecutorworn.
Replacedamagedhosesbeforeusinggdll.Useonly
valve/hosekegulatorspedfiedbymanufacturer.
General Grill Cleaning
• Donotmistakebrownorblackaccumulationofgreaseand
smokeforpaint.Intehorsofgasgdllsarenotpaintedatthe
factory(andshouldneverbepainted).Applyastrongsolution
ofdetergentandwaterorusea grillcleanerwithscrubbrush
oninsidesofgrilllidandbottom.Rinseandallowtocompletely
airdry.Donotapplya caus_cgrilllovencleanertopainted
surfaces.
•Plasticparts:Washwithwarmsoapywaterandwipedry.
•Donotusecitrisol,abrasivedeaners,degreasersora
concentratedgrillcleaneronplasScparts.Damagetoand
failureofpartscanresult.
•Porcelainsurfaces:Becauseofglass-likecomposigon,most
residuecanbewipedawaywithbakingsodahvatarsolu_onor
speciallyformulatedcleaner,Usenonabrasivescoudngpowder
for stubbomstains.
•Paintedsurfaces:Washwithmilddetergentornonabrasive
cleanerandwarmsoapywater.Wipedrywithasoft
nonabrasivecloth.
•Stainlesssteelsurfaces:Tomaintainyourgrill'shighquality
appearance,washwithmilddetergentandwarmsoapywater
andwipedrywithasoftclothaftereachuse.Baked-ongrease
depositsmayrequiretheuseofanabrasiveplasSccleaning
pad.Useonlyindirectionofbrushedfinishtoavoiddamage.
Donotuseabrasivepadonareaswithgraphics.

|
CAUTION
NATURAL HAZARD • SPIDERS
FACT:Sometimesspidersandothersmallinsectsclimb
intotheburnertubesattachedtotheburners.The
spidersspinwebs,buildnestsandlayeggs.The_
websornestscanbeverysmall,butthey
areverystrongandcan blocktheflow
ofgas.Cleanburnerspriortouseafter
storing,atthebeginningofgrillingseason
orafteraperiodofonemonthnotbeingused.
Spiderguardsareontheairintakesinaneffortto
reducethisproblem,butitwillnoteliminateit!An
obstructioncanresultina'_lashback"(afireinthe
burnertubes).Thegrillmaystilllight,buttheobstruction
doesnotallowfullgasflowtotheburners.
IF YOUEXPERIENCETHEFOLLOWING:
1.Smellgas.
2. Burner(s)willnotlight.
3. Asmallyellowflamefromburner(shouldbe blue).
4. Firecomingfromaroundorbehindcontrolknob.
STOP!
Immediatelyturn off gas at LPcylinded.
SOLUTION:
Waitfor grilltocool.
Followthe"CleaningtheBumerAssembljYinstructions.
Cleanburnersoften.Usea 12"pipecleanertocleanout
theburnertubes.Youmayalsoforceastreamofwater
froma hosenozzlethroughburnertubestocleanthem.
Storing Your Grill
• Cleancookinggrates.
•Stereindrylocation.
•WhenLPcylinderisconnectedtogrill,storeoutdoorsinawell-
ver_latedspaceandoutofreachofchildren.
•Covergrillifstoredoutdoors.Choosefromavarietyofgdll
coversofferedbymanufacfurar.
•SteregrillindoorsONLYifLPcylinderisturnedoffand
disconnected,removed_omgrillandstoredoutdoors.
• Whenremovinggrillfromstorage,follow=C/eaningtheBumer
Assembly'instructionsbeforestartinggdll.
Cleaningthe BurnerAssembly
Followtheseinstructionstocleanand/orreplacepartsofburner
assemblyorifyouhavetroubleignitinggrill.
1. Turngasoffat controlknobsandLPcylinder.
2, Removecookinggratesandflametamers,
3, Removescrewsandcarryovertubesfromrearofburners,
4, Removescrewandwasherstodisengagebumerfrom
bracketonfirebox.
5. Removescrewstodetachelectrodefromburner.Electrode
shouldremaininfirebox.
6. Carefullylifteachburnerupandawayfromvalveopenings.
Wesuggestthreewaystocleantheburnertubes.Usetheone
easiestforyou.
(A) Bendastiffwire(a lightweightcoathangerworkswell)
intoa smallhook.Runthehookthrougheachbumer
tubeseveraltimes.
(B) Usea narrowbottlebrushwithafle)dblehandle(donot
usea brasswirebrush),runthebrushthrougheach
burnertubeseveraltimes.
(C) Weareyeprotection:Useanairhosetoforceairinto
theburnertubeandouttheburnerports.Checkeach
porttomakesureaircomesouteachhole.
7. Wirebrushentireoutersurfaceofburnerteremovefood
residueanddirt.
8. Cleananyblockedportswitha stiffwiresuchasanopen
paperclip.
9. Checkburnerfordamage,duetonormalwearandcorrosion
someholesmaybecomeenlarged.Ifanylargecracksor_
holesarefoundreplacebumer.
VERYIMPORTANT:Burnertubesmustreengagevalve _.
openings.Seeillustrationsat right.
10. Attachelecb'odetoburner, burnC°to.vn'ectalve_'
11. Carefullyraplacebumers. engagement____,
12. Attachburnerstobracketsonfirebox.
13. Repositioncarryovertubesandattach
toburners.Replaceflametamersand _
cookinggrates.
461262006 • 9

IndirectCooking
Poultryandlargecutsofmeatcookslowlytoperfectionon
thegrillbyindirectheat.Theheatfromselectedburners
circulatesgentlythroughoutthegrill,cookingmeetorpoul_j
withoutthetouchofadirectflame.Thismethodgreatlyreduces
flare-upswhencookingextrafattycutsbecausethereisnodirect
flametoignitethefatsandjuicesthatdripduringcooking.
IndirectCooking Instructions
•Alwayscookwiththelidclosed.
•DuetoweathercondiUons,cookingUmesmayvary.During
coldandwindyconditionsthetemperaturese_ngmayneed
tobeincreasedtoinsuresufficientcookingtemperatures.
Food Safety
Foodsafetyisa veryimportantpartofenjoyingtheoutdoor
cookingexperience.Tokeepfoodsafefromharmfulbacteria,
followthesefourbasicsteps:
Clean:Washhands,utensils,andsurfaceswithhotsoapywater
beforeandafterhandlingrawmeatandpoul_y.
Separate:Separaterawmeatsandpoultryfromready-to-eat
foodstoavoidcrosscontamination.Usea deanplatterand
utensilswhenremovingcookedfoods.
Cook:Cookmeatandpoul_j thoroughlytokillbacteria.Usea
thermometertoensureproperinternalfoodtemperatures.
Chill:RefrigeratepreparedfoodsandleftoversprompUy.
For more informationcall: USDA Meat and Poultry Hotiineat
1-800-535-4555 In Washington, DC [phone], 10:00 am-
4:00 pm EST,
1 Burner Cooking
Cookwithdirectorindirectheat.
Bestforsmallermealsorfoods.
Consumeslessfuel.
HowToTellIf MeatIsGrilledThoroughly
•Meatandpoulftycookedona grilloftenbrownsveryfastonthe
outside.Usea meatthermometertobesurefoodhasreached
asafeinternaltemperature,andcutintofoodtocheckfor
visualsignsofdoneneas.
•Wholepoul_yshouldreach180°F;breasts,170° F.Juices
shouldrunclearendfleshshouldnotbepink.
• Hamburgersmadeofanygroundmeatorpoultryshouldreach
160° F,andbebrowninthemiddlewithnopinkjuices.Beef,
vealandlambsteaks,roastsandchopscanbecookedto 145°
F.Allcutsofporkshouldreach160° F.
• NEVERpartiallygrillmeatorpoultryandfinishcookinglater.
Cookfoodcompletelytodestroyharmfulbacteria.
• Whenreheathgtakeoutfeedsorfullycookedmeatslikehot
dogs,grillto165° F,orunUIsteaminghoL
2 Burner Cooking
Greatindirectcookingonlow.
Producesslow,evenheating.
Idealforslowroastingandbaking.
10 • 461262006

CARE AND CLEANING OF YOUR STAINLESS STEEL GRILL
Routinecleaning isnecessaryto preservethe appearance and corrosion resistanceof Stainless Steel.The perceptionthat
many peoplehave is that stainless steelwill not rust.That is not thecase in certainconditions. Rust marks are regularsttel
particlesthat have becomeattached to the surface of stainless steel. They may also occur ifyou are usinga steel woolor
wirewool scouring pad in stead of a nylon scouring padto clean your grill. Incoastal areas, small rust pits may developon
the surface of yourgrill that cannotbe fully removed bya cleaner.Concentrate bleachesand other solutionscontaining
chlorinecan also cause rust pitsand should not be used.
Cooking creates smokethat may eventuallycoat and discolor the stainless steel surface. Grease fireswill darken the
stainlesssteel surface,but will not affect the integrity ofthe steel. Periodiccleaningof the cooking surface and insidedthe
grill helpsdecreasethe risk of a fire. The methods beloware suggestionsfor cleaningstainless steel surfaces.Choose a
cleaning methodappropriatefor your needs.It is recommendedthat you usea Char-Broil®grill cover to help prolongthe
life and preventdiscolorationofyour grill.
Routine Care
After each use, letyour grill cooland thenwipe the grill witha soft, damp, soapy clothand rinsewith clean water.It is
important to removeany food particlesor marinadefrom thestainless steel surfaceof your grill. Most marinadesare highly
acidic and damagestainlesssteel. DO NOT USE STEELOR WIREWOOL. Toclean, polish and protectyour stainless steel
grill on a weekly basis useChar-Broil®Stainless Steel Grill Cleaner. Forquick,convenient cleaning, useChar-Broil®
Stainless Steel Grill Wipes.
StubbornStains and Rust
Stubborn stains, discolorationand possibly rustand rust pitting canoccur fromcooking, exposureto harsh outdoor
conditions, or extreme cookingtemperatures. Forstubbornrust stains and greasestains, you can restoreyour grill withthe
Char-BroilStainless Steel RestorationKit. It is availableat major retailersor you can buy it online at www_rilllovers.com.
Forthelatestnew products and informationfor the careand cleaningof your stainlesssteelgrill go to www.charbroiLcom.
*Always rub orwipe inthe direction of the grain or polishlines inthe stainless steelsurface, notacross them.
** Do not let stainless steel cleaners come in contact with paintedor plastic surfaces asdamage may occur.
ROUTINE CARE
Char-Broil® Stainless Steel
Grill Cleaner
ROUTINE CARE
Char-Broil® Stainless Steel
Grill Wipes
STUBBORN STAINS AND RUST
Char-Broil® Stainless Restoration Kit
461262006 *11

K_e.y
A 1
B 1
C 1
D 1
E 1
F 1
G 4
H 1
I 1
J 3
K 1
L 1
M 5
N 5
O I
P I
Q I
R I
S 1
T 1
U 1
V I
W I
X I
Y I
Z I
AA 1
BB 1
CC 1
DD 1
EE 1
FF 1
GG 2
HH 1
Description
Firebox Bowl.................
Right Side Upper Panel, Firebox•
Left Side Upper Panel, Firebox..
Right Side Panel, Firebox.......
Left Side Panel, Firebox ........
Rear Panel, Firebox ...........
Part #
•.. 80005584
•.. 80005585
•1.80005586
•.. 80005702
•.. 80005701
... 80005590
Bumen ......................... 80005703
Electronic Ignition Kit ......
Electronic Ignition Button...
CanTover Tube...........
Contol Panel ............
VaNe/Manifold/Reguhtor. •.
........ 80005704
........ 80004341
........ 80005592
........ 80005705
........ 80005740
ControIKnob .................... 80004216
Control Knob Bezel .......
Bottom Shelf.............
Left Side Panel, Cart ......
Right Side Panel, Cart .....
Lower Back Panel, Cart ....
Upper Back Panel, Car[ ....
...... 80005596
...... 80005706
...... 80005707
...... 80005708
...... 80005623
...... 80005624
Front Brace...................... 80005709
Heat Shield,Tank ................. 80005710
Left Rail, Grease Tray ............. 80005711
Right Rail, Grease Tray ............ 80005712
Sideburner Drip Pan............... 80005626
Sideburner Lid ................... 80005627
Left Sideburner Shelf .............. 80005628
Fascia, Left Sideburner Shelf........ 80005713
Sideburner Burner Kit.............. 80004311
Right Side Shelf .................. 80005714
Fascia, Right Side Shelf............ 80005715
Left Door. ....................... 80005717
Right Door ...................... 80005719
Door Hande w/Caps .............. 80005718
Lid Assembly .................... 80005720
II 1
JJ 1
KK 1
LL 1
MM 1
NN 1
OO 4
PP 2
QQ 2
RR 1
SS 1
TT 1
UU 2
VV 1
VWV 1
XX 1
1
1
1
Description Part #
innerinsert,LidAssembly .......... 80005721
Lid Handle ...................... 80005722
TemperatureGauge ............... 80004030
Logo Plate ...................... 80005723
Lid Assembly Hardware Pack........ 80004371
Warming Rack ................... 80004050
Flame Tamer .................... 80003332
Locking Caster ................... 80000268
Fixed Caster..................... 80004093
Sideburner Cooking Grate .......... 80000638
Cooking Grate(set of 2)............ 80005724
Grease Tray ..................... 80003584
Match Holder .................... 80005589
Logo Plate, Dual Fuel.............. 80005594
TowelBar ....................... 80005716
Sideburner Wind Diverter........... 80005038
Replacement FlameTamer
Support Pins ................... W80000020
Product Guide (English)............ 80005671
Hardware Pack................... 80005676
I Caster Wrench
1 AA Battery
1 Control Knob
1 Control Knob Bezel
4 #8x3/8" Self-TappingScrew
2 #8--32x3/8"Screw
2 4mm Lock Washer
2 #10=24x3/8"Screw
8 1/4-20x1½' Screw
2 5ram Fiat Washer
2 5mm Lock Washer
18 1/4-20xl/2" Screw
26 7mm Fiat Washer
26 7mm Lock Washer
Tools required for assembly:
CasterWrench- Provided •Phillipsscrewdriver- Not provided
Estimated assembly time:
30-45minutes
Cetefied Grll PartsAndAccessortes, ChaFBr®landDes gn®,Char-Broil(GasG_ll Briquettes)®,Char-Damonds®,CookingZoneand Desgn®, DiamondFlame®,ExecutveChef®, Faststert®,Flare
Fighter@,FlavorMastsr@,GasGrill Siloue_eand Design®.H20 Smoker@,LavaFlame®,MasterFlame®,MasterFlameP_cis®n CookingSystsm®, PowerSpark_,Quantum®,VIP®, P_cis®nFlame anrJ
Design®,Sterm@,andTruFlarne®are re6iteeredTra_Jernarksof the W.C.BradleyCompany. Thermos®is a _egisteredtradema®of theThermosCompanyand its affiliates.
ArUsanCollec_®nbyChaFBroil iv C3 and DesignTM, Char-BroilandDesignTM , Flame DesignTM, FlavorTentsTM, Grill 2GoTM, GrilliffiSttskTM, Keeperof the FlarneTM, Keepersof theFlameTM, NaturalGripTM,
OutdoorCookingCollectionandDesign_MPatioBistroTM, Pre®®onFlameTM ,Pro-CbeckTM, QuickSetGdlls and Design_MSmokerTen_s_, The Big EasyTM , The MinuteGrillTM, The Edge_4 TheTuscan
CollectionTM, andThe UIbanGrillTM are Trademarksofthe W.C.B_dley Compan_ Un®elsal Gr_llParts and Des_gnl_isa _rademarkof theThermos Companyandits affiliates.
Protectedunder one or moreof thefollow®gU.S. Patents: 4,598,692;4,624,240;4,747,361;4,747,361;4,817,583;4,924,846;4,989,579;5,063,966;5,076,256;6,076,257;6,090,398;5,109,834;5,224,676;
5,277,106;5,421,319;5,441,226;6,452,707;5,458,309;5,566,606;5,566,606;5,579,755;5,562,094;5,613,486;5,640,475;5,706,707;5,711,663;5,765,543;6,931,149;6,996,573;6,096,132;6,135,104;
6,173,644B1;6,279,566;6,397,731;6,418,023;6,439,222;6,523,461; D282,619;D339,714;D341,292;D343,337;D358,059; D361,466;D364,535;D372,637;D373,701;D377,735;D383,035;D307,010;
D405,643;D405,643;D406,005;D4O6,OO£;D413,043;D413,229;D413,229;D414,982; D415,388;D416,164;D416,441;D416,441;D417,587;D422,516;D423,274;D423,676;D428,303;D435,396;D436,004;
D438,059;D438,060;D438,427;D439,110;D442,506;D443,179;D443,354;D447,384;D447,385;D447,909;D448,610;D448,614;D448,615; D448,616;D448,975;D449,462;D451,759;D456,262S;D460,313,
D461,359and D504,O4thCanada:67743;67744;92607;92608 and1,316,424.Other PatentsPending.Assemblyinstru_ons © 2005.
12 • 461262006

¢o,I
OD

E1Attachthetwolockingcastersattherear
ofthebottomshelfandthetwofixed
castersatthefront.Usetheprovided
casterwrenchtofullytightencasters.
Lockingusster-----........_
80000268
Fixedcaster_
80004093
Bottomshelf_ .
80005706
Rear
Fa Attachsidepanelstobottomshelfusingthree
1/4-20x1/2"screws,7mmlockwashers,and
7ramfiatwashersperpanel.
IMPORTANT:Panelwithlargeholemust
Beonleftsideofbottomshelf. 7mmII
Leftsidepanel----......._
(withlargehole)
80005707
Makesuresidepanels
arepushedasfartothe
rearofbottomshelfas
possiblebeforefully
tighteningscrews. _....----RigMsidepanel
80005708
14 • 461262006

UPlacelower back panel
between side panels at
rear of bottom shelf.
Secure lower back panel to
side panels using two
1/4-20x1/2" screws,
7ram lock washers, and
7ram flat washers on each
side.
80005623
-- m
This step requires two people
to lift and position grill heed
onto cert. Carefully lowerthe grill
head onto the cart, aligning slots at
bottom of grill head with posts on
cart side panels. Makesure the
regulator hose is hanging outside
the cart, Grill head must face open
side of cart.
Grillhead_.--.-.- --.---_
Regt
461262006 • 15

DInsertfront brace under control paneland between cart side panels. Secure usingtwo 1/4=20x11/2"screws, 7ramlock
washers, and 7mm fiat washers on each side.
NOTE: MAKE SURE THAT THE FRONT BRACE IS MOUNTED IN THE MOST DOWNWARD POSITION WHEN
ASSEMBLED TO CART,
DOn back of grill, place upper back panel between side panels and
above lower back panel. Secure upper back panel, in lower holes,
usingone 1/4-20xl V2"screw, 7ram lock washer, and 7ram flat
washer on each side. Do not fully tighten screws until side shelf
installation is complete in latersteps,
l/4-20xfV_" 7ramlock 7ramflat
screw washer washer
pperbackpanel
80005624
_6 • 461262006

Inserttabs on right side shelf into rectangular slots in side of firebox.Attach rear
of shelf using one 1/4-20x1/2" screw, 7mm lock washer,and 7ram fiat washer
in upper hole. Use one l/4-20xlW' screw, 7ram lock washer, and
7ram flat washer in lower hole.Attach front of shelf and fascia using three
1/4-20x1/2" screws, 7ram lock washers, and 7ram fiat washers.
Tabs
into
DInserttabs on left sideburner shelf assembly into rectangular slots in side of firebox. Attach rearof shelf using one 1/4-
2gx1/2" screw, 7ram lock washer,and 7mm flat washer in upper hole. Use one l/4-20xlW' screw, 7turn lock washer, and
7ram fiat washer in lower hole.Attach front of shelf and fascia using three 1/4-20xl/2" screws, 7mm lock washers, and 7ram
fiat washers. Now you may fully tighten lower screws on upper back panel.
1/4-20x11/2'' screw Tabs
into
holes
/
Fascia,left sideburnershelf
80005713
461262006 • 17

First,removethetwoscrewsandlockwashemfromthesidebumervalvebracket.Posilonsideburnervalvebracket
beneathsidebumershelffasciasothatvalvestemcomesthroughlargercenterholeinfascia.Secureusinglockwashers
andscrewsthatwereremovedfrombracket.Attachsidebumerbezeltofasciausingtwo#8-32x3/8"screwsand4mmlock
washers.Presssideburnercontrolknobontovalvestem.
\
Sidebumer
valvebracket
Controlknobbezel
80005596
_"_] Insertsidebumerburnerintoleftshelf,makingsureburnertubeengagessideburnervalve(A).Centerstudonbottomof
burnerfitsintocenterholeinburnerbracketonshelf.SeeillustrationCfor properburner-to-valveengagement.Secure
burnertobracketusingtwo#10-24x318"screws,5mmlockwashers,and5mmfiatwashers(B).
80004311
18 • 461262006

mPlacesidebumer wind diverter over
sidebumer.Align notch in diverter to
fit around electrode. Placeburner
cap onto sideburner. Place
sidebumer cooking grate onto
sidebumer shelf, aligning grate legs
with holes on shelf.
Burnercap
Sidebumerwinddive_er
80005038
Insideof cart, insert ends of left and rightgrease tray rails into slots between upper and lower back panels near grease tray
opening.Attach opposite ends of rails to bottomedge of front brace using one #8x318" self-tapping screw per rail.Tothe left
of the rails, repeat this procedureto install the tank heatshield. Attach heat shield to front brace usingtwo #8x3/8" self-
tapping screws.
461262006 • 19

Inserthingepinonbottomofdoorsintoholeinbottomshelf.Pressupperhingepinin_ontbrace,alignhingeholeontopof
door,andreleasehingepinintodoor.
[]E]
Hingepin
onbottom
ofdoor
Left door htdoor
80005717 80005719
Installflametamersbyslidingoneendofeachflametamerintoslotsatfrontoffireboxandrestingoppositeendonpinsin
backoffirebox.
20 • 461262006