Thermos 461630510 User manual

Serial Number
Date Purchased
IMPORTANT: Fill out the product record information below.
See rating label on grill for serial number.
11/02/09 • G208-002-120801
© 2009 Char-Broil, LLC Columbus, GA 31902 Printed in China
For support and to register your
grill, please visit us at
www.charbroil.com
Estimated assembly time: 35-40 minutes
If you have questions or need
assistance during assembly,
please call 1-800-241-7548.
PRODUCT GUIDE
MODEL 461630510
Assembly instructions © 2009
This product is manufactured by Char-Broil, LLC, a division of the W. C. Bradley Company under the terms of a license agreement granted by Char-Broil Thermos
Holdings, LLC. In the United States, in the category of gas grills and grill accessories, Thermos is a registered trademark of Char-broilThermos Holdings, LLC. In the
UnitedStatesinallothercategoriesandworldwideinallcategories,ThermosisaregisteredtrademarkofThermosL.L.C.oroneofitsaffiliates.Allrightsreserved.
Thefollowing are trademarksregistered by W.C. BradleyCo. in theU.S. Patent andTrademarkOffice:Caldera®; Charcoal2Go®; Char-Broil®;America's Legendary
Barbeque Company®; American Gourmet®; Bandera®; Brush Hawg®; CB 940®; Char-Diamonds®; Char-Broil Charcoal/Gas®; Everybody Grills®; Everybody
Outside®; FastStart®; Grill 2 Go®; Grill 2 Go® Express®; Grill Lovers®; Infrared Grilling That’s All About U®; Keepers of the Flame®; New Braunfels Smoker
Company®; Patio Bistro®; Patio Caddie®; Patio Kitchen®; Pro-Sear®; RED®; Quantum®; Santa Fe®; Sear and Grill®; Sierra®; Signature Series®; Sure2Burn®;
TheBigEasy®;Trentino®;U®; WildWestTradition®;andthefollowingmarks:
® ®
Protected under one or more of the following U.S. Patents: 5,421,319; 5,458,309; 5,579,755; 5,996,573; 6,135,104; 6,279,566; 6,331,108; 6,484,900; 6,526,876; 6,595,197; 6,640,799; 6,640,803; 6,729,873; 6,739,473; 6,749,424; 6,792,935; 6,951,213; 7,047,590;
7,516,693;D364,535;D372,637;D373,701; D377,735;D383,035;D397,910;D405,643; D406,005;D406,009;D413,043;D413,229;D414,982;D415,388;D416,164;D416,441;D417,587;D417,588;D422,516;D423,274;D423,876;D428,303;D430,772;D435,396;
D436,004;D438,059; D438,060;D438,427; D439,110; D442,505;D443,179;D443,354;D443,464; D447,384;D447,385; D447,909;D448,610;D448,614;D448,615; D448,616;D448,975; D449,492;D450,544;D451,759;D454,028; D454,031;D455,205; D455,206;
D456,202;D456,222;D456,223;D457,789; D458,520;D458,760; D458,802;D459,088;D459,148 D459,149;D459,161; D459,163;D459,586;D459,943; D460,312;D460,313; D460,318;D461,359;D465,123; D465,693;D466,307; D466,439;D466,752;D473,414;
D474,371; D477,498; D477,501; D477,504; D477,506; D477,746; D478,471; D478,472; D480,914; D491,410; D494,009; D494,413; D498,523; D500,359; D504,048; D530,098; D535,000; Canada:D97,504;D99,355; D102,037; D104,200;D108,377; 2,315,567;
France:D010,231;D010,422;D010,590;D010,849;1,089,646;SouthKorea:384,565;UnitedKingdom:2,099,402.OtherPatentsPending. ©2009W.C.BradleyCompany
Thefollowing are trademarks of W.C. BradleyCo.:Advantage Series™;Auto-Clean™;ChefTested™; CommercialSeries™; Designer Series™;; Diamond Flame™;
DoubleChef™; Fireball™; Firenzy™;FlavorMaster™;FrontAvenue™;Grill 2 Go®Advantage™; Hog andYardBird™; H20 Smoker™;Infrared. Grilling’sJuicy Little
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Grill™;Torchfork™;UniversalGrillParts™;YouBringtheParty™ TEC™isatrademarkofTecInfraredGrills.
TM REVISION 04
®

2
TABLE OF CONTENTS
For Your Safety....................................2-3
Grilling Guide......................................4-7
Use and Care ....................................8-13
Limited Warranty....................................14
Parts List..........................................15
Parts Diagram......................................16
Assembly.......................................17-25
Troubleshooting..................................26-27
Registration Card...................................31
1. Do not store or use gasoline or other
flammable liquids or vapors in the vicinity of
this or any other appliance.
2. An LP cylinder not connected for use shall not
be stored in the vicinity of this or any other
appliance.
WARNING
CAUTION
For residential use only. Do not use for commercial
cooking.
DANGER
DANGER: Indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
WARNING
WARNING: Indicates an potentially hazardous situation
which, if not avoided, could result in death or serious injury.
CAUTION
CAUTION: Indicates a potentially hazardous situation or
unsafe practice which, if not avoided, may result in minor
or moderate injury.
Safety Symbols
The symbols and boxes shown below explain what each heading
means. Read and follow all of the messages found throughout
the manual.
DANGER
If you smell gas:
1. Shut off gas to the appliance.
2. Extinguish any open flame.
3. Open lid.
4. If odor continues, keep away from the
appliance and immediately call your gas
supplier or your fire department.
THIS GRILL IS FOR OUTDOOR USE ONLY.
CAUTION:
Read and follow all safety statements, assembly
instructions, and use and care directions before attempting
to assemble and cook.
INSTALLER/ASSEMBLER:
Leave this manual with consumer.
CONSUMER:
Keep this manual for future reference.
WARNING:
Failure to follow all manufacturer’s instructions could result
in serious personal injury and/or property damage.
CAUTION:
Some parts may contain sharp edges – especially as noted
in the manual! Wear protective gloves if necessary.

3
WARNING
CALIFORNIA PROPOSITION 65
1. Combustion by-products produced when using
this product contain chemicals known to the State of
California to cause cancer, birth defects, and other
reproductive harm.
2. This product contains chemicals, including lead
and lead compounds, known to the State of
California to cause cancer, birth defects or other
reproductive harm.
Wash your hands after handling this product.
WARNING
Do not attempt to repair or alter the
hose/valve/regulator for any “assumed” defect. Any
modification to this assembly will void your warranty
and create the risk of a gas leak and fire. Use only
authorized replacement parts supplied by
manufacturer.
CAUTION
Using pots larger than 6 quarts in capacity could
exceed weight limit of the
side burner shelf
resulting in failure
of grill cart
components.
or side shelf,
Installation Safety Precautions
•Use grill, as purchased, only with LP (propane) gas and the
regulator/valve assembly supplied. If your grill is Dual Fuel ready,
a conversion kit must be purchased for use with natural gas.
•Grill installation must conform with local codes, or in their
absence of local codes, with either the National Fuel Gas
Code, ANSI Z223.1/ NFPA 54, Natural Gas and Propane
Installation Code, CSA B149.1, or Propane Storage and
Handling Code, B149.2, or the Standard for Recreational
Vehicles, ANSI A 119.2/NFPA 1192, and CSA Z240 RV Series,
Recreational Vehicle Code, as applicable.
• All electrical accessories (such as rotisserie) must be
electrically grounded in accordance with local codes, or
National Electrical Code, ANSI / NFPA 70 or Canadian
Electrical Code, CSA C22.1. Keep any electrical cords and/or
fuel supply hoses away from any hot surfaces.
• This grill is safety certified for use in the United States and/or
Canada only. Do not modify for use in any other location.
Modification will result in a safety hazard.

First Time Use
Read your Assembly Manual and ensure the grill is put together
properly. Remove all Point-of-Purchase advertising material from
all grill surfaces before first use. We recommend operating your
grill on its highest setting for 15-20 minutes prior to your first use.
This aids in removing the oils used during manufacturing.
Lava Rock / Briquettes
This gas grill has been designed, engineered, and tested to be
used with flame tamers or heat distribution plates to provide
more even heating, improve the cleaning process, and reduce
flare-ups. The addition of after market lava rocks, charcoal, or
briquettes of any type will cause poor combustion and increase
the likelihood of a grease fire, and is not recommended. Using
briquettes, lava rock, or charcoal in this grill will void your
warranty. For extra smoke flavor, we recommend using a
smoker box with wood chips.
Temperature
The temperature gauge in the hood of your new grill measures
air temperature. The air temperature inside your grill will never
be as hot as the temperature at the cooking surface.
Note: Since 1995, all regulators (the part that attaches to the gas
tank to regulate the flow of gas) have included a safety feature
that restricts gas flow in the event of a gas leak. You can
inadvertently activate this safety feature without having a gas
leak. This typically occurs when you turn on the gas using the
grill control knob before you turn on the LP tank valve. If the gas
regulator safety feature activates, the grill will only reach
temperatures between 250°F and 300°F even with all burners on
the high setting.
If your grill is not getting hotter than 250°F to 300°F these
steps should be taken first to reset the gas regulator safety
device:
1. Open the grill lid.
2. Turn off all knobs on the control panel in front.
3. Turn off the tank knob.
4. Disconnect the regulator from the LP tank.
5. Wait 30 seconds.
6. Reconnect the regulator to the LP tank.
7. Slowly open the LP tank knob all the way. Do not put
excessive force on the valve at the full open position to avoid
damaging the valve.
8. Turn on the appropriate control knob and light the grill per the
instructions on the control panel.
An illustration of this process is included in this Product Guide.
See Troubleshooting section for additional information.
Pre-Heating Your Grill
Just like your home oven, your grill should be pre-heated to
provide optimum performance. Pre-heat the grill on high for 10-
15 minutes – longer if weather conditions require. Please refer to
the lighting instructions inside the Product Guide if you have
questions about how to light your grill. A match-light chain and
hole is provided for your convenience.
GRILLING GUIDE – Getting Started
Regulator Coupling Nut
4

Outdoor grilling is really quite simple. You'll succeed with
burgers, dogs, or steaks usually on your very first try. With
experience, you will learn how to work with your grill, creating
more imaginative meals all the time. This knowledge makes up
the art of grilling. Before you start grilling, organize your food
according to cooking technique and required cooking time, and
optimize the use of your grilling area.
Direct Cooking
Direct cooking involves grilling your meat directly over high heat.
It is perfect for searing steaks, chops, and other smaller pieces of
meat and vegetables that quickly make their way to the table.
Indirect Cooking
Indirect cooking utilizes select burners to circulate heat
throughout the grill, without direct contact between the meat and
the flame. The meat is placed over the burner that is 'off'. This
method is generally used to slow cook large cuts of meat and
poultry. A pan can be placed underneath the meat to catch
grease and food drippings, and helps minimize clean-up.
Rotisserie Cooking
Rotisserie cooking is best for 'round' meat, such as large roasts,
whole poultry, and pork. It generally requires an accessory motor
and spit rod that allows the meat to be turned at a constant
speed. Rotisserie cooking is best done in front of a special
rotisserie burner, or utilizing an indirect cooking burner
arrangement. A pan can be placed underneath the meat to catch
grease and food drippings, and helps minimize clean-up.
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.
Separate: Separate raw meats 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.
GRILLING GUIDE – Grilling 101
5

USDA Recommended Safe Minimum
Internal Temperatures
Beef, Veal, Lamb, Steaks, & Roasts 145° F
Fish 145° F
Pork 160° F
Beef, Veal, Lamb Ground 160° F
Egg Dishes 160° F
Turkey, Chicken & Duck Whole,
Pieces & Ground 165° F
Cooking on your new grill is a hands-on experience, and it is
recommended to remain outside with your grill while cooking.
Grilling can be affected by many external conditions. In cold
weather, you will need more heat to reach an ideal cooking
temperature, and grilling may take longer. The meat's internal
temperature and thickness can also affect cooking times. Cold
and thicker meats will take longer to cook.
Internal Meat Temperatures
Meat cooked on a grill often browns very fast on the outside.
Therefore, use a meat thermometer to ensure it has reached
safe internal temperatures.
Please refer to the USDA for complete, up-to-date information.
Our internal temperature chart is based on USDA standards for
meat doneness. Check it out at
Sauces
Sauces containing sugars and fats can cause flare-ups, and your
food may burn. In general, apply these sauces during the final
10 minutes of cooking. Keep in mind, use of excessive sauces
or glazes will also require extra cleaning afterwards.
Marinades and Rubs
To enhance the flavor of grilled foods, a liquid marinade or dry
rub can be used prior to cooking. Meat can be either soaked or
injected with liquid marinade up to 24 hours prior to grilling. Dry
rubs can be applied directly to the meat immediately before
grilling.
www.isitdoneyet.gov
GRILLING GUIDE – Tips & Tricks Wood Chips
For extra smoke flavor when grilling, try adding wood chips.
Soak the chips in water for approximately 30 minutes before
adding to a smoke box or pan. Place smoke box or pan on top of
the cooking grate above the flame. Turn grill on high until the
wood starts to smoke. Reduce heat to desired temperature for
cooking, and place food on cooking grate as desired. Close lid to
retain more smoke. Hardwood varieties that work particularly
well with grilled foods include Alder, Apple, Cherry, Grapevines,
Hickory, Mesquite, Oak, Rosemary and Sassafras.
Skewers
Metal skewers should be flat, with long handles. Round skewers
allow food to roll when turned, so it may not cook as evenly. Use
metal skewers when cooking meat kabobs. Wooden skewers
should be soaked in water for an hour before use, and are best
used for quick cooking foods such as vegetables and fruits.
Utensils
Use tongs or a spatula to handle the food instead of a fork, and
don't turn the food too
often. Piercing the food
with a fork will release
juices that you want in
the meat, and may
cause flare-ups.
6

Why Clean?
We've all heard the saying, 'an ounce of prevention is worth a
pound of cure.’ This is great advice when it comes to keeping
your grill clean.
Routine Care
Periodic cleaning of this grill is necessary,
as grill fires can occur when grease and
food debris collect in the bottom of the grill.
After each use, remove any remaining
food particles from the cooking grate and
inside of the grill using a grill brush. Do
this after the grill has cooled down, yet is
still warm. It is much easier to clean food
particles while warmth is still present, than
after the food particles have completely
cooled and hardened. This grill is not
designed to be 'burned off' by closing the
lid and turning the burners on High for an
extended time. The excessive heat
generated can cause leftover grease to
catch fire, and can cause permanent
damage to your grill.
General Cleaning
Plastic parts: Wash with warm soapy water and wipe dry. Do not
use 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
glass cleaner. Use non-abrasive scouring powder for stubborn
stains.
Painted surfaces: Wash with mild detergent or non-abrasive
cleaner and warm water. Wipe dry with a soft non-abrasive cloth.
Stainless steel surfaces: Stainless steel can rust under certain
conditions. This can be caused by environmental conditions
such as chlorine or salt water, or improper
cleaning tools such as wire or steel
wool. It can also discolor due to heat,
chemicals, or grease build-up. To
maintain your grill's high quality
appearance, wash with mild detergent
and warm water, or use a stainless
steel grill cleaner. Baked-on grease
deposits may require the use of an
abrasive plastic cleaning pad. Use only
in direction of brushed finish to avoid
damage. Do not use abrasive pad on
areas with graphics.
GRILLING GUIDE – Cleaning Your Grill Cooking surfaces: If a bristle brush is used to clean any of the
grill cooking surfaces, ensure no loose bristles remain on cooking
surfaces prior to grilling. It is not recommended to clean cooking
surfaces while grill is hot.
Storing Your Grill
• Clean cooking grates.
• Store grill in dry location.
• When LP cylinder is connected to grill, store outdoors in a 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 cylinder is turned off,
disconnected, and removed from grill. Never store LP cylinder
indoors.
• When removing grill from storage, follow the 'Cleaning the
Burner Assembly' instructions in the Use and Care section of
the Product Guide.
Critters
Spiders like to make their homes in the venturi tubes of grills.
These must be inspected and cleaned regularly to ensure there
are no blockages. Refer to the Use and Care portion of this
Product Guide for complete information.
7

• NEVER store a spare LP cylinder under or near
the appliance or in an enclosed area.
• Never fill a cylinder beyond 80% full.
• An over filled or improperly stored cylinder is a
hazard due to possible gas release from the
safety relief valve. This could cause an intense
fire with risk of property damage, serious injury or
death.
• If you see, smell or hear gas escaping,
immediately get away from the LP
cylinder/appliance and call your fire department.
DANGER
USE AND CARE
LP Cylinder Removal, Transport and Storage
•Turn OFF all control knobs and LP cylinder valve. Turn coupling
nut counterclockwise by hand only - do not use tools to
disconnect. Loosen cylinder screw beneath bottom shelf, then
lift LP cylinder up and out of cart. Install safety cap onto LP
cylinder 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.
•A disconnected LP cylinder in
storage or being transported
must have a safety cap installed (as shown).
Do not store an LP cylinder in enclosed spaces
such as a carport, garage, porch, covered
patio or other building. Never leave an LP cylinder
inside a vehicle which may become overheated
by the sun.
•Do not store an LP cylinder in an area where children play.
OPD Hand Wheel
LP (Liquefied Petroleum Gas)
•LP gas is nontoxic, odorless and colorless when produced. For
Your Safety, LP gas has been given an odor (similar to rotten
cabbage) so that it can be smelled.
•LP gas is highly flammable and may ignite unexpectedly when
mixed with air.
LP Cylinder Filling
•Use only licensed and experienced dealers.
•LP dealer must purge new cylinder before filling.
•Dealer should NEVER fill LP cylinder more than 80% of LP
cylinder volume. Volume of propane in cylinder will vary by
temperature.
•A frosty regulator indicates gas overfill. Immediately close LP
cylinder 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 cylinder, 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 Cylinder Valve
Retainer Strap
Safety
Cap
LP Cylinder
•The LP cylinder used with your grill must meet the
following requirements:
•Use LP cylinders only with these required measurements: 12"
(30.5cm) (diameter) x 18" (45.7 cm) (tall) with 20 lb. (9 kg.)
capacity maximum.
•LP cylinders must be constructed and marked in accordance
with specifications for LP cylinders 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 cylinder collar for
marking.
•LP cylinder valve must have:
•Type 1 outlet compatible with
regulator or grill.
•Safety relief valve.
•UL listed Overfill Protection
Device (OPD). This OPD safety
feature is identified by a unique triangular hand wheel. Use
only LP cylinders equipped with this type of valve.
•LP cylinder must be arranged for vapor withdrawal and include
collar to protect LP cylinder valve. Always keep LP cylinders in
upright position during use, transit or storage.
LP cylinder in upright position for vapor withdrawal
8

WARNING
If “growing” bubbles appear do not use or move the LP
cylinder. Contact an LP gas supplier or your fire
department!
Connecting Regulator to the LP Cylinder
1.LP cylinder must be properly secured onto grill. (Refer to
assembly section.)
2.Turn all control knobs to the OFF position.
3.Turn LP cylinder OFF by turning hand-wheel clockwise to a
full stop.
4.Remove the protective cap from LP cylinder valve. Always use
cap and strap supplied with valve.
Safety Relief Valve
Nipple has to be centered
into the LP cylinder valve.
OPD Hand Wheel
Type 1 outlet with
thread on outside
c k w
o
l
i
s
C
e
f
f
O
Do not use a POL transport plug
(plastic part with external threads)!
It will defeat the safety feature of
the valve.
Strap and Cap
LP Cylinder Exchange
•Many retailers that sell grills offer you the option of replacing
your empty LP cylinder through an exchange service. Use only
those reputable exchange companies that inspect, precision fill,
test and certify their cylinders. Exchange your cylinder only
for an OPD safety feature-equipped cylinder as described
in the "LP Cylinder" section of this manual.
•Always keep new and exchanged LP cylinders in upright
position during use, transit or storage.
•Leak test new and exchanged LP cylinders BEFORE
connecting to grill.
LP Cylinder Leak Test
For your safety
•Leak test must be repeated each time LP cylinder is exchanged
or refilled.
•Do not smoke during leak test.
•Do not use an open flame to check for gas leaks.
•Grill must be leak tested outdoors in a well-ventilated area,
away from ignition sources such as gas fired or electrical
appliances. During leak test, keep grill away from open flames
or sparks.
•Use a clean paintbrush and a 50/50 mild soap and water
solution.
s Do not use household cleaning agents. Damage to gas
train components can result.
Brush soapy solution onto areas indicated by arrows
in figure below.
5.Hold regulator and insert nipple into LP
cylinder valve. Hand-tighten the
coupling nut, holding regulator in a
straight line with LP cylinder valve so
as not to cross-thread the connection.
•Place dust cap on cylinder valve outlet whenever the cylinder is
not in use. Only install the type of dust cap on the cylinder valve
outlet that is provided with the cylinder valve. Other types of caps
or plugs may result in leakage of propane.
9

6.Turn the coupling nut clockwise and tighten to a full stop. The
regulator will seal on the back-check feature in the LP cylinder
valve, resulting in some resistance. An additional one-half to
three-quarters turn is required to complete the
connection. Tighten by hand only – do not use tools.
NOTE:
If you cannot complete the connection, disconnect regulator and
repeat steps 5 and 6. If you are still unable to complete the
connection, do not use this regulator!
Straight
Hold coupling nut and regulator
as shown for proper connection
to LP cylinder valve.
DANGER
• Do not insert any tool or foreign object into the valve
outlet or safety relief valve. You may damage the valve
and cause a leak. Leaking propane may result in
explosion, fire, severe personal injury, or death.
Leak Testing Valves, Hose and Regulator
1.Turn all grill control knobs to OFF.
2.Be sure regulator is tightly connected to LP cylinder.
3.Completely open LP cylinder valve by turning hand wheel
counterclockwise. If you hear a rushing sound, turn gas off
immediately. There is a major leak at the connection. Correct
before proceeding.
4.Brush soapy solution onto areas circled below, or other similar
5.If “growing” bubbles appear, there is a leak. Close LP
cylinder valve immediately and retighten connections. If leaks
cannot be stopped do not try to repair. Call for replacement
parts.
6.Always close LP cylinder valve after performing leak test by
turning hand wheel clockwise.
NOTE: Sideburner
shelf fascia not
shown for clarity.
• Outdoor gas appliance is not intended to be installed
in or on a boat.
• Outdoor gas appliance is not intended to be installed
in or on an RV.
• Never attempt to attach this grill to the self-contained
LP gas system of a camper trailer or motor home.
• Do not use grill until leak-tested.
• If a leak is detected at any time, STOP and call the fire
department.
• If you cannot stop a gas leak, immediately close
LPcylinder valve and call LP gas supplier or your fire
department!
WARNING
fittings on your grill.
NOTE: Your grill
may NOT be
equipped with a
sideburner.
10

WARNING
For Safe Use Of Your Grill And To Avoid Serious
Injury:
•Do not let children operate or play near grill.
•Keep grill area clear and free from materials that burn.
•Do not block holes in bottom or back of grill.
•Check burner flames regularly.
•Use grill only in well-ventilated space. NEVER use in
enclosed space such as carport, garage, porch, covered
patio, or under an overhead structure of any kind.
•Do not use charcoal or ceramic briquets in a gas grill.
(Unless briquets are supplied with your grill.)
•Use grill at least 3 ft. from any wall or surface. Maintain
10 ft. clearance to objects that can catch fire or sources of
ignition such as pilot lights on water heaters, live electrical
appliances, etc.
•Apartment Dwellers:
Check with management to learn the requirements and fire
codes for using an LP gas grill in your apartment complex. If
allowed, use outside on the ground floor with a three (3) foot
clearance from walls or rails. Do not use on or under
balconies.
•NEVER attempt to light burner with lid closed. A buildup
of non-ignited gas inside a closed grill is hazardous.
•Never operate grill with LP tank out of correct position
specified in assembly instructions.
•Always close LP tank valve and remove coupling nut
before moving LP tank from specified operation
position.
Safety Tips
sBefore opening LP cylinder valve, check the coupling nut for
tightness.
sWhen grill is not in use, turn off all control knobs and LP
cylinder valve.
sIf the outdoor cooking gas appliance is not in use, the gas
must be turned off at the supply cylinder. Storage of an
outdoor cooking gas appliance indoors is permissible only if
the cylinder is disconnected and removed from the appliance.
sNever move grill while in operation or still hot.
sUse long-handled barbecue utensils and oven mitts to avoid
burns and splatters.
sMaximum load for side shelves is 10 lbs.
sThe grease cup must be inserted into grease clip and
emptied after each use. Do not remove grease cup until grill
has completely cooled.
s Clean grill often, preferably after each cookout. If a bristle
brush is used to clean any of the grill cooking surfaces,
ensure no loose bristles remain on cooking surfaces prior to
grilling. It is not recommended to clean cooking surfaces
while grill is hot.
sIf you notice grease or other hot material dripping from grill
onto valve, hose or regulator, turn off gas supply at once.
Determine the cause, correct it, then clean and inspect valve,
hose and regulator before continuing. Perform a leak test.
sThe regulator may make a humming or whistling noise during
operation. This will not affect safety or use of grill.
sOnly use the pressure regulator and hose assembly supplied
with this grill. Replacement pressure regulator and hose
assemblies must be specified or supplied by Char-Broil, LLC.
sIf you have a grill problem see the "Troubleshooting Section".
sIf the regulator frosts, turn off grill and LP cylinder valve
immediately. This indicates a problem with the cylinder and it
should not be used on any product. Return to supplier!
CAUTION
•Putting out grease fires by closing the lid is not
possible. Grills are well ventilated for safety reasons.
•Do not use water on a grease fire. Personal injury may
result. If a grease fire develops, turn knobs and LP tank
off.
•Do not leave grill unattended while preheating or
burning off food residue on high. If grill has not been
regularly cleaned, a grease fire can occur that may
damage the product. Follow instructions on General
Grill Cleaning and Cleaning The Burner Assembly to
prevent grease fires.
11

CAUTION
If burner does not light, turn knobs to OFF, wait 5
minutes, and try again. Always close valve during the 5
minute waiting period. If the burner does not ignite with
the valve open, gas will continue to flow out of the burner
and could accidentally ignite with risk of injury.
Burner Flame Check
• Light burner,Remove cooking grates and flametamers.
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.
HI
LOW
Match-Lighting
s Do not lean over grill while lighting.
3. Open lid during lighting.
4. Place match into match holder (hanging from side of cart).
5. Place lit match through the match light hole and near the burner.
6. Light right burner by pushing knob in and turning to the HI
position.
Hose Check
• Before each use, check to see if hoses are cut, worn or kinked.
Replace damaged hoses before using grill. Use only
valve/hose/regulator specified in the Parts List.
Normal
Hose
Kinked
Hose
Ignitor Lighting
s Do not lean over grill while lighting.
1.
2.
3.
4.
5.
Turn OFF gas burner control valves.
Turn ON gas at LP cylinder.
Open lid during lighting.
To ignite, turn left knob to the HI position.
Push IGNITOR button rapidly.
6. If ignition does NOT occur in 5 seconds, turn the burner
controls OFF, wait 5 minutes and repeat the lighting
procedure.
7. To ignite right burner, turn knob to the HI position.
If ignitor does not work, follow match lighting instructions.
After Lighting: Turn knobs to HI position for warm-up.
Turn controls and gas source or tank OFF when not
in use.
WARNING
rotate knobs from HI to LOW. You should see
Turning Grill Off
• Turn all knobs to OFF position. Turn LP tank off by turning
OPD hand wheel clockwise to a full stop.
Ignitor Check
• Turn gas off at LP tank. Press and hold ignitor button. "Click"
should be heard and spark seen each time between collector
box or burner and electrodes. 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
do not spring back, replace valve assembly before using grill.
Turn knobs to LOW position then turn back to OFF position.
Valves should turn smoothly.
• 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.
General Grill Cleaning
• Do not mistake brown or black accumulation of grease and
smoke for paint. Interiors of gas grills are not painted at the
factory (and should never be painted). Apply a strong solution
of detergent and water or use a grill cleaner with scrub brush
on insides of grill lid and bottom. Rinse and allow to completely
air dry. Do not apply a caustic grill/oven cleaner to painted
surfaces.
Strike the match.
Be sure the burner lights and stays lit.
1.
2.
Turn OFF gas burner control valves.
Turn ON gas at LP cylinder.
Push in and turn left knob to the HI position.
12

CAUTION
SPIDER ALERT!
GAS COLLECTOR
BOX & IGNITOR
VALVE
CONTROL PANEL BURNER
VENTURI
LIFT OUT
BURNER ASSEMBLY
AIR
SHUTTER
SPIDER WEBS
INSIDE VENTURI
SPIDER WEBS
INSIDE VENTURI
CLEAN OUT
VENTURI
REMOVE
BURNER
CLIPS
If you notice that your grill is getting hard to light or that the
flame isn’t as strong as it should be, take the time to check and
clean the venturi’s.
In some areas of the country, spiders or small insects have been
known to create “flashback” problems. The spiders spin webs, build
nests and lay eggs in the grill’s venturi tube(s) obstructing the flow of
gas to the burner. The backed-up gas can ignite in the venturi behind
the control panel. This is known as a flashback and it can damage
your grill and even cause injury.
To prevent flashbacks and ensure good performance the burner and
venturi assembly should be removed from the grill and cleaned
before use whenever the grill has been idle for an extended period.
• Plated wire grates: Wash grates with concentrated grill
cleaner or use soap and water solution. Dry thoroughly and
store indoors between cookouts.
• Stainless steel surfaces: To maintain your grill’s high quality
appearance, wash with mild detergent and warm soapy water
and wipe dry with a soft cloth after each use. Baked-on grease
deposits may require the use of an abrasive plastic cleaning
pad. Use only in direction of brushed finish to avoid damage.
Do not use abrasive pad on areas with graphics.
• Cooking surfaces: If a bristle brush is used to clean any of
the grill cooking surfaces, ensure no loose bristles remain on
cooking surfaces prior to grilling. It is not recommended to
clean cooking surfaces while grill is hot.
Storing Your Grill
• Clean cooking grates.
• Store in dry location.
• When LP cylinder is connected to grill, store outdoors in a 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 cylinder 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.
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 cylinder.
2. heat tent
3.
4.
5.
6.
7.
VERY IMPORTANT: Burner tubes must re-engage valve
openings. See illustration (A).
8.
electrode
9.
heat tent
grease cup
10.
Remove cooking grate and .
Under grill remove grease cup, disconnect ignitor wire from
burner.
Inside grill remove burner assembly (A), clean ceramic
portion of electrode with rubbing alcohol and a swab.
Clean outside of burner with soap and water. Lay burner
upside down on flat surface, insert garden hose to force
water through tubes. Make sure water comes out of all
burner holes. Open clogged holes with a thin wire. Shake
out excess water and examine holes. Due to normal wear
and corrosion some holes may become enlarged. If any
large cracks or holes are found replace burner.
If grill is to be stored, coat burner lightly with cooking oil.
Wrap in protective cover to keep insects out.
If not storing grill after cleaning, replace burner into grill
bottom.
Reattach ignitor wire to .
Reposition and cooking grate. Reattach clean
to grease clip.
Before cooking again on grill, perform a “Leak Test” and
“Burner Flame Check”.
A
Valve
Correct burner-to-valve engagement
Burner Tube
B
Check that the burners are not damaged. Because of
normal wear and corrosion some holes may have
enlarged. If you notice large cracks or large holes,
replace the burner.
11.
13

This warranty only applies to units purchased from an authorized retailer. Manufacturer warrants to the original consumer-purchaser only that this
product shall be free from defects in workmanship and materials after correct assembly and under normal and reasonable home use for the periods
indicated below beginning on the date of purchase*. The manufacturer reserves the right to require that defective parts be returned, postage and or
freight pre-paid by the consumer for review and examination.
*Note: A dated sales reciept WILL be required for warranty service.
The original consumer-purchaser will be responsible for all shipping charges for parts replaced under the terms of this limited warranty.
This limited warranty is applicable in the United States and Canada only, is only available to the original owner of the product and is not transferable.
Manufacturer requires proof of your date of purchase. Therefore, you should retain your sales slip or invoice. Registering your product is not a
substitute for proof of purchase and the manufacturer is not responsible for or required to retain proof of purchase records.
This limited warranty applies to the functionality of the product ONLY and does not cover cosmetic issues such as scratches, dents, corrosions or
discoloring by heat, abrasive and chemical cleaners or any tools used in the assembly or installation of the appliance, surface rust, or the
discoloration of stainless steel surfaces.
This limited warranty will not reimburse you for the cost of any inconvenience, food, personal injury or property damage.
ITEMS MANUFACTURER WILL NOT PAY FOR:
1. Shipping cost, standard or expedited, for warranty and replacement parts
2. Service calls to your home.
3. Repairs when your product is used for other than normal, single-family household or residential use.
acts of God, improper installation or maintenance, installation not in accordance with electrical or plumbing codes, or use
of products not approved by the manufacturer.
5. Any food loss due to product failures or operating difficulties.
6. Replacement parts or repair labor costs for units operated outside the United States or Canada.
7. Pickup and delivery of your product.
8. Repairs to parts or systems resulting from unauthorized modifications made to the product.
9. The removal and/or reinstallation of your product.
DISCLAIMER OF IMPLIED WARRANTIES and LIMITATION OF REMEDIES
Repair or replacement of defective parts is your exclusive remedy under the terms of this limited warranty. In the event of parts availability issues,
Manufacturer will not be responsible for any consequential or incidental damages arising from the breach of either this limited warranty or any
applicable implied warranty, or for failure or damage resulting from acts of God, improper care and maintenance, grease fire, accident, alteration,
replacement of parts by anyone other than Manufacturer, misuse, transportation, commercial use, abuse, hostile environments (inclement weather,
acts of nature, animal tampering), improper installation or installation not in accordance with local codes or printed manufacturer instructions.
THIS LIMITED WARRANTY IS THE SOLE EXPRESS WARRANTY GIVEN BY THE MANUFACTURER. NO PRODUCT PERFORMANCE
SPECIFICATION OR DESCRIPTION WHEREVER APPEARING IS WARRANTED BY MANUFACTURER EXCEPT TO THE EXTENT SET
FORTH IN THIS LIMITED WARRANTY. ANY IMPLIED WARRANTY PROTECTION ARISING UNDER THE LAWS OF ANY STATE,
INCLUDING IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR USE, IS HEREBY
LIMITED IN DURATION TO THE DURATION OF THIS LIMITED WARRANTY.
Neither dealers nor the retail establishment selling this product has any authority to make any additional 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.
NOTE: Some states do not allow an exclusion or limitation of incidental or consequential damages, so some of the above limitations or exclusions
may not apply to you. This limited warranty gives you specific legal rights as set foth herein. You may also have other rights which vary from state
to state. In the state of California only, if refinishing or replacement of the product is not commercially practicable, the retailer selling this product or
the 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 selling this
product in order to obtain performance under this limited warranty.
If you wish to obtain performance of any obligation under this limited warranty, you should
write to:
Consumer Relations
P. O. Box 1240
Columbus, GA 31902-1240
Consumer returns will not be accepted unless a valid Return Authorization is first acquired. Authorized returns are clearly marked on the outside of
the package with an RA number and the package is shipped freight/postage pre-paid. Consumer returns that do not meet these standards will be
refused.
LIMITED WARRANTY
4. Damage, failures, or operating difficulties resulting from accident, alteration, careless handling, misuse, abuse, fire, flood,
RUST is not considered a manufacturing or materials defect.
the manufacturer reserves the right to substitute like or similar parts that are equally functional.
SCOPE OF COVERAGE PERIOD OF COVERAGE TYPE OF FAILURE COVERAGE
PERFORATION, MANUFACTURING,
AND MATERIAL DEFECTS ONLY
All Parts 1 year from date of purchase*
14

PARTS LIST
15
Key Qty Description
A 1 FIREBOX
B 1 LID
C 1 LOGO PLATE
D 1 VALVE/HOSE/REGULATOR ASSEMBLY
E 1 CONTROL PANEL
F 1 BURNER
G 1 ELECTRODE/COLLECTOR
H 2 SIDE SHELF
I 2 MOUNTING BRACKET, F/ SIDE SHELF, (LF/RB)
J 2 MOUNTING BRACKET, F/ SIDE SHELF, (LB/RF)
K 1 CART LEG,UPPER LEFT
L 2 WHEEL
M 1 AXLE ROD
N 1 SIDE BRACE
O 1 CART LEG,UPPER RIGHT
P 1 MATCH HOLDER
Q 1 RIGHT BACK LEG,STRAIGHT
R 1 LEFT BACK LEG,STRAIGHT
S 1 RIGHT FRONT LEG,CURVED
T 2 EXTENDER
U 1 LEFT FRONT LEG,CURVED
V 2 SUPPORT BRACKET
W 2 BACK BRACE
X 1 FRONT PANEL
Y 1 HANDLE
Z 1 HEAT TENT
AA 1 COOKING GRATE
BB 2 TANK EXCLUSION WIRE
CC 1 HEAT SHIELD
DD 2 KNOB
EE 1 IGNITOR
FF 2 LOWER HINGE
GG 2 UPPER HINGE
HH 1 TANK RETAINER
II 1 GREASE CUP
JJ 1 GREASE CUP CLIP
… 1 HARDWARE PACK
… 1 ASSY INSTRUCTIONS, ENGLISH
NOT Pictured

B
C
Y
F
II
G
JJ
H
I
J
BB
V
S
Q
T
X
O
AA
A
Z
FF
GG
H
J
I
P
HH
K
D
N
V
M
L
R
U
W
CC
EE
DD
E
PARTS DIAGRAM
16

17
ASSEMBLY
1
Hitch Pin
Qty. 2
Hinge Pin
Qty. 2 #10-24x1-1/4’’
Machine Screw
Qty. 1
#10-24
Flange Nut
Qty. 1
Left Front Leg
(Curve)
Support Bracket
Left Back Leg
(Straight)
Side Brace
Upper left Leg
Hinge Pin
Hitch Pin
Left Leg
‘Place one upper left leg as shown. NOTE: Left front and left back legs do not have leg extenders. In front, attach upper left leg,
side brace and left front leg (curve) with #10-24x1-1/4" machine screw and #10-24 flange nut.
‘Attach support bracket in the third hole from bottom of leg with hinge pins and hitch pins (A).
2
#10-24x1-1/4’’
Machine Screw
Qty. 3
#10-24
Flange Nut
Qty. 3
Upper right Leg
Right Front Leg
(Curve)
Right Back Leg
(Straight)
Support Bracket
Leg Extender
Right Leg
‘Place as shown. Attach upper right leg and right front leg (curve) with #10-24x1-1/4" machine screw and #10-24 flange nut.
Tighten screws.
‘Attach support bracket with #10-24x1-1/4" machine screws and #10-24 flange nuts.
A
Upper left Leg
Upper right Leg

3
4
Front Panel
Lay front legs down on the floor
Slide front panel between legs. Attach with #10-24x2’’ machine screws and #10-24 flange nuts.‘
#10-24x2”
Machine Screw
Qty.4
#10-24
Flange Nut
Qty.4
Back Braces to Cart
Attach back braces with #10-24x1-1/4’’ machine screws and #10-24 flange nuts.
Wheels
Turn assembly upside down.
Insert axle rod into wheel, legs and other wheel. Attach with a wheel bushing and hitch pin. Attach all in second hole.
‘
‘
‘
#10-24
Flange Nut
Qty.8
Hitch Pin
Qty.1
Wheel Bushing
Qty.1
#10-24x1-1/4”
Machine Screw
Qty.8
“Cone” side of wheel against leg
Wheel
Side Brace
Back Brace
Hitch Pin
Wheel
Bushing
Back Brace
Front Panel
18
Axle Rod

5Control Panel
Stand cart upright.
In front, slide control panel between left and right legs, attach control panel with #10-24x2’’ machine screws and #10-24
flange nuts. Tighten all screws.
‘
‘
#10-24x2”
Machine Screw
Qty. 4
#10-24
Flange Nut
Qty.4
19
Control panel
Side Brace
6Valve/Hose/Regulator and Ignitor
Attach v‘
‘ Attach ignitor to control panel using the stamped nut that’s provided. NOTE: if your grill come with Snap-in ignitor, please
see Option.
alve/hose/regulator assembly to control panel with #10-24x1/2’’ machine screws.
#10-24x1/2”
Machine Screw
Qty. 2
Option: Snap the
ignitor into the
control panel
Ignitor Ignitor
Stamped nut
Hose
Main burner valve

7
8 Heat Shield
Attach heat shield with #10-24x1/2’’ machine screws and #10-24 flange nuts.
Tank Retainer
Insert tank retainer into side brace and secure with #10-24x3/8’’ wing nut.
‘
‘
#10-24
Flange Nut
Qty. 2
#10-24x1/2”
Machine Screw
Qty. 2
‘ Hook tank exclusion wires onto front panel brackets, attach other end to back brace with #8-32x3/8’’ sheet metal screws.
#8-32x3/8’’
Sheet Metal Screw
Qty. 2
Heat Shield
#10-24x3/8’’
Wing Screw
Qty. 1
Tank Retainer
20