MODEL 463821908 • PRODUCT GUIDE
THIS GRILL IS FOR OUTDOOR USE ONLY.
CAUTION:
WARNING:
Read and follow all safety statements, assembly
instructions, and use and care directions before
attempting to assemble and cook.
Failure to follow all manufacturer’s instructions
could result in serious personal injury and/or
property damage.
INSTALLER/ASSEMBLER:
CAUTION:
Leave this manual with consumer.
Some parts may contain sharp edges –
especially as noted in the manual! Wear
protective gloves if necessary.
CONSUMER:
Keep this manual for future reference.
If you have any questions or need assistance during assembly, please call 1-800-241-7548.
To insure your satisfaction and for follow-up service, register your grill online at www.grillregistration.com
463821908 • 80016556 • 01-10-08
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TABLE OF CONTENTS
For Your Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Grill Service Center. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Product Record Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Use and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Parts Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-22
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-25
Limited Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Registration Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
To insure your satisfaction
and for follow-up service,
register your grill
online at:
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.
463821908 • 3
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LP tank
USE AND CARE
• The LP tank used with your grill must meet the following
requirements:
• Use LP s only with these required measurements: 12" (30.5cm)
(diameter) x 18" (45.7 cm) (tall) with 20 lb. (9 kg.) capacity
maximum.
DANGER
• NEVER store a spare LP tank under or near the
appliance or in an enclosed area.
• LP tanks must be constructed and marked in accordance with
specifications for LP tanks of the U.S. Department of
Transportation (DOT) or for Canada, CAN/CSA-B339, tanks,
spheres and tubes for transportation of dangerous goods.
Transport Canada (TC). See LP tank collar for marking.
• LP tank valve must have:
• Type 1 outlet compatible with
regulator or grill.
• Safety relief valve.
• UL listed Overfill Protection
Device (OPD). This OPD safety
OPD Hand Wheel
feature is identified by a unique triangular hand wheel. Use
only LP tanks equipped with this type of valve.
• LP tank must be arranged for vapor withdrawal and include
collar to protect LP tank valve. Always keep LP tanks in upright
position during use, transit or storage.
• Never fill a tank beyond 80% full.
• An over filled or improperly stored tank is a
hazard due to possible gas release from the
safety relief valve.
• If you see, smell or hear gas escaping,
immediately get away from the LP tank/appliance
and call your fire department.
• If the above is not followed exactly, a fire causing
death or serious injury may occur.
LP tank in upright position for vapor withdrawal
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 tank Removal, Transport and Storage
• Turn OFF all control knobs and LP tank valve. Turn coupling
nut counterclockwise by hand only - do not use tools to
disconnect .Loosen tank screw beneath bottom shelf, then lift
LP tank up and out of cart. Place dust cap on tank valve outlet
whenever the tank is not in use. Only install the type of dust
cap on the tank valve outlet that is provided with the tank
valve. Always use cap and strap supplied with valve. Other
types of caps or plugs may result in leakage of propane.
Failure to use dust cap as directed may result in serious
personal injury and/or property damage.
• LP gas is highly flammable and may ignite unexpectedly when
mixed with air.
LP tank Filling
• Use only licensed and experienced dealers.
• LP dealer must purge new tank before filling.
• Dealer should NEVER fill LP tank more than 80% of LP tank
volume. Volume of propane in tank will vary by temperature.
LP tank Valve
• A disconnected LP tank in
storage or being transported
• A frosty regulator indicates gas overfill. Immediately close LP
tank valve and call local LP gas dealer for assistance.
must have a dust cap installed (as shown).
Do not store an LP tank in enclosed spaces
such as a carport, garage, porch, covered
patio or other building. Never leave an LP tank
inside a vehicle which may become overheated
by the sun.
• Do not release liquid propane (LP) gas into the atmosphere.
This is a hazardous practice.
Dust
Cap
Retainer Strap
• 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.
• Do not store an LP tank in an area where children play.
4 • 463821908
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LP tank Exchange
Connecting Regulator to the LP tank
• Many retailers that sell grills offer you the option of replacing
your empty LP tank through an exchange service. Use only
those reputable exchange companies that inspect, precision fill,
test and certify their tanks. Exchange your tank only for an
OPD safety feature-equipped tank as described in the "LP
tank" section of this manual.
1. LP tank must be properly secured onto grill. (Refer to
assembly section.)
2. Turn all control knobs to the OFF position.
3. Turn LP tank OFF by turning hand-wheel clockwise to a full
stop.
• Always keep new and exchanged LP tanks in upright position
4. Remove the protective cap from LP tank valve. Always use
during use, transit or storage.
cap and strap supplied with valve.
• Leak test new and exchanged LP tanks BEFORE
connecting to grill.
LP tank Leak Test
For your safety
OPD Hand Wheel
• Leak test must be repeated each time LP tank is exchanged or
Type 1 outlet with
thread on outside
refilled.
• Do not smoke during leak test.
Safety Relief Valve
• 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.
Strap and Cap
• Use a clean paintbrush and a 50/50 mild soap and water
solution. Brush soapy solution onto areas indicated by arrows
in figure below.
Do not use a POL transport plug
(plastic part with external threads)!
It will defeat the safety feature of
the valve.
s
Do not use household cleaning agents. Damage to gas
train components can result.
5. Hold regulator and insert nipple into LP
tank valve. Hand-tighten the coupling
nut, holding regulator in a straight line
with LP tank valve so as not to cross-
thread the connection.
Continued on next page.
Nipple has to be centered
into the LP tank valve.
WARNING
If “growing” bubbles appear do not use or move the LP
tank. Contact an LP gas supplier or your fire department!
463821908 • 5
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Leak Testing Valves, Hose and Regulator
1. Turn all grill control knobs to OFF.
2. Be sure regulator is tightly connected to LP tank.
3. Completely open LP tank valve by turning hand wheel
counterclockwise. If you hear a rushing sound, turn gas off
immediately. There is a major leak at the connection. Correct
before proceeding.
4. Brush soapy solution onto areas circled below.
Hold coupling nut and regulator
as shown for proper connection
to LP tank valve.
s
Never remove threaded
orifice at end of valve.
6. Turn the coupling nut clockwise and tighten to a full stop. The
regulator will seal on the back-check feature in the LP tank
valve, resulting in some resistance. An additional one-half to
three-quarters turn is required to complete the
connection. Tighten by hand only – do not use tools.
NOTE:
If you cannot complete the connection, disconnect regulator and
repeat steps 5 and 6. If you are still unable to complete the
connection, do not use this regulator!
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.
5. If “growing” bubbles appear, there is a leak. Close LP tank
valve immediately and retighten connections. If leaks cannot
be stopped do not try to repair. Call for replacement parts.
Order new parts by giving the serial, model number and name
and part number of items needed (see parts list) to the Grill
Service Center at 1-800-241-7548.
WARNING
6. Always close LP tank valve after performing leak test by
turning hand wheel clockwise.
• Outdoor gas appliance is not intended to be installed
in or on a boat.
• Outdoor gas appliance is not intended to be installed
in or on an RV.
• Never attempt to attach this grill to the self-contained
LP gas system of a camper trailer or motor home.
• Do not use grill until leak-tested.
• If a leak is detected at any time, STOP and call the fire
department.
• If you cannot stop a gas leak, immediately close
Lptank valve and call LP gas supplier or your fire
department!
6 • 463821908
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Safety Tips
WARNING
s
Before opening LP tank valve, check the coupling nut for
tightness.
For Safe Use of Your Grill and to Avoid Serious
s
When grill is not in use, turn off all control knobs and LP tank
Injury:
valve.
s
If the outdoor cooking gas appliance is not in use, the gas
• Do not let children operate or play near grill.
• Keep grill area clear and free from materials that burn.
• Do not block holes in sides or back of grill.
• Check burner flames regularly.
• Use grill only in well-ventilated space. NEVER use in
enclosed space such as carport, garage, porch,
covered patio, or under an overhead structure of any
kind.
must be turned off at the supply tank. Storage of an outdoor
cooking gas appliance indoors is permissible only if the tank
is disconnected and removed from the appliance.
s
Never move grill while in operation or still hot.
Use long-handled barbecue utensils and oven mitts to avoid
burns and splatters.
Maximum load for side shelves is 10 lbs.
s
s
s
The grease cup must be inserted into grease clip and
• Do not use charcoal or ceramic briquets in a gas grill.
emptied after each use. Do not remove grease cup until grill
has completely cooled.
(Unless briquets are supplied with your grill.)
s
Clean grill often, preferably after each cookout. If a bristle
• 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..
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.
s
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 it, then clean and inspect valve,
hose and regulator before continuing. Perform a leak test.
s
The regulator may make a humming or whistling noise during
operation. This will not affect safety or use of grill.
s
Only 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.
s
If you have a grill problem see the "Troubleshooting Section".
s
If the regulator frosts, turn off grill and LP tank valve
immediately. This indicates a problem with the tank and it
should not be used on any product. Return to supplier!
• 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.
CAUTION
• Putting out grease fires by closing the lid is not
possible. Grills are well ventilated for safety
reasons.
• Do not use water on a grease fire. Personal injury
may result. If a grease fire develops, turn knobs
and LP tank off.
• Do not leave grill unattended while preheating or
burning off food residue on HI. If grill has not been
regularly cleaned, a grease fire can occur that may
damage the product.
• 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.
463821908 • 7
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Burner Flame Check
Ignitor Lighting
• Remove cooking grates and flame tamers. Light burners, rotate
knobs from HI to LO. You should see a smaller flame in LO
position than seen on HI. Always check flame prior to each use.
If only low flame is seen refer to "Sudden drop or low flame" in
the Troubleshooting Section.
s
Do not lean over grill while lighting.
1. Turn OFF gas burner control valves.
2.Turn ON gas source or tank.
3. Open lid during lighting.
4. To ignite, turn ignition left knob to PRE-HEAT ,Go to step 3 .
5. Push IGNITOR button rapidly.
6. If ignition doe NOT occur in 5 seconds, turn the burner
controls OFF, wait 5 minutes and repeat the lighting
procedure.
HI
LO
7. To ignite right burner, turn right knob to PRE-HEAT.
If ignitor does not work, follow match lighting instructions.
Turning Grill Off
• Turn all knobs to OFF position. Turn LP tank off by turning
hand-wheel clockwise to a full stop.
Ignitor Check
CAUTION
• Turn gas off at LP tank. Press ignitor button rapidly. "Click"
should be heard and spark seen each time between collector
box or burner and electrode. See "Troubleshooting" if no click
or spark.
If ignition does NOT occur in 5 seconds, turn the
burner controls OFF, wait 5 minutes and repeat the
lighting procedure. If the burner does not ignite with
the valve open, gas will continue to flow out of the
burner and could accidently ignite with risk of injury.
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 LO position then turn back to OFF position.
Valves should turn smoothly.
Match-Lighting
s
Hose Check
Do not lean over grill while lighting.
1. Open lid during lighting. Turn on gas at LP tank.
• 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.
2. Place lit match into match holder, then into side of grill bottom
(as shown below).
General Grill Cleaning
3. Push in and turn IGNITION BURNER knob to HI. Be sure
• 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.
burner lights and stays lit.
4. To ignite right burner, turn right knob to HI.
• Plastic parts: Wash with warm soapy water and wipe dry.
s
Do not use citrisol, abrasive cleaners, degreasers or a
concentrated grill cleaner on plastic parts. Damage to and
failure of parts can result.
• Porcelain surfaces: Because of glass-like composition, most
residue can be wiped away with baking soda/water solution or
specially formulated cleaner. Use nonabrasive scouring powder
for stubborn stains.
• Painted surfaces: Wash with mild detergent or nonabrasive
cleaner and warm soapy water. Wipe dry with a soft
nonabrasive cloth.
• Cooking surfaces: If a bristle brush is used to clean any of
the grill cooking surfaces, ensure no loose bristles remain on
cooking surfaces prior to grilling. It is not recommended to
clean cooking surfaces while grill is hot.
8 • 463821908
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Cleaning the Burner Assembly
CAUTION
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 grate and vaporiser bar.
3. Under grill remove grease cup, disconnect ignitor wire and
clips from burner. To remove clips pull down on large end of
clip attached to the valve, turn away from valve, rotate
upward and remove small end of clip from burner tube (A).
4. Inside grill remove burner assembly (B), clean ceramic
portion of electrode with rubbing alcohol and a swab.
5. 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.
6. If grill is to be stored, coat burner lightly with cooking oil.
Wrap in protective cover to keep insects out.
SPIDER ALERT!
GAS COLLECTOR
BOX & IGNITOR
BURNER
CONTROL PANEL
SPIDER WEBS
INSIDE VENTURI
VALVE
AIR
VENTURI
SHUTTER
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.
LIFT OUT
BURNER ASSEMBLY
7. If not storing grill after cleaning, replace burner into grill
bottom.
8. To reattach clips hold large curved end away from burner
tube, insert small curved end into hole under burner tubes,
turn clip towards valve, snap into place.
REMOVE
BURNER
CLIPS
VERY IMPORTANT: Burner tubes must reengage valve
openings. See illustration (A).
SPIDER WEBS
CLEAN OUT
VENTURI
9. Reattach ignitor wire to electrode.
INSIDE VENTURI
10. Reposition vaporiser bar and cooking grate. Reattach clean
grease cup to grease clip.
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.
11. Before cooking again on grill, perform a “Leak Test” and
“Burner Flame Check”.
Burner Tube
Valve
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.
Storing Your Grill
A
• Clean cooking grates.
Correct burner-to-valve engagement
• Store in dry location.
• Cover grill if stored outdoors. Choose from a variety of grill
covers offered by manufacturer.
• When LP tank is connected to grill, store outdoors in a well-
ventilated space and out of reach of children.
• If the outdoor cooking gas appliance is not in use, the gas must
be turned off at the supply tank. Storage of an outdoor cooking
gas appliance indoors is permissible only if the tank is
disconnected and removed from the appliance.
• Store grill indoors ONLY if LP tank is turned off and
disconnected, removed from grill and stored outdoors.
• When removing grill from storage, follow “Cleaning the Burner
Assembly” instructions before starting grill.
B
463821908 • 9
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Food Safety
How To Tell If Meat Is Grilled Thoroughly
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:
• 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.
Clean: Wash hands, utensils, and surfaces with hot soapy water
before and after handling raw meat and poultry.
• Whole poultry should reach 180° F; breasts, 170° F. Juices
should run clear and flesh should not be pink.
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.
• Hamburgers made of any ground meat or poultry should reach
160° F, and be brown in the middle with no pink juices. Beef,
veal and lamb steaks, roasts and chops can be cooked to 145°
F. All cuts of pork should reach 160° F.
Cook: Cook meat and poultry thoroughly to kill bacteria. Use a
thermometer to ensure proper internal food temperatures.
• NEVER partially grill meat or poultry and finish cooking later.
Chill: Refrigerate prepared foods and leftovers promptly.
Cook food completely to destroy harmful bacteria.
For more information call: USDA Meat and Poultry Hotline at
1-800-535-4555 In Washington, DC (202) 720-3333, 10:00 am-
4:00 pm EST.
• When reheating takeout foods or fully cooked meats like hot
dogs, grill to 165° F, or until steaming hot.
10 • 463821908
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PARTS LIST – Model No. 463821908
Key Qty Description . . . . . . . . . . . . . . . . . . . Part #
Key Qty Description . . . . . . . . . . . . . . . . . . . Part #
A
B
C
D
E
F
G
H
I
1
1
1
2
1
2
1
1
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Firebox. . . . . . . . . . . . . . . . . . . . . 80011600
Valve/Hose/Regulator . . . . . . . . . 80016425
Control Panel. . . . . . . . . . . . . . . . 80016558
Control Knobs . . . . . . . . . . . . . . . 80008245
Ignitor. . . . . . . . . . . . . . . . . . . . . . 5156113
Axle F/Wheel . . . . . . . . . . . . . . . . 80011619
Left Cart Assy w/match holder. . . 80011604
Burner Assembly . . . . . . . . . . . . . 80011601
Wheels. . . . . . . . . . . . . . . . . . . . . 80008000
Right Cart Leg . . . . . . . . . . . . . . . 80011605
Leg Extenders . . . . . . . . . . . . . . . 80008291
Bottom Shelf . . . . . . . . . . . . . . . . 80011606
Back Support Brace. . . . . . . . . . . 80011607
Tank Retainer. . . . . . . . . . . . . . . . 80008294
Front Panel . . . . . . . . . . . . . . . . . 80011608
Side Shelf . . . . . . . . . . . . . . . . . . 80011609
Lid . . . . . . . . . . . . . . . . . . . . . . . . 80011610
Logo Plate Assembly . . . . . . . . . . 80011611
Handle Assembly. . . . . . . . . . . . . 80011612
Sideburner Frame . . . . . . . . . . . . 80011613
Sideburner Pan . . . . . . . . . . . . . . 80011614
Sideburner Grate . . . . . . . . . . . . . 80010163
Tool Holder. . . . . . . . . . . . . . . . . . 80011615
Sideburner Valve Cup . . . . . . . . . 80011616
Sideburner . . . . . . . . . . . . . . . . . . 80016559
Sideburner Knob . . . . . . . . . . . . . 80010161
AA
BB
CC
DD
EE
FF
GG
HH
II
1
1
1
2
2
1
1
1
1
1
1
Heat Tent . . . . . . . . . . . . . . . . . . . 80008273
Cooking Grate . . . . . . . . . . . . . . . 80008274
Swing Away . . . . . . . . . . . . . . . . . 80008275
Lower Hinge. . . . . . . . . . . . . . . . . 80011618
Upper Hinge. . . . . . . . . . . . . . . . . 80011617
Grease Cup . . . . . . . . . . . . . . . . . 80000270
Clip, Grease Cup . . . . . . . . . . . . . 80000271
Heat Shield F/Tank . . . . . . . . . . . 80016679
Heat Shield F/Firebox . . . . . . . . . 80016680
Product Manual, English . . . . . . . 80016556
Hardware Pack . . . . . . . . . . . . . . 80009105
J
K
L
1
2
6
7
4
Venturi Clip
Axle Bolt
Wing Nut, Plastic
#10-24x2" Carriage Bolt
Hitch Pin
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Z
22 #10-24 Flange Nut
28 Silicone Washer
4
3
5
6
#10-24x1-1/4" Machine Screw
#10-24 Wing Nut, Metal
#10-24 T-Wing Screw
#10-24x2" Machine Screw
16 #10-24x1/2" Machine Screw
2
2
Insulation Washer
Hinge Pin
Certified Grill Parts And Accessories®, Char-Broil and Design®, Char-Broil (Gas Grill Briquettes)®, Char-Diamonds®, Cooking Zone and Design®, Diamond Flame®, Executive Chef®, Faststart®, Flare
Fighter®, FlavorMaster®, Gas Grill Silouette and Design®, H2O Smoker®, Lava Flame®, MasterFlame®, MasterFlame Precision Cooking System®, PowerSpark®, Quantum®, VIP®, PrecisionFlame and
Design®, Sierra®, and TruFlame® are registered Trademarks of the W.C. Bradley Company. Thermos® is a registered trademark of the Thermos Company and its affiliates.
Artisan Collection by Char-Broil ™, C3 and Design™, Char-Broil and Design™, Flame Design™, FlavorTents™, Grill 2 Go™, Grillin’ Stick™, Keeper of the Flame™, Keepers of the Flame™, Natural Grip™,
Outdoor Cooking Collection and Design™, Patio Bistro™, PrecisionFlame™, Pro-Check™, QuickSet Grills and Design™, SmokerTents™, The Big Easy™, The Minute Grill™, The Edge™, The Tuscan
Collection™, and The Urban Grill™ are Trademarks of the W.C. Bradley Company. Universal Grill Parts and Design™ is a trademark of the Thermos Company and its affiliates.
Protected under one or more of the following U.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;
6,173,644B1; 6,279,566; 6,397,731; 6,418,923; 6,439,222; 6,523,461; 6,935,327; 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; D449,492; D451,759; D456,202S;
D460,313, D461,359 and D504,048. Canada: 87743; 87744; 92607; 92608 and 1,316,424. Other Patents Pending. Assembly instructions © 2006.
463821908 • 11
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PARTS DIAGRAM – Model No. 463821908
Q
BB
II
R
EE
DD
CC
H
S
AA
V
U
Y
X
A
HH
T
P
Z
B
W
C
M
N
O
J
D
E
G
F
I
GG
FF
F
L
K
12 • 463821908
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ASSEMBLY – Model No. 463821908
A Attach right leg assembly to bottom shelf with (2) #10-24x2" carriage bolts and #10-24 Plastic wing nuts.
1
B Push Leg Extenders into the bottom of the right legs.
C Place left leg assembly into bottom shelf. Insert axle bolts into wheels, legs and bottom shelf. Secure with hitch pins.
Left Leg Assembly
Wheel
1” Hitch Pin
Qty.2
Right Leg Assembly
#10-24 X 2” Carriage Bolt
Bottom
Qty.2
Shelf
“Cone” side of wheel against leg
Axle Bolt
Qty.2
#10-24 Plastic Wing Nuts
Qty.2
Leg Extender
Attach back support brace to legs with (4) #10-24x2" carriage bolts and #10-24 Plastic wing nuts.
2
Back Support Brace
#10-24 X 2” Carriage Bolt
Qty.4
#10-24 Plastic Wing Nuts
Qty.4
463821908 • 13
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A Place bottom of front panel into three slots in the bottom shelf.
3
B Attach front panel to legs with four #10-24x2" machine screws and #10-24 flange nuts.
#10-24 X 2”
Machine Screw
Qty.4
#10-24 Flange Nut
Qty.4
A Place valve/hose/regulator onto control panel. Attach with #10-24 x ½” machine screws. NOTE: Make sure the two valve
stems are centered in their clearance holes; otherwise, this can cause main burner level problems.
B Insert ignitor body into ignitor hole on control panel, then tighten it with sheetmetal nut. NOTE: if your grill come with
Snap-in ignitor, please see Option.
4
Ignitor
#10-24 x ½”
Machine Screw
Qty.2
Option: Snap the
ignitor into the control
panel.
Snap-in
Ignitor
Sheetmetal Nut
Valve/Hose/Regulator
Valve/Hose/Regulator
14 • 463821908
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Attach control panel to firebox using #10-24 x ½” machine screws, silicon washers and #10-24 flange nuts.
5
Firebox
#10-24 x ½”
Machine Screw
Qty. 4
Silicon Washer
Qty. 4
#10-24
Flange Nut
Qty. 4
Control Panel
A Place firebox onto cart, make sure the regulator hose hangs inside cart and control panel overlaps front panel.Attach to cart with
#10-24x1-1/4" machine screws, Silicon washers and #10-24 flange nuts.
6
B Place burners assembly into firebox, making sure valves are inside the burner tubes. Attach to firebox with #10-24 x ½”
machine screws and silicon washers.
Burner Assembly
C Attach wire of main burner to ignitor.
B
#10-24 x ½”
Machine Screws
Qty. 2
Silicon Washer
Qty: 6
#10-24
Flange Nuts
Qty. 4
#10-24x1-1/4"
Machine Screw
Qty: 4
A
Firebox
Correct burner-to-valve engagement
C
Front Panel
463821908 • 15
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A
B
C
Attach tool holder to front leg using two #10-24x2" machine screws and #10-24 flange nuts. Place sideburner pan into frame and
attach with a #10-24x2" carriage bolt and #10-24 metal wing nut in back and a T-wing screw in front.
Attach sideburner valve cup. Place sideburner into hole. Make sure side burner valve is inside sideburner tube. Fasten sideburner
with a wing nut. Hook burner clip to sideburner tube and around manifold. Attach sideburner ignitor wire to ignitor.
Place sideburner knob and grate.
7
#10-24x2" Carriage Bolt
Sideburner Pan
A
#10-24
#10-24
Metal Wing Nut
Qty. 1
Sideburner Frame
Flange Nut
Qty: 2
#10-24
T-Wing Screw
Qty: 1
#10-24x2"
Sideburner Clip
Qty: 1
Machine Screw
Metal
Wing Nut
Tool
Holder
Sideburner
Flange Nut
T-Wing
Screw
Sideburner
Valve
#10-24x2”
B
Cup
Carriage Bolts
Qty: 1
#10-24 X 2”
Machine Screw
Qty. 2
Sideburner
Knob
Correctly assembled valve in sideburner tube
Sideburner Grate
C
Sideburner
ignitor wire
Sideburner
Clip
16 • 463821908
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Attach side shelf with#10-24 T-wing screw.
8
#10-24
T-Wing Screw
Qty: 4
Attach lower lid hinges to back of firebox using #10-24x1/2" machines screws, silicon washers and #10-24 flange nuts per hinge.
The center flat portion of the hinge should be at the bottom (see inset).
9
#10-24
Flange Nuts
Qty:4
Silicon Washer
Qty:8
#10-24 X ½”
Machine Screw
Qty:4
Lower Hinge
Center flat portion
of hinge on bottom
463821908 • 17
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Attach handle to front of lid with silicon washers , insulation washers and #10-24 wing nuts. Upper lid hinges attach to back with
#10-24x1/2" machine screws, fiber washers and #10-24 flange nuts. Do not tighten the screws.
10
#10-24 Wing Nut
Qty:2
#10-24X1/2”
Machine Screw
Qty:4
Silicon Washer
Qty:10
#10-24
Flange Nuts
Qty:4
Insulation Washer
Qty:2
Place lid assembly onto firebox, aligning hinges. Hinges on lid fit inside hinges on firebox. Secure with
hinge pins and hitch pins. Tighten upper lid hinges screws.
11
1” Hitch Pin
Qty. 2
Hinge Pin
Qty. 2
18 • 463821908
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Place heat tent onto V-shaped bar rests inside firebox. Place cooking grate onto firebox.
12
Cooking Grate
Heat Tent
A
B
Insert ends of Swing Away pivot wire into holes in sides of grill lid. Insert ends of Swing Away leg wire into holes in sides of
13
firebox. NOTE: Pivot and leg wires, running side-to-side, should be under wires running front-to-back. If pivot and leg wires are
on top Swing Away is installed upside-down.
Push control knobs onto valves.
Pivot Wire Swing Away
Leg
A
B
463821908 • 19
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Insert tank wire into holes in bottom shelf of the cart.
13
Tank Wire
Hang grease cup clip from bottom of firebox and place grease cup into grease clip. Tank collar opening must face to left of grill. Set
14 bottom of tank into bottom shelf. Rotate tank wire up to secure tank.
LP tank IS SOLD SEPARATELY. Fill and leak check the tank before attaching to grill and regulator (see Use & Care
Section). See Use & Care section of this manual to perform the "Burner Flame Check" and for important safety instructions
before using.
Grease Cup Clip
Grease Cup
CAUTION
Failure to install grease cup clip and cup will
cause hot grease to drip from bottom of grill
with risk of fire or property damage.
CAUTION
Always keep LP Tanks in
upright position during use,
transport, and storage
tank valve must face to front of cart once tank
is attached. Failure to install tank correctly
may allow gas hose to be damaged in
operation, resulting in the risk of fire.
20 • 463821908
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EMERGENCIES: If a gas leak cannot be stopped, or a fire occurs due to gas leakage, call the fire department.
Emergencies
Possible Cause
Prevention/Solution
Gas leaking from
cracked/cut/burned
hose.
• Damaged hose.
• Turn off gas at LP tank or at source on natural gas systems. If
anything but burned, replace valve/hose/regulator. If burned,
discontinue use of product until a plumber has investigated cause
and corrections are made.
Gas leaking from LP
tank.
• Mechanical failure due to rusting or
mishandling.
• Replace LP tank.
Gas leaking from LP
tank valve.
• Failure of tank valve from mishandling or
mechanical failure.
• Turn off LP tank valve. Return LP tank to gas supplier.
Gas leaking between
LP tank and regulator
connection.
• Improper installation, connection not
tight, failure of rubber seal.
• Turn off LP tank valve. Remove regulator from tank and visually
inspect rubber seal for damage. See LP tank Leak Test and
Connecting Regulator to the LP tank.
Fire coming through
control panel.
• Fire in burner tube section of burner due
to blockage.
• Turn off control knobs and LP tank valve. Leave lid open to allow
flames to die down. After fire is out and grill is cold, remove burner
and inspect for spider nests or rust. See Natural Hazard and
Cleaning the Burner Assembly pages.
Grease fire or
• Too much grease buildup in burner area.
• Turn off control knobs and LP tank valve. Leave lid open to allow
flames to die down. After cooling, clean food particles and excess
grease from inside firebox area, grease cup, and other surfaces.
continuous excessive
flames above cooking
surface.
Troubleshooting
Problem
Possible Cause
Prevention/Solution
GAS ISSUES:
Burner(s) will not light
using ignitor.
• Trying to light wrong burner.
• See instructions on control panel and in Use and Care section.
• Make sure valves are positioned inside of burner tubes.
• Burner not engaged with control valve.
• Obstruction in burner.
Continued on next
page.
• Ensure burner tubes are not obstructed with spider webs or other
matter. See cleaning section of Use and Care.
• No gas flow.
• Make sure LP tank is not empty. If LP tank is not empty, refer to
“Sudden drop in gas flow.”
• Vapor lock at coupling nut to LP tank.
• Turn off knobs and disconnect coupling nut from LP tank.
Reconnect and retry.
• Coupling nut and LP tank valve not fully
connected.
• Turn the coupling nut approximately one-half to three-quarters
additional turn until solid stop. Tighten by hand only - do not use
tools.
ELECTRICAL ISSUES:
• Electrode cracked or broken; “sparks at
crack.”
• Replace electrode(s).
• Electrode tip not in proper position.
Main Burners:
• Tip of electrode should be pointing toward gas port opening on
burner. The distance should be 1/8” to 1/4”. Adjust if necessary.
Sideburner (if featured):
• Tip of electrode should be pointing toward gas port opening on
burner. the distance should be 1/8” to 3/16”. Adjust if necessary.
• Wire and/or electrode covered with
cooking residue.
• Clean wire and/or electrode with rubbing alcohol and clean swab.
• Wires are loose or disconnected.
• Reconnect wires or replace electrode/wire assembly.
• Replace ignitor wire/electrode assembly.
• Wires are shorting (sparking) between
ignitor and electrode.
463821908 • 21
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Troubleshooting (continued)
Problem
Possible Cause
Prevention/Solution
Burner(s) will not light
using ignitor.
PIEZO PUSH-BUTTON AND ROTARY:
• Push-button sticks at bottom.
• Replace ignitor.
• Replace knob.
• Rotary knob rotates without clicking.
• Sparking between ignitor and electrode.
• Inspect wire insulation and proper connection. Replace wires if
insulation is broken.
Burner(s) will not
match light.
• See “GAS ISSUES:” on previous page.
• Match will not reach.
• Use long-stem match (fireplace match).
• Improper method of match-lighting.
• See “Match-Lighting” section of Use and Care.
Low flame, drop in gas
flow.
• Out of gas.
• Check for gas in LP tank.
• Excess flow valve tripped.
• Turn off control and tank knobs, wait 30 seconds, turn tank knob on
slowly, light grill. If flames are still low, turn off control and tank
knobs and disconnect regulator. Reconnect regulator, turn tank knob
on slowly, light grill.
• Vapor lock at coupling nut/LP tank
connection.
• Turn off control and tank knobs and disconnect regulator. Reconnect
regulator, turn on tank knob slowly, light grill.
Flames blow out.
Flare-up.
• High or gusting winds.
• Low on LP gas.
• Turn front of grill to face wind or increase flame height.
• Refill LP tank.
• Excess flow valve tripped.
• Refer to “Sudden drop in gas flow” above.
• Grease buildup.
• Clean burners and inside of grill/firebox.
• Trim fat from meat before grilling.
• Excessive fat in meat.
• Excessive cooking temperature.
• Adjust (lower) temperature accordingly.
Persistent grease fire.
• Grease trapped by food buildup around
burner system.
• Turn knobs to OFF. Turn gas off at LP tank. Leave lid in position and
let fire burn out. After grill cools, remove and clean all parts.
Flashback...
• Burner and/or burner tubes are blocked.
• Turn knobs to OFF. Clean burner and/or burner tubes. See burner
cleaning section of Use and Care.
(fire in burner tube(s)).
Unable to fill LP tank.
• Some dealers have older fill nozzles
with worn threads.
• The worn nozzles don’t have enough “bite” to engage the valve. Try
a second LP dealer.
22 • 463821908
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LIMITED WARRANTY
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.
All Parts - 1 year
Upon consumer supplying proof of purchase as provided herein, Manufacturer will repair or replace the parts listed below which are proven
defective during the applicable warranty period. Parts required to complete such repair or replacement shall be free of charge to you except for
shipping costs. The original consumer-purchaser will be responsible for all shipping charges of 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 reasonable proof of your date of purchase. Therefore, you should retain your sales slip or invoice and register
your new product immediately. Defective or missing parts subject to this limited warranty will not be replaced without registration or proof of purchase.
manual included with this product and retain your sales receipt for proof of purchase.
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.
If an original replacement part is not available, a comparable replacement part will be sent. You will be responsible for all shipping charges of
parts replaced under the terms of this limited warranty.
ITEMS MANUFACTURER WILL NOT PAY FOR:
1. Service calls to your home.
2. Repairs when your product is used for other than normal, single-family household or residential use.
3. Damage resulting from accident, alteration, misuse, abuse, fire, flood, acts of God, improper installation, installation not in accordance with
electrical or plumbing codes, or use of products not approved by the manufacturer.
4. Any food loss due to product failures.
5. Replacement parts or repair labor costs for units operated outside the United States or Canada.
6. Pickup and delivery of your product.
7. Repairs to parts or systems resulting from unauthorized modifications made to the product.
8. The removal and/or reinstallation of your product.
9. Shipping cost, standard or expedited, for warranty and replacement parts.
DISCLAIMER OF IMPLIED WARRANTIES; LIMITATION OF REMEDIES
Repair or replacement of defect parts is your exclusive remedy under the terms of this limited warranty. Manufacturer will not be responsible for
any consequential or incidental damages arising from the breach of either this limited warranty or any applicable 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 documented purchase price of the product paid by the original consumer.
This warranty only applies to units purchased from an authorized retailer and or re-seller.
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 for 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:
Char-Broil Consumer Relations
P. O. Box 1240
Columbus, GA 31902-1240
Consumer returns will not be accepted unless a valid Return Authorization is first acquired by calling 1-800-241-7548 and then clearly marked
on the outside of the package and the package is shipped freight/postage pre-paid to the address above.
463821908 • 23
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Please register your grill online at:
WWW.GRILLREGISTRATION.COM
(If you register online, you do not need to send in this registration card.)
La parrilla estaba ensamblada
Chimenea
/ Envíelo a:
463821908 • 27
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STOP
Should you encounter a problem with our product
CALL US FIRST
Do not return this product to the store.
WE CAN HELP
GRILL SERVICE CENTER
1-800-241-7548
HOURS 8AM-6PM EST Mon-Fri
Please ensure your warranty registration is complete.
Grilling Safety Checklist
Read and understand owners manual.
Never overfill LP tank. Overfilled tanks may cause freeze-up of
regulator.
Check tubes for spider webs. Ensure valves are correctly installed in
burner tubes.
Always ensure control knobs are in OFF position and regulator is
attached to tank BEFORE opening tank valve to avoid low flames.
Perform leak test regularly.
Thank You for Your Purchase!
Char-Broil, LLC • Columbus, GA 31902 • Printed in China
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