MODEL 463268107 • PRODUCT GUIDE
Find out how to purchase your (NG)
n;_tural gas conversion kit GO to
www.charbroiLcom
/_ CAUTION:
Readand follow all safety statements,assembly
instructions,and useand care directions before
attempting to assembleand cook.
INSTALLER/ASSEMBLER:
Leavethis manualwith consumer.
CONSUMER:
Keepthis manual for future reference.
z_ WARNING:
Failure tofollow all manufacturer's instructions could
result in seriouspersonal injury and/or property
damage.
\CAUTION:
Someparts may contain sharpedges- especiallyas
notedin themanual! Wear protectivegloves if
necessary.
463268107 • 80006542.12-20-06
if you smell gas:
1. Shut off gas to the appliance.
2. Extinguish any open flame.
3. Open lid.
4. ifodor continues, keep away from the
appliance and immediately call your gas
supplier or your fire department.
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.
Call Grill Service Center for Help and Parts
, Ifyou need assistance with your product or warranty parts call
1-800-241-7548, Hours of Service Center Operation are
8:00 A,M. To 6:00 P.M. EST Monday- Friday,
, Toorder non-warranty replacement parts or accessories
pleasevisit uson theweb at www.charbroil.com or call
1-800-241-7548 and one of ourfriendly and knowledgeable
agents will be glad to assist you.
iMPORTANT:Fill out the product record information below.
Model Number
Serial Number See ratinglabelongrillforserialnumber.
Date Purchased
CALIFORNIA PROPOSITION65
Combustion by-products produced when using this
productcontain chemicals known to the State of
California to cause cancer, birth defects, and other
reproductiveharm.
Installation Safety Precautions
*Use grill, as purchased, only with LP (propane) gas and the
regulator/valve assembly supplied. A conversion kit must be
purchased for usewith naturalgas.
Grill installation must conform with localcodes, 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, CSAB149.1, or Propane Storage and
Handling Code, B149.2, or the Standard for Recreational
Vehicles,ANSI A 119.2/NFPA1192,and CSAZ240 RV Series,
Recreational VehicleCode, as applicable.
, All electrical accessories (such as rotisserie) must be
electrically grounded in accordance with local codes, or
National Electrical Code, ANSI / NFPA70. Keep any electrical
cords and/orfuel supply hoses away from any hot surfaces.
, This grill is safety certifiedfor use in the United Statesonly. Do
not modify for use in any other location. Modificationwill result
in a safety hazard.
Safety Symbols
The symbols and boxes shown below explain what each heading
means. Read and follow all of the messages found throughout
the manual.
DANGER: Indicatesan imminentlyhazardous situation
which, if notavoided,will resultin death orserious injury.
WARNING: Indicatesan potentially hazardous situation
which, if not avoided, couldresult in death or serious
injury.
c.uT,o.
For residential use only. Do not use for commercial
cooking.
-- m
II l cAu'rlo.
CAUTION: Indicates a potentially hazardous situation or
unsafe practice which, if not avoided, may result in minor
or moderate injury.
2 , 463268107
For Your Safety...................................... 2
Grill Service Center................................... 2
Product Record Information ............................ 2
Installation Safety Precautions .......................... 2
Safety Symbols...................................... 2
Use and Care..................................... 4-11
Parts List.......................................... 12
Parts Diagram...................................... 13
Assembly ....................................... 14-23
Troubleshooting.................................. 24-26
Limited Warranty.................................... 28
Registration Card ................................... 30
Do not attempt to repair or alter the
hose/valve/regulatorfor 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.
CONVERSION-READY
Easily converts from (LP) liquid
propane to (NG) natural gas
hat,rat gas conversion kit, Go to
www.charbroil.com
463268107 • 3
•NEVERstore a spare LP cylinder under or near
the appliance or in an enclosed area.
ii
•Never fill a cylinder beyond 80%full.
•An over filled or improperlystored cylinder isa
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,
immediatelyget away from the LP
cylinder/appliance and call your fire department.
LP Cylinder Removal, Transport and Storage
, Turn OFF aii control knobs and LP cylinder valve. Turncoupling
nutcounterclockwise by hand only- do not use tools to
disconnect. Loosencylinder screw beneath bottom shelf, then
lift LP cylinder up and out of cart. Installsafety cap onto LP
cylinder valve.Always use cap and strap suppliedwith valve.
Failure to use safety cap as directed may result in serious
personal injuryand/or property damage.
, A disconnected LP cylinder in LPCylinder Valve_-,,_
storage or being transported /' (,__,__,,,,_ '_
must have a safety cap installed (as shown). _,,_'_ _-"_
Do not store an LP cylinderin enclosed spaces _ _\/
such as a carport, garage, porch, covered
patio or other building. Never leave an LP cylinder Safety
inside a vehicle which may become overheated Cap
by the sun. RetainerStrap
, Do not store an LP cylinder in an area where children play.
LP Cylinder
The LPcylinder 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). See LP cylinder collar for marking.
• LP cylinder valve must have:
, Type I outletcompatible with
regulator or grill.
, Safety reliefvalve.
, ULlisted Overfill Protection OPDHandWheel
Device (OPD). This OPDsafety
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 (Liquefied Petroleum Gas)
• LP gas is nontoxic, odorless and colorless when produced. For
Your Safety, LP gas has been given anodor (similar to rotten
cabbage) so that it can be smelled.
• LP gas is highlyflammable and may ignite unexpectedly when
mixed with air.
LP Cylinder Filling
Useonly licensed and experienced dealers.
• LP dealer must purge new cylinder beforefilling.
• Dealer should NEVERfill LP cylinder more than 80% of LP
cylinder volume. Volume of propane in cylinder will vary by
temperature.
• A frosty regulator indicates gas overfill. Immediatelyclose 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.
, Toremove gas from LP cylinder, contact an LPdealer or call a
local fire department for assistance. Check the telephone
directory under "Gas Companies" for nearest certified LP
dealers.
4 , 463268107
LP Cylinder Exchange
•Many retailers that sell grills offer you the option of replacing
your empty LPcylinder through an exchangeservice. Use only
those reputable exchangecompanies that inspect, precisionfill,
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 LPcylinders BEFORE
connecting to grill.
Connecting Regulator to the LP Cylinder
1. LP cylinder must be properlysecured onto grill. (Refer to
assembly section.)
2. Turnall control knobs to the OFF position.
3. Turn LP cylinder OFF byturning hand-wheel clockwise to a
full stop.
4. Remove the protective capfrom LP cylinder valve.Always use
cap and strap supplied with valve.
LP Cylinder Leak Test
Foryour safety
• Leak test must be repeated each time LP cylinder isexchanged
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 ina well-ventilated area,
away from ignitionsources such as gas fired or electrical
appliances. Duringleak test, keep grill away from open flames
or sparks.
•Use a clean paintbrush and a 50/50 mild soap and water
solution. Brush soapy solution onto areas indicated by arrows
infigure below.
,& Do not use household cleaning agents. Damage to gas
train components can result.
SafetyReliefValve
_eI outlet with
thread on outside
Strapand Cap
Do not use a POLtransport plug
(plastic part with external threads)!
itwill defeat the safety feature of
the valve.
5. Hold regulator and insertnipple intoLP
cylinder valve. Hand4ighten the
coupling nut, holding regulator in a
straight line with LP cylinder valve so
as not to cross4hread the connection.
Nipplehasto becantered
intothe LPcylindervalve.
if"growing"bubbles appear donot useor movethe LP
cylinder.Contactan LP gas supplieroryour fire
department!
463268107 • 5
Holdcoupling nut and regulator
asshownfor proper connection
to LPcylinder valve.
6. Turnthe coupling nut clockwise and tighten to afull stop.The
regulatorwill seal on the back-checkfeature 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!
Leak Testing Valves, Hose and Regulator
1. Turn all grill control knobs to OFF.
2. Be sure regulator istightly connected to LP cylinder.
3. Completely open LP cylinder valve byturning 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.
• Do notinsert any toolor foreign object intothe valve
outlet or safety relief valve. You maydamage thevalve
and cause a leak. Leaking propane mayresult in
explosion,fire, severe personal injury,or death.
, Outdoorgas appliance is not intendedto be installed
in or on a boat.
, Outdoorgas appliance is not intendedto be installed
in oron an RV.
° Never attemptto attach thisgrill to the self-contained
LPgas system of a campertrailer ormotor home.
• Do notuse grill until leak-tested.
, If a leak isdetected at any time, STOPand call thefire
department.
, If youcannot stopa gas leak,immediately close
LPcylindervalve and call LPgas supplieror your fire
department!
,
,
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. Order new parts by giving the serial, model number and
name and part numberof items needed (see parts list)to the
Grill Service Center at 1-800-241-7548.
Always close LPcylinder valve after performing leak test by
turning hand wheel clockwise.
6 , 463268107
ForSafe Useof YourGrill and to Avoid Serious
injury:
•Do not let children operateor play near grill.
• Keepgrill area clear andfree from materialsthat burn.
• Donotblock holes in sidesor backof grill.
• Checkburner flames regularly.
• Use grill only inwell-ventilated space. NEVERuse in
enclosedspace such as carport, garage, porch,
covered patio, or underan overhead structure of any
kind.
• Do notuse charcoal or ceramic briquetsin a gas grill.
(Unlessbriquets are supplied withyour grill.)
•Use grill at least 3ft. from any wall or surface.
Maintain 10ft. clearanceto objects that can catch fire
or sourcesof ignition such as pilot lightsonwater
heaters,live electrical appliances,etc.
•Apartment Dwellers:
Checkwith managementto learnthe requirements
and fire codes for usingan LPgasgrill in your
apartment complex.If allowed, use outside on the
groundfloor with a three (3)foot clearancefrom walls
or rails. Donotuse onor under balconies.
•NEVERattempt to light burner with lid closed. A
buildup of non-ignitedgas inside a closed grill is
hazardous.
•Never operate grill with LP cylinder out of correct
position specified in assembly instructions.
•Always close LP cylinder valve and remove
coupling nut before moving LP cylinder from
specified operation position.
Safety Tips
A Beforeopening LP cylinder valve, check the coupling nutfor
tightness.
A When grill is not in use, turn off all control knobs and LP
cylinder valve.
,A. Never move grill while in operation or still hot.
A Use long-handled barbecue utensils and oven mitts to avoid
burnsand splatters.
,A. Maximum loadfor sideburnerand side shelf is 10 Ibs.
A The grease tray must be inserted into grill and emptied after
each use. Do not remove grease tray until grill has
completely cooled.
A If you notice greaseor other hot material dripping from grill
onto valve, hose or regulator, turn off gas supply at once.
Determine thecause, correct it, then clean and inspect valve,
hoseand regulator before continuing. Perform a leaktest.
A Keep ventilation openings in cylinder enclosure (grill cart) free
and clear of debris.
A Do notstore objects or materials inside the grill cart
enclosure thatwould block the flow of combustion air to the
undersideof either thecontrol panel or the firebox bowl.
A The regulator may make a humming or whistling noiseduring
operation. This will not affect safety or use of grill.
,A. If you have a grill problem see the "TroubleshootingSection".
A Ifthe regulator frosts, turn off grill and LP cylindervalve
immediately.This indicates a problem with the cylinder and it
should not be used on any product. Return to supplier!
CAUTION
• Puttingout grease fires by closing the lid isnot
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 cylinderoff.
• 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.
Ignitor Lighting
,A. Do not leanover grill while lighting.
1. Openlidduring lighting.
2. TurnONgassourceor tank.
3. Toignite,turntheIGNITIONBURNERknobtoIGNFE_-.
4. PushandholdELECTRONICIGNITORbutton.
5. If ignitiondoesNOToccurin5seconds,turntheburner
controlsOFF(_, wait5minutes,andrepeatlighting
procedure.
6. Igniteremainingburnersbyturningto HIGH_, startingwith
theburnersclosestto theIGNITIONBURNERfirst.
Ifignition still does not occur,follow match-lighting
instructions.
Lighting instructions continued onnextpage.
463268107 • 7
Turn controls and gas source or tank OFF when not
in use.
CAUTION
if ignition does NOT occur in 5seconds, 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.
Match-Lighting
A Do not lean over grill while lighting.
1. Open lid. Turn on gas at LP cylinder.
2. Place lit match into match holder (hangingfrom cart side
panel), then into lighting hole onright or left side of grill.
3. Push inand turnfar right orfar left burner knob to HIGH_.
Be sure burner lights and stays lit.
4. Light adjacent burners in sequence by pushing knobs in and
turning to HIGH_.
Sideburner Ignitor Lighting
ADo not lean over grill while lighting.
1. Open sideburner lid. Turn on gas at LP cylinder.
2. Turnsideburner knob to HIGH (_, pushand hold
ELECTRONIC IGNITOR button.
3. if sideburner does NOT light,turn knob to OFF(_, wait 5
minutes, then repeat lighting procedure.
Sideburner Match Lighting
1. Open sideburner lid. Turn on gas at LP cylinder.
2. Place lit match near burner.
3. Turnsidebumer knob to HIGH (_.
Be sure burner lights and
stays lit.
8 , 463268107
Burner Flame Check
, Remove cooking grates and flame tamers. Light burners, rotate
knobs from HIGH_) to LOW (_. Youshould see a smaller
flame in LOW position than seen on HIGH. Perform burner
flame check on sidebumer, also. Always check flame prior to
each use. If only lowflame is seen refer to "Sudden drop or low
flame" in the Troubleshooting Section.
Turning Grill Off
, Turn all knobs to OFF(_ position. TurnLP cylinder off by
turning hand-wheel clockwise to a full stop.
Ignitor Check
• Turn gas off at LP cylinder. Press and hold electronic ignitor
button. "Click" should be heard and spark seen each time
between collector box or burner and electrode. See
"Troubleshooting"if no click or spark.
Valve Check
_mportant: Makesure gas is off at LP cylinder before
checking valves. Knobs lock in OFF position.Tocheck
valves, first push in knobs and release, knobs should spring
back. if knobs do not spring back, replace valve assembly
before usinggrill. Turn knobs to LOW position then turn back to
OFF position. Valves should turn smoothly.
Hose Check
• Before each use, check to see if hoses are cut or worn.
Replace damaged hoses before usinggrill. Use only
valve/hose/regulator specified by manufacturer.
General Grill Cleaning
, Do not mistake brown or black accumulation of grease and
smoke for paint. Interiorsof gas grills are notpainted at the
factory (and should never be painted).Apply a strong solution
of detergent andwater or usea grill cleanerwith scrub brush
on insidesof grill lid and bottom. Rinse and allow to completely
air dry. Do not apply a caustic grillloven cleaner to painted
surfaces.
, Plastic parts: Wash with warm soapy water and wipe dry.
A Do not use citrisol, abrasive cleaners, degreasers or a
concentrated grillcleaner on plastic parts. Damage to and
failure of parts can result.
• Porcelain surfaces: Because of glass-like composition, most
residue can bewiped away with baking soda/water solutionor
specially formulated cleaner. Use nonabrasive scouring powder
for stubborn stains.
• Painted surfaces: Wash with mild detergent or nonabrasive
cleaner and warmsoapy water.Wipe dry with a soft
nonabrasive cloth.
• Stainless steel surfaces: Tomaintain 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 useof an abrasive plastic cleaning
pad. Use only indirection of brushed finish to avoid damage.
Do not use abrasive pad on areas with graphics.
CAUTION
/SPIDER ALERT!
SPIDERAND WEBS
INSIDE BURNERTUBE
If you notice that yourgrill is getting hard tolight or that the
flameisn't as strong asit should be, takethe time to check and
cleanthe venturi's.
CONTROLPANEL
Insomeareasofthecountry,spidersor smallinsectshavebeen
knowntocreate"flashback"problems.Thespidersspinwebs,build
nestsandlayeggsinthegrill'sventuritube(s)obstructingtheflowof
gasto theburner,Thebacked-upgascanigniteintheventuribehind
thecontrolpanel.Thisisknownasaflashbackanditcandamage
yourgrillandevencauseinjury.
Topreventflashbacksandensuregoodperformancetheburnerand
venturiassemblyshouldbe removedfromthegrillandcleaned
beforeusewheneverthegrillhasbeenidleforan extendedperiod.
\ J
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. Remove cooking grates and flame tamers.
3. Removescrews and carryover tubes from rear of burners.
4. Removescrew and washers to disengage burner from
bracket on firebox.
5. Removescrews to detach electrode from burner. Electrode
should remain in firebox.
6. Carefully lift each burner up andaway from valve openings.
Wesuggest three ways to clean the burner tubes. Use the one
easiest for you.
(A) Bend a stiff wire (a lightweight coat hanger works well)
into a small hook. Run the hook through each burner
tube several times.
(B) Use a narrow bottle brush with a flexible handle (do not
use a brass wire brush), run the brush through each
burner tube several times.
(C) Wear eye protection: Use an air hose to force air into
the burner tube andout the burner ports. Check each
port to make sure aircomes out each hole.
7. Wire brush entire outer surface of burner to removefood
residue and dirt.
8. Clean any blocked ports with a stiff wire such as an open
paper clip.
9. Check burner for damage, due to normalwear and corrosion
some holes may becomeenlarged. Ifany large cracks or
holes are found replace burner.
VERY IMPORTANT:Burner tubes must reengage valve
openings. See illustrations at right.
10. Attach electrode to burner. Correct
burner-to-valve
11. Carefully replace burners, engagement
12. Attach burners to brackets on firebox.
13. Repositioncarryover tubes and attach
to burners. Replace flame tamers and
cooking grates.
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 reachof children.
, Cover grill if stored outdoors. Choose from a variety of grill
covers offered by manufacturer.
, Store grill indoors ONLYif LPcylinder 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.
HHHHHHHHHHHHHHHHHHH
Electrode
463268107 • 9
indirect Cooking
Poultry and large cuts of meat cook slowly to perfection on
the grill by indirect heat. The heatfrom selected burners
circulates gently throughout the grill, cooking meat or poultry
without the touch ofa direct flame. This method greatly reduces
flare-ups when cooking extra fatty cuts because there is no direct
flame to ignitethe fats and juices that drip during cooking.
indirect Cooking instructions
, Always cook with the lid closed.
, Due to weather conditions,cooking times mayvary. During
cold and windy conditions the temperature setting may need
to be increasedto insure sufficient cooking temperatures.
Food Safety
Food safety is a very important part of enjoying the outdoor
cooking experience. Tokeepfood safe from harmful bacteria,
follow these four basic steps:
Clean: Wash hands, utensils, and surfaces with hot soapy water
before and after handlingraw meatand poultry.
Separate: Separate raw meats and poultry from ready-to-eat
foods to avoid cross contamination. Usea clean platter and
utensils when removing cooked foods.
Cook: Cook meat and poultry thoroughly to kill bacteria. Usea
thermometer to ensure proper internalfood temperatures.
Chill: Refrigerate prepared foods and leftovers promptly.
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.
1 Burner Cooking
Cookwith direct or indirectheat.
Bestfor smallermeals or foods.
Consumes less fuel.
How To Tell if Meat is Grilled Thoroughly
* Meat and poultry cooked on a grill often browns very fast on the
outside. Use a meat thermometer to be sure food has reached
a safeinternal temperature, and cutinto food to check for
visual signs of doneness.
* Whole poultry should reach 180° F; breasts, 170° RJuices
should run clear andflesh should not be pink.
* Hamburgersmade ofany ground meat or poultry should reach
160° F,and be brown in the middlewith no pinkjuices. Beef,
veal and lamb steaks, roasts and chops can be cookedto 145°
F.All cuts of pork should reach 160° F.
* NEVER partially grill meat or poultry and finish cooking later.
Cook food completely to destroy harmful bacteria.
* When reheatingtakeout foods or fully cooked meats like hot
dogs, grill to 165° F,or untilsteaming hot.
2 Burner Cooking
Greatindirectcooking on low.
Producesslow,even heating.
Ideal for slow roastingand baking.
10 •463268107
CARE AND CLEANING OF YOUR STAINLESS STEEL GRILL
Routine cleaningis necessaryto preservethe appearanceand corrosionresistanceof StainlessSteel. Theperception that
many people have is that stainless steelwill not rust.That isnot the case in certain conditions.Rust marksare regularsttel
particlesthat have becomeattachedto the surface of stainless steel. They may also occur ifyou are using a steelwool or
wire wool scouring pad instead of a nylon scouring padto clean your grill. Incoastal areas, small rust pits maydevelop on
the surface of your grill that cannot befully removed bya cleaner. Concentratebleachesand other solutions containing
chlorinecan also cause rust pits and should not be used.
Cooking creates smokethat may eventuallycoat and discolor the stainless steelsurface. Greasefires will darken the
stainlesssteelsurface, butwill not affect the integrity of the steel.Periodic cleaningof the cooking surfaceandinside dthe
grill helpsdecreasethe risk of a fire. The methodsbeloware suggestionsfor cleaningstainless steel surfaces. Choosea
cleaning methodappropriatefor your needs.It is recommendedthat you use a Char-Broil@grill cover to help prolongthe
life and preventdiscoloration of yourgrill.
Routine Care
Aftereach use, let your grill cool and thenwipe the grill with a soft, damp, soapy cloth and rinse with clean water. It is
important to removeanyfood particlesor marinadefromthe stainless steel surface ofyour grill. Most marinadesare highly
acidic and damagestainless steel. DO NOTUSE STEELORWIRE WOOL.Toclean, polishand protect your stainlesssteel
grill ona weekly basis useChar-Broil@Stainless SteelGrill Cleaner.Forquick, convenientcleaning,use Char-Broil@
Stainless Steel Grill Wipes.
Stubborn Stains and Rust
Stubbornstains, discolorationand possibly rustand rust pitting canoccur fromcooking, exposure to harsh outdoor
conditions, orextremecooking temperatures. Forstubborn rust stains and greasestains, youcan restoreyour grill with the
Char-BroilStainless Steel RestorationKit. It is availableat major retailersor you canbuy itonline at www.grilllovers.com.
Forthe latest new productsand informationfor the care and cleaningdyour stainlesssteel grill go towww.charbroil.com.
* Always rub or wipe in the direction of the grain or polishlines in the stainlesssteel surface, not across them.
** Do notlet stainless steel cleanerscome incontact with paintedor plastic surfacesas damagemayoccur.
ROUTINE CARE
Char-Broil@ Stainless Steel
Grill Cleaner
ROUTINE CARE STUBBORN STAINS AND RUST
Char-Broil@ Stainless Steel Char-Broil@ Stainless Restoration Kit
Grill Wipes
463268107 • 11
A 1
B 2
C 2
D 1
E 1
F 1
G 1
H 1
I 1
J 1
K 1
L 1
M 1
N 1
O 1
P 1
Q 1
R 1
S 4
T 1
U 1
V 1
W 3
X 1
Y 5
Z 5
AA 1
BB 1
CC 1
DD 1
EE 1
FF 1
GG 1
HH 1
II 1
JJ 1
KK 1
KK1 1
KK2 1
KK3 1
LL 1
Description Part #
Bottom Shelf..................... 80006494
Locking Caster ................... 80000268
Fixed Caster..................... 80004093
Left Side Panel, Firebox............ 80006577
Right Side Panel, Firebox........... 80006578
Lower Back Panel, Cart ............ 80006497
Tank Exclusion, Wire Frame......... 80006498
Front Brace...................... 80006499
Tank Heat Shield ................. 80006575
Left Rail, GreaseTray ............. 80005604
Right Rail, GreaseTray ............ 80005605
Firebox Bowl..................... 80006576
Left Side Upper Panel ............. 80005586
Right Side Upper Panel ............ 80005585
Left Side Panel, Cart .............. 80006495
Right Side Panel, Cart ............. 80006496
Match Holderw/Chain ............. 80006654
Rear Upper Panel................. 80006585
Burnersw/Spider Guards........... 80005591
Valve/Manifold/Regulator ........... 80006581
Control Panel .................... 80006582
Electronic ignitionKit .............. 80008194
CarryoverTubes.................. 80006583
Logo Plate Dual Fuel .............. 80005594
Control Knobs.................... 80006617
Control Knob Bezels............... 80005596
Upper Back Panel ................ 80006580
Left Sideburner Shelf .............. 80006586
Fascia, Left Side Shelf ............. 80006587
Sideburner Pan .................. 80006588
Sideburner Lid ................... 80006589
Right Side Shelf .................. 80006590
Fascia, Right Side Shelf............ 80006591
Towel Bar ....................... 80006592
LidAssembly .................... 80006593
inner Insert, Lid Assembly .......... 80006594
Lid Handle ...................... 80006595
Tube Handle..................... 80006740
Right Handle End Cap ............. 80006638
Left Handle End Cap .............. 80006639
Logo Plate ...................... 80005616
MM 1
NN 1
OO 1
PP 2
QQ 1
RR 4
SS 1
TT 1
UU 1
VV 1
WW 1
XX 1
YY 1
ZZ 1
AAA 1
Description Part #
TemperatureGauge ............... 80006666
Lid Assembly Hardware Pack........ 80004371
Left Door Assembly ............... 80006742
Door Handle..................... 80006598
Right DoorAssembly .............. 80006750
FlameTamers.................... 80003332
Tank Wire....................... 80008188
Cooking Grate, Set of 3 ............ 80006599
Warming Rack ................... 80006753
Sidebumer Grate ................. 80006640
Grease Tray w/Handle ............. 80008970
Sideburner Burner Kit.............. 80004311
Electronicignition Button ........... 80004343
Sideburner Wind Diverter........... 80005038
Sideburner Cap Clip............... 80006265
Not Pictured
1
1
1
1
1
1
Replacement Flame Tamer
Support Pins ................... W80000020
Door MagnetAssembly ........... 80008850
Caster Wrench ................... 80000283
Product Guide (English) ............ 80006542
Product Guide (Spanish) ........... 80006543
Hardware Pack (for retailer store only). 80006541
1 Screw Nut Pack (for purchaser) ...... 80008951
5 #8x3/8" Self-TappingScrew
2 4mm FlatWasher
2 5mm FlatWasher
28 7mm FlatWasher
4 #8-32x3/8" Pan Head Screw
8 #8-32x3/8" Flat Head Screw
2 #10-24x3/8" Screw
12 114-20x112"Screw
8 114-20x314"Screw
8 1/4-20x1½" Screw
4 4mm LockWasher
2 5mm LockWasher
28 7mm LockWasher
Tools required for assembly:
Caster Wrench -Provided , Phillips screwdriver -Not provided
Estimated assembly time:
3045 minutes
12 * 463268107
UU
\MM
EE
VV
DD AAA XX V
¢C
AA
\
O0
/
PP
_..-Q
RR
:, ,
KK2
KK _/
K
KKi
E
HH
GG
I
FF
QQ
PP
Ss
AC
463268107 • 13
Attach the two locking casters at the rear of the bottom shelf
and the twofixed casters at the front. Usethe provided caster
wrench tofully tighten casters.
Lockingcaster-__
80000268 -_
Attach side panels to bottomshelf using three
1/4-20x112"screws, 7ram lock washers, and 114.20x112"
7ram flat washers per panel.
_MPORTANT:Panel with large hole must
Be on left side of bottom shelf.
Left side panel ........
(with large hole)
80006577
Makesure side panels
are pushed asfar
rearof bottom shelf as
possiblebeforefully
tightening screws.
7mmlock
7mmflat
Right side panel
80006578
14 •463268107
Placelower back panel between side panels at rear of bottom shelf. Make sure the slots are positionedas shown (A). Secure
lower back panelto side panelsusing two 1/4-20x112"screws, 7mm lock washers, and 7mm flat washers on each side.
1/4-20x1/2"screw
7ramlockwasher
7mmfiat washer Lowerback panem
80006497
This step requires two people
to lift and position grill head
onto cart. Carefully lowerthe grill
head onto the cart, aligning slots at
bottom of grill head with posts on
cart side panels. Make sure the
regulator hose is hanging outside
the cart. Grill head must face open
side of cart.
Grill head
Reg
463268107 •15
Insertfront brace undercontrol panel and between cartside panels. Make suredoor hinge pins areon the top side and
facing thefront. Secure using two 1t4-20xlt/2 ' screws, 7ram lock washers, and 7ram flat washers on each side.
NOTE: MAKE SURE THAT THE FRONT BRACE IS MOUNTED IN THE MOST DOWNWARD POSITIONWHEN
ASSEMBLED TO CART.
On back of grill, place upper back panel between side panelsand
above lower back panel. Secureupper back panel, in lower holes,
usingone 114-20xlt/2'' screw, 7ram lock washer, and 7ram flat
washer on each side. Do not fully tighten screws until side shelf
installation is complete in later steps.
1/4-20x11/2'' 7ramlock 7ramflat
screw washer washer
4p.------- Rearupper panel
80006580
16 • 463268107
inserttabs onright side shelf into rectangular slots in side of firebox. Attach rear
of shelf using one 114o20x314"screw, 7ram lockwasher, and 7ram flat washer
in upper hole.Use one l14.20xlY2" screw,7ram lock washer,and
7ram flat washer in lower hole.Attach front of shelf and fascia using three
1/4-20x3/4" screws, 7ram lock washers, and 7ram flat washers.Attach towel
bar to right side shelf with two tl4.20x112" screws, 7ram lock washers and
7ram flat washers.
/
1/4o20x11/"screw
/
Right sideshelf
80006590
inserttabs onleft sideburner shelf assembly into rectangular slots in sideof firebox. Attach rear of shelf using one 1/4-
20x3/4" screw, 7ram lock washer,and 7ram flat washer in upper hole. Use one t14.20xlW' screw, 7ram lock washer, and
7ram flat washer in lower hole.Attach front of shelf and fascia using three 114.20x314"screws, 7ram lock washers, and 7ram
flat washers. Now you may fully tighten lower screws on upper back panel
1/4-20x3/4" 7rn
washer
1/4o20xlY," screw
screw
Tabs
Leftsideburnershelf into
80006586 holes
Fascia,leftsideburner shelf
80006587
463268107 • 17
First, remove the two screws and lock washers factory attached to the sideburner valve bracket. Position sideburner
valve bracket beneath sideburner shelffascia sothat valve stem comes through larger centerhole in fascia. Align the holes
on valve bracket with left and right holes on fascia. Secure using lock washers and screws that were removed from bracket.
Next, place sideburner bezel over valve stemon front side offascia. Align small holes on bezelwith upper and lower holeson
fascia. Attach usingtwo #8-32x3/8" screws and 4ram lock washers. Press sideburner control knob ontovalve stem.
installbezelwith"OFF"attop,
Note: Use left and right
holes on fascia to
attach valve bracket
ScrewsandWashers
removedfrom valvebracket
Note: Use upRerand lower
holeson fascia to
attach bezel
#8o32x318"screw
ControJknobbezel
80005596
Valve stern
Insertsideburner burner into left shelf, making sure burner tube engages sideburner valve (A). Center stud on bottom of
burner fits into center hole in burner bracket on shelf. See illustration C for proper burner4o-valve engagement. Secure
burner to bracket using two#10-24x3/8" screws, 5ram lock washers, and5ram flat washers (8).
80004311
18 • 463268107
Under sideburner shelf, attach sideburner ignitor wire to electrode (A).
Place sideburner wind diverter over sideburner (8). Align notch indiverter to fit around electrode. Place burner cap onto
sidebumer.Attach sideburner cap clip (C). Placesideburner cooking grate onto sideburner shelf, aligning grate legs with
holes in shelf.
SideburnerignitorWire
Sideburner
capclip
Insideof cart, insert rear shield tabs intotwo left slots between upper and lower back panels. Attach left and center front
shield tabs under front brace with #8x3/8" self-tapping screws, insertleft and right grease tray rails into slots beneath grease
tray opening in rear upper panel.Attach railsto brace, with #8x3/8" self-tapping screws.
Somecomponentsnotshownfor
illustrationpurposes,
Tankheatshield
8001
463268107 •19
Insertend of tankwire (without hole) into back of lower back panel. Attach other end to bottom offront bracewith a
#8x3/8" self-tapping screw,
80008188
Insertwire ends intolower back panel (A). Attach front right side of wire shelf tothe right side panel with one#8-32x3/8"
screw, 4ram flat washer and 4ram lock washer (B). Leg attaches to bottom shelfwith 4ram flat washer and 4ram lock
washer and a #8o32x3/8" screw (C).
20 , 463268107
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