Char-Broil 463268107 User manual

Brand: Char-Broil

Model: 463268107

Category: Barbecues & grills

Type: User manual

This manual is also suitable for

463260307

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.

•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.

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

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

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KK2

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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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Char-Broil 463268107 User manual

Brand: Char-Broil

Model: 463268107

Category: Barbecues & grills

Type: User manual

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