Char-Broil 466231203 Owner's manual

Brand: Char-Broil

Model: 466231203

Category: Barbecues & grills

Type: Owner's manual

This manual is also suitable for

463232103

466231203 • 1

466231203 / P80112002A (041503)



Ifyouhaveanyquestions

orneedassistance

during assembly,

please ca ll

18002417548 U.S

18003876057 CAN

THIS GRILL IS FOR

OUTDOOR USE ONLY

466231203

2 • 466231203

CallGrillServiceCenterForHelpAndParts

• Ifyouneedhelporwarrantypartscall 18002417548U.S.

or18003876057CAN,orsendaFAXto17065766355.

Businesshours:Open24hoursSevendaysaweek.

• Toordernonwarrantyreplacementpartsoraccessories(grill

cover,cleaners,paint)call18009932677orsendaFAXto

17065652121.

Important:FilloutWarrantyInformationbelow

WarrantyInformation

Model Number _______________________________

Lot Number (oncartonlabel) _____________________

Serial Number _______________________________

Date Purchased ______________________________

InstallationSafetyPrecautions

• Usegrillonlywith LP(propane)gasandtheregulator/valve

assembly supplied.

• Grillinstallationmustconformwithlocalcodes,orintheir

absencewith National Fuel Gas Code, NFPA 54 / ANSI

Z223.1 or CAN/CGAB149.2 Propane Installation

Code.HandlingandstorageofLPcylindersmustconform

to LPGasCode NFPA/ANSI 58. Grillisnotforuseinoron

recreationalvehiclesand/orboats.

• Allelectricalaccessories(suchasrotisserie)mustbe

electrically grounded in accordancewith local codes, or

National Electrical Code, ANSI / NFPA 70or Canadian

Electrical Code, CSA C22.1.Keepanyelectricalcords

and/orfuelsupplyhosesawayfromanyhotsurfaces.

• Thisgrillissafetycertifiedforusein theUnitedStatesand

Canadaonly.Donotmodifyforuseinanyotherlocation.

Modificationwill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.

• Forresidentialuseonly.Donotuseforcommercial

cooking.

CA CA

UTION UTION

UTION

FORYOURSAFETY

1.Donotstoreorusegasolineorother

flammablevaporsandliquidsinthe

vicinityofthisoranyotherappliance.

2.AnLPTanknotconnectedforuse

shallnotbestoredinthevicinityof

thisoranyotherapp liance.

FORYOURSAFETY

Ifyousmellgas:

1. Shutoffgastotheappliance.

2. Extinguishanyopenflame.

3. Openlid.

4. Ifodorcontinues,immediatelycall

yourgassupplieroryourfire

department.

WARNI NG WARNI NG

WARNI NG

• DANGER: Indicatesanimminentlyhazardous

situationwhich,ifnotavoided,willresultindeathor

serious injury.

D D

ANG ER ANG ER

ANG ER

• CAUTION:Indicatesapotentiallyhazardous

situationwhich,ifnotavoided,mayr esultinminor

ormoderateinjury.

CA CA

UTION UTION

UTION

• WARNING:Bealerttothepossibilityofserious

bodilyinjuryiftheinstructionsarenotfollowed.Be

suretoreadandcarefullyfollowallofthemessages.

WARNI NG WARNI NG

WARNI NG

466231203 • 3

ForYourSafety ......................................................................... 2

CallGrillServiceCenterForHelpAndParts........................... 2

InstallationSafetyPrecautions ................................................. 2

SafetySymbols ......................................................................... 2

TableofContents..................................................................... 3

Warranty .... ................................................................................ 3

BeforeBeginningAssembly ..................................................... 4

PartsList ................................................................................... 4

Exploded View .......................................................................... 5

Assembly ................................................................................ 69

UseandCare ........................................................................ 914

StoringYourGrill ..................................................................... 13

Indirect Cooking ...................................................................... 14

FoodSafety.............................................................................. 14

Troublesh ooting ...................................................................... 15

CharBroilwarrantstotheoriginalconsumerpurchaserthat

thisproduct shallbefreefromdefectsinworkmanshipand

materialsundernormalandreasonableuseandcorrect

assembly(ifassembledbyconsumerpurchaser),fromdateof

purchase.

Stainless steel and die cast parts  99 years

Electronic ignition and burners  10 years

Remaining parts  2 years

CharBroilwill,atitsoption,refinishorreplaceany

productorpartfoundtobedefectiveduringthewarranty

period.CharBroilwillrequireyoutoreturnthepart(s)

claimedtobedefective,foritsinspection,freightorpostage

prepaid. 

Ifyouwishtoobtainperformanceofanyobligationunderthis

limitedwarranty,youshouldwriteto:

CHARBROIL

Consumer Warranty / P.O. Box 1240

Columbus, GA 319021240

CharBroilmayrequirereasonableproofofpurchaseand

wesuggestyoukeepyourreceipt.InthestateofCaliforniaonly,

ifrefinishingorreplacementoftheproductisnotcommercially

practicable,theretailersellingthisproductorCharBroil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fromwhichitwaspurchasedortoanyretail

establishmentsellingthisproductinordertoobtainperformance

underthiswarranty.

Thiswarrantydoesnotincludethecostonany

inconvenienceorpropertydamageduetofailureoftheproduct

anddoesnotcoverdamageduetomisuse,abuse,accident,

damagearisingoutoftransportationoftheproduct,ordamage

incurredthroughcommercialuseoftheproduct.Thisexpress

warrantyisthesolewarrantygivenbythemanufacturerandisin

lieuofallotherwarranties,expressorimplied,includingimplied

warrantyofmerchantabilityorfitnessforaparticularpurpose.

NeitherCharBroildealersnortheretailestablishmentsellingthis

producthasanyauthoritytomakeanywarrantiesortopromise

remediesinadditiontoorinconsistentwiththosestatedabove.

CharBroil'smaximumliability,inanyevent,shallnotexceedthe

purchasepriceoftheproductpaidbytheoriginalconsumer

purchaser.Somestatesdonotallowtheexclusionorlimitationof

incidentalorconsequentialdamages.Sotheabovelimitationsor 

exclusionsmaynotapplytoyou.Thiswarrantygivesyouspecific

legalrightsandmayalsohaveotherrightswhichvaryfromstate

tostate.

Warr antyTable of Contents

4 • 466231203

Key Qty Description Part #

A 1 LidPlate P00118036A

B 1 LidSidePanel,Left P00105037K

C 1 LidSide Panel, Right P00106037K

D 1 HeatIndicator P006011 81A

E 1 PlasticLid Handle P00202012A

F 1 LogoPlate P00403003H

G 1 Warming Rack P01505007E

H 2 Cooking Grid P016150 03E

I 3 Flame Tamer P01705005E

J 1 Griddle P057020 02E

K 3 Burner P020010 31E

L 1 BurnerSupportBracket P02203052B

M 3 Gas Collector Box with Electrode P026090 02B

N 1 ElectricWireset P02615062A

O 1 ElectricIgnitor(4port) P02 502024C

P 1 BowlSidePanel, Left P00720011A

Q 1 Bowl Side Panel,Right P00721011A

R 1 Bowl  Front Panel P007240 14A

S 1 Bowl RearPanel P007250 14A

T 1 Rear Wind Shield P00728051A

U 1 Grease Draining Tray P02705 084B

V 1 Grease Receptacle P02701015B

W 1 Gas Manifold P05003062A

X 3 GasValvefor Main Burner P03222024B

Y 1 HeatShieldforControlPanel P03007032B

Z 1 ControlPanel P02P075 01A

AA 3 Control Knob P03411111G

BB 3 Control Knob Seat P03415041J

C C 4 Spring P055040 17E

DD 1 Sideburner Frame (Lef t) P01102013D

EE 1 Side Shelf,Right P01103012D

FF 1 BracketforSideShelfLeft Front P01 204004C

GG 2 Bracketfor Side Shelf LeftRear,Right Front P01 206003C

HH 1 Bracket for Side Shelf RightRear P01 207002C

II 2 Front Panel,SideShelf, Left P07503001B

JJ 1 CartBottomShelf P01003006D

KK 2 Cart Side Panel P07604002B

LL 1 Cart RearPanel P07702002B

M M 1 Door Bracket P03301001D

N N 2 DoorFrontPlate P04301002A

OO 2 DoorHandle P00214006A

PP 2 Bowl Sup port Bracket P01306002D

QQ 1 LeftSide CartLeg, Front P00 910005C

R R 1 Left SideCartLeg, Rear P00911005C

SS 1 Right Side Cart Leg, Front P00 912005C

TT 1 RightSideCartLeg,Rear P00 913005C

U U 4 Caster Seat P04507003A

VV 4 3" Caster P05106003D

WW 1 PullOut Tank Tray P04 009 005C

XX 2 Bracket forPullOut TankTray P04 010 006C

YY 1 Handle for Pull OutTankTray P00210004D

ZZ 2 SlideSet P05 516003C

AAA 1 Sideburner Lid P0011508AA

BBB 1 Lid Knob forSideburner P00201008A

CC C 1 PotSupport P00814002D

DDD 1 Electrode P02 614007C

EEE 1 Sideburner P02002003D

FFF 1 Gas Valve for Sideburner P032181 02G

GGG 1 Control Knob P03401031F

HHH 1 Connection Tube P037020 02A

III 1 Reg ulator with Hose (27") P03601004A

JJJ 1 AA Battery P05301001A

KKK 1 Front Panel,Side Shelf, Right P07502001B

LLL 1 Sideburner Control Knob Seat P03408051J

MM M 1 Match Lighting St ickwith Chain P05507031E

1 Caster Wrench P05 515002C

1 GrateLifter P05515014F

1 Hardware Pack P06004004A

1 Owner's Manual P80112002A

Parts List  466231203

• Necessarytoolsforassemblyofyourgrillinclude:

Phillips

®

screwdriver,pliersandadjustablewrench.

Before Beginning Assembly

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;

6,279,566;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;andD449,492.

OtherPatentsPending.

466231203 • 5

Ex ploded View  466231203

L M

E E

T T

KKK

I I

W W

AAA

BBB

CCC

DDD

EEE

FFF

GGG

HHH

I I I

JJJ

LLL

MMM

6 • 466231203



Assembly  466231203

• Unpack and remove all protective packaging.

1. Positionbottomshelfwiththe4holepatterntotheleftside.

See Fig. 1.

VERY IMPORTANT: Thelabelsonthecartlegs

indicatetheirassemblypositiontothebottomshelf.

LF LF

LF=Left

Front,

LR LR

LR=Left Rear,

RF RF

RF=Right Front, and

RR RR

RR=Right

Rear.Labelsshouldfaceinwardtowardeachotherwhen

correctlyassembled. Remaining components cannot be

assembled if leg positions are incorrect.

2. Installthefourcartlegstotheindicatedcornersofthe

bottomshelfusing8ofthe 1/4x21/2"Phillipsheadscrews

provided.Donotfullytightenscrews.

3. Installcrossbraces,facinginward,tocartlegsonboth

sidesusing8ofthe 1/4x1/2"Phillipsheadscrews.Fully

tighten.See Fig. 1.

FIGURE 1

Cross

Brace

Bottom

Shelf

4. Screwthe4cas tersintothecasterseatsinthebottomof

eachcartleg.Turnthethreadedcasterstembyhand,

clockwiseuntilitstops.Fullytightenwiththewrench

provided.See Fig. 2.

5. Installthetwosidepanelsandonerearpaneltothecartby

using4ofthe 3/16x3/8"Phillipsheadscrewsoneach

panel.Leaverearpanelscrewsloose.See Fig. 2.

FIGURE 2

Caster

Rear

panel

4hole pattern

toward left side

Side

panel

Side

panel

6. USE CAUTION when handling the pullout tank tray.

Slide rails have sharp edges.Installthehandleonthe

pullouttankusing2ofthe 1/4" nuts.Fullytighten.See

Fig. 3.

7. Fullyextendthepullouttanktrayandattachthesliderails

to the 4holepatterninthebottomshelf using4ofthe

1/4x1/2"Phillipsheadscrews.Fullytighten.See Fig. 3.

FIGURE 3

Handle

Pullout

tank tray

Slide

Rail

466231203 • 7

8. Attachthedoorbrackettot he lower holesinthe frontlegs

withtheendtabspointingupwardandtheflangetotherear,

pointingdownward.Use2ofthe 1/4x1/2"Phillipshead

screws.Donotfullytighten.See Fig. 4.

9. Placedoorsintothehingeholesofthebottomshelfand

doorbracket.Pushdoorbracketdownuntildoorsare

secureandcanopenandclosefreely.Donotfullytighten

doorbracketscrews.See Fig. 4.

10 . Removeprotectivefilmfromdoors.Installdoorhandlesto

doorsusing4ofthe 3/16x3/8" Phillipsheadscrews.See

Fig. 4.

11. Attachthe4sideshelfbracketstothetopsofthecartlegs

using8ofthe 1/4x1/2"Phillipsheadscrews.

IMPORTANT: Bracket with cutout installs on front left

leg. Besuretheflatsideofeachbracketfacesoutward.

Fullytighten.See Fig. 4.

12 . Placethesideburnershelfovertheleftbracketsandcross

brace.Besureignitorwireishangingloose.Besure the

insideshelfholesalignwithcrossbraceholes.Secure

shelffirmlytotheendsofthebracketsusing2ofthe

1/4x1/2"Phillipsheadscrews. Repeat this procedurefor

thesideshelfontherightsideofthecart.See Fig. 4.

FIGURE 4

FIGURE 6

Sideburner

shelf

Side

shelf

Shelf bracket,

flat side facing

outward

Lower

hole

Do or

bracket

Do or

Handle

Hinge

hole

Align

holes

Toreducetheweightofthegrillhead,openthegrilllidand

removethepackedcomponents. This step requires 2 people

to lift and position the grill head onto the cart.

14 . HINT:Slidegrillheadintocartfromthefront. Use care to

avoid scratching tops of side shelves.Alignthe2holes

beneaththehangledgeoneachsideofthe grillheadwith

the 2holesinthesideshelf andcrossbraceonthecart.

Raisethegrilllidandinsert4ofthe 1/4x3/4"Phillipshead

screws.Beneaththesideshelves,add 1/4" nuts.Donot

fullytighten.See Fig. 6.

15.Attachheatindicatortogrilllidusingnutprovided.Make

suregraphicsonheatindicatorareproperlyorientedbefore

tighteningnut.See Fig. 6.

Grill

head

Hang

ledge

Gas hose

Hang

ledges

rest on

shelves

Bracket with

cutout

Heat indicator

Remove

film

Match

lighting

stick

FIGURE 5

13 . Attachmatchlightingstick

andchaintotherightrear

leg,belowshelfbracket,

using one M4x10mm,

selftapping, Phillipshead

screw.See Fig. 5.

8 • 466231203

FIGURE 8

17 . Securegrillheadtoallcartlegsusing4ofthe 1/4x21/2"

Phillipsheadscrewsand 1/4" nuts. See Fig. 8.

18 . Fully tighten all leg screws, rear panel screws, door

bracket screws, and grill head screws.

19 . Fromthebackofthecart,slidethegreasedrainingtrayinto

thegrillhead.Placethegreasereceptacleintothenotches

onthebottomofthetray. See Fig. 8.

Grease

draining

tray

Grease

receptacle

Attach grill head

to all 4 legs

20 . PlaceyourLPgastank(notincluded)ontothepullouttank

trayandpushtrayintocart.Besurethetankvalveisfacing

forward.See. Fig. 9. READ USE & CARE SECTION

BEFORE ATTACHING REGULATOR TO LP TANK.

Contact

Spring

AA Battery

21 . Unscrewtheignitorcaplocatedonthecontrolpaneland

removethecontactandspringfromtheignitorslot.

See Fig. 10.

22 . PlacethesuppliedAAbatteryintotheignitorslotwiththe

positivepolefacingtowardyou.

23 . Placethespringwith contactoverthebattery.Screwthe

ignitorcapbackontothecontrolpanel.

FIGURE 10

Ignitor

cap

–

FIGURE 9

LP gas

tank

24 . Attachpaneltofrontofsideburnershelf byplacingtoplipof

panel ABOVEbottomli pofshelf.Secureusingthree

3/16"x3/8"Phillipsheadscrewsand 3/16" nuts.Fully

Tighten.See Fig. 11.

Panel lip

Shelf

lip

FIGURE 11

16 . Firmlyattachignitorwiref romsideburnertotheignitorwire

fromthegrillhead. See Fig. 7a.Beneathleftshelf,insert

sideburnervalveintosideburnertube. See Fig. 7 for

proper engagement. Attachsideburnervalvetoshelfusing

2ofthe M4x10 Phillipsheadscrewsandwashers.Place

knobseat,spring,andsideburnerknobovervalvestem.

Sideburner

tube

Wire from Grill head

FIGURE 7

FIGURE 7a

Valve

Ignitor

wire

Sideburner

knob

Seat

Spring

466231203 • 9

25 . Placethe3flametamersonthelowerledgeabove

burners.See Fig. 12.Theyshouldm eetinthecenter.

26 . Placethecookinggridsorgriddleontheledgeabovethe

flametamers.

27 . Placethesecondarycookingrackintot heslotsonthe

upper leftandupperr ightofthegrillbowlpanels.

FIGURE 12

Griddle

Flame tamer

Cooking

grid

Secondary

cooking

rack

Lower

ledge

BeforeYourFirstCookout

• Performtheleaktestasindicatedintheuseandcare

section.

• Washthecookinggrids,griddle,cookingrack,andall

stainlesssteelsurfaceswithwarm, soapywater.Rinseand

drythoroughly.

• Lightburners.Checktomakesuretheyarelit,thenclose

the lidandwarmthegrillonHIfor15minutes.Curingof

paintandpartswillproduceanodoronlyonfirstlighting.

LPTank

• The LP tank used with your grill must meet the following

requirements:

• PurchaseLPtanksonlywiththeserequiredmeasurements:

12"(30.5cm)(diameter)x18"(45.7cm)(tall)with20lb.(9

kg.) capacity maximum.

• Beconstructed andmarkedin accordance with

specificationsforLPtankoftheU.S.Departmentof

Transportation(DOT)orforCanada,CAN/CSAB339,

cylinders,spheresandtubesfortransportationofdangerous

goods,TransportCanada(TC).SeeLP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featureisidentifiedbya

uniquetriangularhandwheel.Use only

tanks equipped with this type of valve.

• Supplysystemmustbearrangedforvaporwithdrawaland

includecollartoprotectLPtankvalve.

LP(LiquefiedPetroleumGas)

• Isnontoxic,odorlessandcolorlesswhenproduced.For Your

Safety,LPgashasbeengivenanodor(similartorotten

cabbage)sothatitcanbesmelled.

• LPgasishighlyflammableandmayi gniteunexpectedly

whenmixedwithair.

LPTankFill ing

• Useonlylicensedandexperienceddealers.

• LPt ank must be purgedbeforefilling.

• Dealershould NEVERfillLPtankmorethan80%ofLPtank

volume.Volumeofpropaneintankwillvarybytemperature.

• Afrostyregulatorindicatesgasoverfill.ImmediatelycloseLP

tankvalveandcalllocalLPgasdealerforassistance.

• Donotreleaseliquidpropane(LP)gasintotheatmosphere.

Thisisahazardouspractice.

• ToremovegasfromLPtank,contactanLPdealerorcalla

localfiredepartmentforassistance.Checkthetelephone

directoryunder“Gascompanies”fornearestcertifiedLP

de alers.

• LPtankExchange:YoumaychoosetoreplaceyouremptyLP

tankthroughanexchangeservice.Useonlythosereputable

exchangecompaniesthatinspect,precisionfill,testand

certifytheircylinders. Exchange for OPD safety feature

equipped tank as described in LP Tank

• AlwayskeepLPtankinuprightpositionduringuse,transitor

storage.

• Leak test LP tank BEFORE connecting to grill.

OPD Hand Wheel

Use and Care

10 • 466231203

5. Hold regulator, insert nipple (B) into LP tank valve.

Hand tighten coupling nut,holding r egulatorin a

straightline(C)withLPt ankvalve so as not to cross

thread the connection.

6. Turnthecouplingnutclockwisetotightentoafullsolidstop.

TheregulatorwillsealonthebackcheckfeatureinLPtank

valve,resultinginsome resistance. An additional onehalf

to three quarters turn is required to complete

connection. Tighten by hand only  do not use tools.

NOTE: Ifyoucannotcompleteconnection,disconnectregulatorand

repeatsteps5and6.Ifyouarestillunabletocompletethe

connection, do not use this regulator!

Hold coupling nut

and regulator as

shown for proper

connection to LP

tank valve.

Nipple has to be

centered into the

LP tank valve

• Do not insert any foreign objects into the valve

outlet. You may damage the valve and cause a leak.

Leaking propane may result in explosion, fire, severe

personal injury, or death.

• 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 checked.

• If leak is detected at any time, STOP and call the Fire

Department.

• If you cannot stop a gas leak,immediately close LP

tank valve and call LP gas supplier or your fire

department!

WARNI NG WARNI NG

WARNI NG

B B

B B B

C C

Use of this POL transport plug

(A) (plastic part with external

threads) will defeat safety

feature of valve.

A A

A A A

LPTankL eakTest

For your safety

• LeaktestmustberepeatedeachtimeLPtankisexchangedor

refilled.

• Donotsmokeduringleaktest.

• Donotuseanopenflametocheckforgasleaks.

• Grillmustbeleakcheckedoutdoorsinwellventilatedarea,away

fromignitionsourcessuchasgasfiredorelectricalappliances.

Duringleaktest,keepgrillawayfromopenflamesorsparks.

Useacleanpaintbrushand50/50soapandwater

solution. Use mild soap and water.

Do not use household cleaning agents.

Damagetogastraincomponentscanresult.

Brushsoapysolution

ontotheshadedareas.

ConnectingTheRegulatorToTheLPTank

OPD Hand

Wheel

Type 1 outlet with thread on outside

1. LPtankmustbeproperlysecured ontogrill.

2. Turnallcontrolknobsincludingsideburner(iffeatured)totheOFF

position. 

3. TurnLPtankOFFbyturninghandwheel

clockwiset oa full stop.

4. Removetheprotectivecapfrom

LPtankvalve.Alwaysusecapand

strapsuppliedwithvalve.

Strap and Cap

Safety Relief Valve

"growing"

bubbles appear

do not use or move

the LP tank. Contact

an LP gas supplier or

your fire department!

466231203 • 11

• AdisconnectedLPtankinstorageorbeingtransportedmust

haveasafety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aLPtankinsidea

vehiclewhichmaybecomeoverheatedbythesun.

• DonotstoreLPtankinanareawherechildrenplay.

LeakTestingValves,Hoses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counter

clockwise.Ifyouheararushing sound,turngasoff

immediately.Thereisamajorleakattheconnection. Correct

before proceeding.

LPTankRemoval,TransportAndStorage

• TurnOFFallcontrolknobsandLPtankvalve.Turncouplingnut

counterclockwisebyhandonlydonotusetoolstodisconnect.Lift

LPtankwireupwardoffofLPtankcollar,liftLPtankupandoffof 

supportbracket.InstallsafetycapontoLPtankvalve.Alwaysuse

capandstrapsuppliedwithvalve. Failure to use safety cap as

directed may result in serious personal injury and/or

property damage.

LP Tank

Valve

Safety

Cap

Retainer

Strap

• NEVER store a spare LP tank under or near grill or in

enclosed areas.

• Never fill the cylinder beyond 80% full. An overfilled

spare LP tank is hazardous due to possible gas

released from the safety relief valve. The safety relief

valve on a LP tank could activate releasing gas and

cause a fire.

• If you see, smell or hear escaping gas, immediately

get away from the LP tank/grill and call your fire

department.

• All spare LP tanks must have safety caps installed on

the LP tank outlet.

D D

ANG ER ANG ER

ANG ER

4.Brushsoapy

solution onto

following

connections:

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ofitemsneededtotheGr illServiceCenter at

18002417548U.S.or18003876057CAN.

6. AlwayscloseLPtankvalveafterperformingleaktestby

turning hand wheel clockwise.

SafetyTips

Beforeopening LPtankvalve,checkthecouplingnutfor

tightness.

Whengrillisnotinuse,turnoffallcontrolknobsandLPtank

valve.

Nevermovegrillwhileinoperationorstillhot.

Whenmovingthegrillpushitforward,donotpullfrom

behind.

Uselonghandledbarbecueutensilstoavoidburnsand

splatters.

Donotremovegreasereceptacleortrayuntilgrillhas

completely cooled.

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,cleanandinspectvalve,hose

andregulatorbeforecontinuing.Performaleaktest.

Theregulatormaymakeahummingorwhistlingnoise

duringoperation.Thiswillnotaffectsafetyoruseofgrill.

Ifyouhaveagrillproblemseethe "TroubleshootingSection".

12 • 466231203

BurnerFlameCheck

• Removegratesandfl ametamers.Lightburners,rotateknobs

from HItoLOW.YoushouldseeasmallerflameinLOW

positionthanseenonHI.Alwayscheckflamepriortoeach

use.Performflamecheckforsideburner.Ifonlylowflameis

seenreferto"Suddendroporlowflame"in

theTroubleshootingSection.

TurningGrillOff

• TurnallknobstoOFFposition.TurnLPtankOFFbyturning

handwheelclockwisetoafullstop.

LOW

MatchLighting

Do not lean over grill while lighting.

1. Openlid during lighting.

2. Placelitmatchintomatch

lightingstick,thenintolighting

holeonrightsideofgrill.

3. Pushinandturnfarright burner

knobtoHI.Besureburnerlights

andstayslit.

4. Lightadjacentburnersinsequencebypushingknobsin

andturningtoHI.

MatchLighting

1. TomatchlightSIDEBURNER,open

sideburner cover.

2. Placelitmatchnearburner.

3. Pushinandturnsideburner

knob counterclockwise. Be

sureburnerlightsandstayslit.

• If burner does not light turn knobs to OFF, wait 5

minutes, try again.

WARNI NG WARNI NG

WARNI NG

ForSafeUseOfYourGrill:

• Donotletchildrenoperateorplayneargrill.

• Keepgrillareaclearandfreefrommaterialsthatburn.

• Donotblockholesinbottomorbackofgrill.

• Checkburnerflamesregularly.

• Usegrillonlyinwellventilatedspace.NEVERusein

enclosedspacesuchascarport,garage,porch,covered

patio,orunderasurfacethatcancatchfire.

• 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.

• Donotusecharcoal,briquetsorlavarockinthisgrill.

• Apartment Dwellers:

Checkwithmanagementtolearntherequirementsandfire

codesforusinganLPGasGrillinanapartment.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madeof

wood.

• NEVER attempt to light burner with lid closed. A

buildup of nonignited gas inside a closed grill is

hazardous.

• Never operate grill with LP tank out of correct position.

• Always close LP tank valve and remove coupling nut

before moving LP tank from specified operating

position.

WARNI NG WARNI NG

WARNI NG

• 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 on high. If grill has not been regularly

cleaned a grease fire can occur that may damage the

product.

CA CA

UTION UTION

UTION

IgnitorLighting

Do not lean over grill while lighting.

1. Open lidduringlighting

2. Toigniteanyburner,turnknobtoHI,pushandhold

ELECTRONICIGNITORbuttonfor5seconds.

3. Ifignitiondoesnottakeplacewithin5seconds,turnall

burnerknobstoOFF,wait5minutes,thenrepeatlighting

proced ure.

4. IfIGNITORdoesnotwork,followmatchlighting

instructions.

466231203 • 13

IgnitorCheck

• Turn gas off at LP tank.Pushandholdelectronici gnitor

button."Clicks"shouldbeheardandsparkseeneachtime

betweencollectorboxorburnerandelectrode.See

"Troubleshooting"ifnoclickorspark.

ValveCheck

• Important: Make sure gas is OFF at LP tank before

checking valves. KnobslockinOFFposition.Tocheck

valves,firstpushinknobsandrelease,knobsshouldspring

back.If knobsdon'tspringback,replacevalveassembly

beforeusinggrill.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usinggrill.Useonlyvalve/

hose/regulator specified by manufacturer.

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 tank.

2. Removecookinggrates,flametamers,greasetrayandgrease

receptacle.

3. Removecotterpinsfrombeneatheachburner"foot"usinga

screwdriverorneedlenosepliers.

4. Carefullylifteachburnerupandawayfromvalveopenings.

Wesuggestthreewaystocleantheburnertubes.Usetheone

easiestforyou.

(A) Bendastiffwire(alightweightcoathangerworkswell)

intoasmallhook.Runthehookthrougheachburnertube

andburner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andburnerseveraltimes.

burnertubeandouttheburnerports.Check eachporttomake

sureaircomesouteachhole.

5. Wirebrushentireoutersurfaceofburnertoremovefood

residueanddirt.

6. Cleananyblockedportswithastiffwiresuchasanopenpaper

clip.

7. Checkburnerfordamage,duetonormalwearandcorrosion

someholesmaybecomeenlarged.Ifanylargecracksorholes

arefoundreplaceburner.

VERY IMPORTANT: Burner tubes must reengage valve

openings.

8. Carefullyreplace burners.

9. Replacecotterpinbeneatheachburner.

10. Replacegreasetrayandreceptacle,flametamers,and

cooking grates.

Cleanburnerspriortouseafter storing,atthe

beginningofgrillingseasonoraperiodof

onemonthnotbeingused.Spidersandinsectsliketo

buildnestsinburnertubes(especiallyduringcolder

months).Thesenestscancausefiresinburnertubesor

undergrill.

CA CA

UTION UTION

UTION

GeneralGrillCleaning

• Donotmistakebrownorblackaccumulationofgreaseand

smokeforpaint.Interiorsofgasgrillsarenotpaintedatthe

factory (and should never be painted).Applyastrong

solutionofdetergentandwateroruseagrillcleanerwith

scrubbrushtoinsidesofgrilllidandbottom.Rinseandallow

tocompletelyairdry. Do not apply a caustic grill/oven

cleaner to painted surfaces.

• Plastic parts:washwithwarmsoapywaterandwipedry.

Donotusecitrisol,abrasivecleaners,degreasersora

concentratedgrillcleaneronplasticparts.Damagetoand

failureofpartscanresult.

• Porcelain surfaces: because of glasslike composition,

mostresiduecanbewipedawaywithbakingsoda/water

solutionorspeciallyformulatedcleaner.Usenonabrasive

scouringpowderforstubbornstains.

• Painted surfaces:Washwithmilddetergentornonabrasive

cleanerandwarmsoapywater,wipedrywitha soft

nonabrasive cloth.

• Stainless steel surfaces:Tomaintainyourgrill'shigh

qualityappearance,washwithmilddetergentandwarm

soapywater,wipedrywithasoftclothaftereachuse.Baked

ongreasedepositsmayrequiretheuseofanabrasiveplastic

cleaning pad.

StoringYourGrill

• Clean cooking grates

• Storeindrylocation.

• WhenLPtankisconnectedtogrill,storeoutdoorsinwell

ventilatedspaceandoutofreachofchildren.

• Covergrillifstoredoutdoors.Choosefromavarietyofgrill

coversofferedbyCharBroil.

• StoregrillindoorsON LY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.

14 • 466231203

FoodSafety

• Foodsafetyisaveryimportantpartofenjoyingtheoutdoor

cookingexperience.Tokeepfoodsafefromharmful

bacteria,followthesefourbasicsteps:

Clean: Washhands,utensils,andsurfaceswithhotsoapy

waterbeforeandafterhandlingrawmeatandpoultry.

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.

Cook: Cookmeatandpoultrythoroughlytokillbacteria.Usea

thermometertoensureproperinternalfoodtemperatures.

Chill: Refrigeratepreparedfoodsandleftoverspromptly.

HowToTellIfMeatIsGrilledThoroughly

• Meatandpoultrycookedonagrilloftenbr owns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.

• Wholepoultryshouldreach180

0

F;breasts,170

0

F.Juices

shouldrunclearandfleshshouldnotbepink.

• Hamburgersmadeofanygroundmeatorpoultryshould

reach160

0

F,andbebrowni nthemiddlewithnopinkjuices.

Beef,vealandlambsteaks,roastsandchopscanbecooked

to 145

0

F.Allcutsofporkshould reach160

0

• NEVERpartiallygrillmeatorpoultryandfinishcookinglater.

Cookfoodcompletelytodestroyharmfulbacteria.

• Whenreheatingtakeoutfoodsorfullycookedmeatslikehot

dogs,grillto165

0

F,oruntilsteaminghot.

IndirectCooking

Poultryandlargecutsofmeatcookslowlytoperfectiononthe

grillbyindirectheat.Theheatfromselectedburnerscirculates

gentlythroughoutthegrill,cookingmeatorpoultrywithoutthe

touchofadirectflame.Thismethodgreatlyreducesflareups

whencookingextrafattycutsbecausethereisnodirectflameto

ignitethefatsandjuicesthatdripduringcooking.

IndirectCookingInstructions

• Alwayscookwiththelidclosed.

• Duetoweatherconditions,cookingtimesmayvary.During

coldandwindyconditionsthetemperaturesettingmay

needtobeincreasedtoinsuresufficientcooking

temperatures.

1 Burner Cooking

Cookwithdirectorindirectheat.

Bestforsmallermealsorfoods.

Consumeslessfuel.

2 Burner Cooking

Greatindirectcookingonlow.

Produces slow, even heating.

Idealforslowroastingandbaking.

466231203 • 15

Problem

Burner will not

light using ignitor.

Burners will not

match light.

Flames blow out.

Flareup.

Persistent grease

fire.

Flashback...

(fireinburnertubes)

Possible Cause

Wiresand/orelectrodecoveredwith

cooking residue.

Electrodecrackedorbroken"sparksat

crack"

Electrodetipnotinproperposition

Wiresarelooseordisconnected.

Wireisshorting(sparking)between

ignitorandelectrode.

Deadbattery.

Nogasflow.

Obstructionofgasflow.

Disengagementofburnertovalve.

Highorgustingwinds.

Greasebuildup.

Excessivefatinmeat.

Excessivecookingtemperature.

Greasetrappedbyfoodbuilduparound

burnersystem.

Burnerand/orburnertubesareblocked.

Prevention/Cure

Cleanwiresand/orelectrodewithrubbingalcoholandcleanswab.

Replace electrode(s).

MainBurners:Tipofelectrodeshouldbepointingtowardtipofcollector

box.Thedistanceshouldbe1/8"to1/4",adjustifnecessary.

Sideburner:Tipofelectrodeshouldbepointingtowardgasportopening

onburner.Thedistanceshouldbe1/8"to3/16",adjustifnecessary. 

Reconnectwiresorreplaceelectrode/wireassembly.

Replaceignitorwire/electrodeassembly.

ReplacewithanewAAbattery.

Turngasonatsource.

Clearburnertubes.

Reengageburnerandvalve.

Turnfrontofgrilltofacewindorincreaseflameheight.

Cleangrill.

Trimfatfrommeatbeforegrilling.

Adjust(lower)temperatureaccordinglyoruseindirectcooking.

TurnknobstoOFF.Turngasoffatgassource.Leavelidinposition

andletfireburnout. Aftergrillcools,removeandcleanallparts.

Cleanburnerand/orburnertubes.

Troubleshooting

16 • 466231203

A Division of W.C. Bradley Co.

P.O.Box1240

Columbus,GA319021240

Char-Broil 466231203 Owner's manual

Brand: Char-Broil

Model: 466231203

Category: Barbecues & grills

Type: Owner's manual

This manual is also suitable for

463232103

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Char-Broil 466231203 Owner's manual

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Char-Broil 466231203 Owner's manual

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