Char-Broil 4638232 Gas Grill User Manual

Natural Gas Grill
4638234
ASSEMBLY, USE AND
CARE MANUAL
THIS GRILL IS FOR
OUTDOOR USE ONLY
CAUTION: Read and follow all safety
statements, assembly instructions,
and use and care directions before
attempting to assemble and cook.
INSTALLER/ASSEMBLER: Leave
these instructions with consumer.
CONSUMER: Keep this manual for
future reference.
! WARNING
Failure to follow all manufacturer’s
instructions could result in serious
personal injury and/or property
damage.
! CAUTION
Some parts may contain sharp edges
– especially as noted in the manual!
Wear protective gloves if necessary.
If you have any questions or need
assistance during assembly, please
call 1-800-241-7548.
Visit us on the web at:
www.charbroil.com
WARNING
Combustion by-products produced when using this product contain chemicals
known to the State of California to cause cancer, birth defects, or other
reproductive harm.
4638234 / 0–4165057 (01-24-02)
WARNING
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
appliance.
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.
Installation Safety Precautions
• This grill is designed for natural gas use at 7 inch water column
supply pressure. Verify supply pressure with your local gas
company. Not for use with LP gas.
• Grill installation must conform with local codes, or in their
absence with National Fuel Gas Code, NFPA 54 / ANSI
Z223.1 or CAN/CGA-B149.1 Natural Gas Installation Code.
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 Electric 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 or 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.
Call Grill Service Center for Help and Parts
• If you need help or warranty parts call (1-800-241-7548 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.
DANGER
• Indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
Important: Fill out Warranty Information below
Warranty Information
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.
Model Number
UPC (on carton) Label Lot # GG
CAUTION
Serial Number
• Indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury.
Date Purchased
CAUTION
• For residential use only. Do not use for commercial cooking.
2 • 4638234
Table of Contents
For Your Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Call Grill Service Center for Help and Parts. . . . . . . . . . . . . 2
Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . 2
Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Connecting Your grill to the Natural Gas Source . . . . . . . . . 11
Use & Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-15
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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.
Warranty
Manufacturer warrants to the original consumerpurchaser that this product shall be free from defects in
workmanship and materials under normal and reasonable
use and correct assembly (if assembled by consumerpurchaser), as follows:
(1) The aluminum top and bottom castings for the life of
original purchase, excluding the paint finish;
(2) The burner/venturi assembly for a period of three (3)
years from the date of purchase; and
(3) All other parts for a period of one (1) year from the
date of purchase.
Manufacturer will, at its option, refinish or replace any
product or part found to be defective during the warranty
period. Manufacturer 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:
Consumer Warranty / P.O. Box 1240
Columbus, GA 31902-1240
Manufacturer 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 Manufacturer will refund the purchase price paid for the
product, less the amount directly attributable to use by the
original consumer-purchaser prior to discovery of the
nonconformity. In addition, in the state of California only, you
may take the product to the retail establishment 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 Manufacturer 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.
Manufacturer'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.
4638234 • 3
Parts List - Model 4638234
Key Qty. Description . . . . . . . . . . Part #
Key Qty. Description . . . . . . . . . . Part
A
1
Condiment Wire . . . . . 4151005
R
1
Ignitor Wire, 21” . . . . . . . 4153188
B
2
Tent Frame . . . . . . . . . 4151014
S
2
Leg Extender . . . . . . . . . 4154516
C
1
Griddle . . . . . . . . . . . . 4152038
T
1
Right Leg . . . . . . . . . . . . 4503147
D
1
Cooking Grate, 12” . . . 4152045
U
1
Left Leg. . . . . . . . . . . . . . 4503148
E
1
Cooking Grate, 15” . . . 4152046
V
2
¾” Hitch Pin . . . . . . . . . . 4156515
F
1
Chef’s Delite . . . . . . . . 4152058
W
1
Carry-over Tube . . . . . . . 4500227
X
1
Console Assembly . . . . . 4530076
G 1
Handle . . . . . . . . . . . . 4154474
Y
1
Ignitor Knob . . . . . . . . . . 4154208
H
1
Condiment Tray . . . . . 4154518
Z
1
Grill Bottom. . . . . . . . . . . 4580332
I
2
Hub Cap . . . . . . . . . . . 4154530
AA 2
Burner. . . . . . . . . . . . . . . 5068016
J
2
Wheel . . . . . . . . . . . . . 4154531
BB 1
Right Shelf . . . . . . . . . . . 4520015
-- 1
12 Ft. Hose Assy. . . . . 4158033
CC 1
Left Shelf . . . . . . . . . . . . 4520016
K
2
Burner Tent . . . . . . . . . 4500226
DD 1
Grill Top . . . . . . . . . . . . . 4580128
L
1
Upper Panel . . . . . . . . 4503119
EE 1
Shield . . . . . . . . . . . . . . . 5501038
M 1
Lower Panel . . . . . . . . 4503121
FF 2
Control Knob. . . . . . . . . . 4154507
N
2
10x1/2” Screw, Self-tap . 4080043
GG 1
Logo Plate . . . . . . . . . . . 4157147
O 2
Pivot Pin . . . . . . . . . . . 4080066
--
1
Hardware, Shelf . . . . . . . 4254010
--
1
Hardware, Swing-grid . . . 4254018
P
2
3/16 Pal Nut . . . . . . . . 4153096
--
1
Hardware, Cart . . . . . . . . 4254024
Q 1
Ignitor Wire, Main . . . . 4153184
HH 1
Grease Clip. . . . . . . . . . . 5156607
0000000
0000000000
Remove end of rating label on back of upper panel
and apply to your warranty card in box #5. If label
cannot be removed,write the numbers on your
warranty card.
This label contains the model and serial number for your grill. You should write this
information on page 2 of the LP Gas Grill Use and Care in the “Warranty Information” box.
4 • 4638234
GG
DD
G
D
F
E
K
Q
R
B
C
P
W
AA
CC
Z
EE
FF
BB
V
V
X
U
O
Y
N
N
O
I
T
A
H
L
HH
J
S
M
I
4638234 • 5
1
NOTE: To prevent scratching, lay grill on packing material to assemble.
Items to Assemble:
2 Wheels
1 Tank Bracket
2 Axle Bolts
2 Hitch Pins
2 Hub Caps
2 Control Knobs
Hub Cap
Wheel attaches
to BOTTOM HOLE
on legs
Qty: 2
2
Qty: 2
Items to Assemble:
1 Upper Panel
4 2” Carriage Bolt
4 Wing Nut, Plastic
l Lower Panel
3 2” Carriage Bolt
3 Wing Nut, Plastic
Qty:7
Plastic
Qty:7
6 • 4638234
Hub on wheel faces into leg. Attach in
bottom hole on leg with axle bolt and hitch pin.
Lower Panel inserts into Upper Panel
Upper Panell slides under Console
Lower
Panel
3
Stand Cart Upright
Items to Assemble:
1 Left Shelf
2 3/4” Carriage Bolts
2 Wing Nuts, Metal
2 Wing Screws, “AB” point
Repeat for Right Side
1 Right Shelf
2 3/4” Carriage Bolt
2 Wing Nut, Metal
2 Wing Screw, “AB” point
View looking down
Insert 3/4” Carriage Bolts into bracket
on Legs
Qty:2
Qty: 2
End has
sharp point
“AB”
Metal
Qty: 2
4
Make sure all four tabs are
inside slots before fastening
Items to Assemble:
1 Condiment Wire
1 Condiment Tray
1st
2nd
4638234 • 7
5
1st Remove styrofoam pad
Items to Assemble:
2 Tent Frames
2 Burner Tents
2 Grates
1 Griddle
Grates
1 Shield
Griddle
4th: Burner Tent
3rd: Tent Frame
2nd: Shield
6
Items to Assemble:
1 Grill Lid
2 Hinge Pin
2 Hitch Pin
Qty: 2
Hinge Pin
and Hitch Pin
Qty: 2
2nd Items to Assemble:
1 Logo Plate with clips
1 Handle
2 Wing Nuts
Qty: 2
8 • 4638234
7
Items to Assemble
1 Chef’s Delite
2 Swing Grid Bolts
2 Wing Nuts, Metal
Metal
Qty: 2
Qty: 2
8
Items to Assemble:
2 Chains with Coupling
1 Match-Holder
Attach the two chains together. Remove coupling from first chain,
See Use & Care Manual for
“Match Lighting Instructions”
Place end of chain through hole, reattach coupling to end of chain.
Thread eyelet on second chain into loop of match holder.
Back of Grill
Remove coupling from chain
Eyelet End
Match-Holder
4638234 • 9
9
Items to Assemble:
1 Grease Clip
Center of
grill bottom
Hang grease clip from center of grill bottom.
Use an empty soup can (not included) to hang from grease clip.
Grease clip
! CAUTION
• Failure to install can in clip will cause hot
grease to drip from bottom of grill with
risk of fire or property damage.
Check to make sure ALL valves are engaged
in the burner tubes and the clips are attached
(as shown). Tighten clip if needed by simply
squeezing the two long sides, A and B, of the
clip together. Clip(s) may loosen when grill is
moved, recheck each time.
View of underside of Grill Bottom
Console
Assembly
A
B
Burner Tube
10
Item to Assemble:
1 12’ Natural Gas Hose
1. On the back right side, attach 12’ natural gas hose to valve.
2. Use a wrench to hold fitting on grill. Tighten the connection with
an adjustable wrench.
3. Leak test as shown on Page 12 before using grill.
10 • 4638234
Clip
Valve
Connecting Your Grill to the Natural Gas Source
1. Coat pipe nipple with gas resistant dope. Screw socket onto
gas manifold at gas source (A).
With proper assembly, plug cannot be removed without
pushing sleeve back. To disconnect, push sleeve back and pull
plug out of sleeve (this automatically shuts off gas).
2. Connect unattached end of natural gas hose to socket. Push
sleeve back on socket (B) and insert plug until sleeve snaps
forward, locking plug into socket.
When socket and plug are connected, valve in socket opens
automatically to permit full gas flow. When coupling is
disconnected, valve in socket instantly and positively shuts off
flow of gas. Because valve in socket positively shuts off flow
of gas, grill can be disconnected from gas source by
disconnecting hose from socket. Socket can be left on
manifold of gas source if so desired.
WARNING
• Connection to gas source must be done by a certified
Plumber.
Please Note: Hose and assembly are A.G.A. Certified and
C.G.A. Listed for natural gas, manufactured gas, mixed gas
and for liquefied petroleum and for LP Gas-Air mixtures on
basis of 0.64 specific gravity for 1000 BTU’s per cubic foot of
gas at 0.3 in. Water column pressure drop. Only ANSI Z21.54
approved hoses should be used with this grill.
The appliance and its individual shut off valve must be
disconnected from the gas supply piping system during any
pressure testing of that system at test pressures in excess
of ½ psig (3.5kPa).
The appliance must be isolated from the gas supply piping
system by closing its individual manual shut off valve during
any pressure testing of the gas supply piping system at test
pressures equal to or less than ½ psi (3.5 kPa).
WARNING
• Do not use hard metal piping of any kind to connect this
type of grill to a natural gas source. Use ONLY hose
specified by manufacturer. Using hard metal piping or
convoluted metal tubing is an unsafe practice.
Movement of the grill can cause breakage of metal pipe.
A
Pipe Nipple
Socket
Sleeve
Gas
Flow
Hose
Plug
Insert cover in socket
when hose is removed
Gas Manifold
Push sleeve back to attach
B
Socket
Plug
4638234 • 11
WARNING
• 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!
Leak Testing Valve and Hose
1. Turn all grill control knobs to OFF.
2. Check to make sure grill is connected to natural gas source
and gas supply is turned on.
3. Brush a soapy solution onto areas and connections shaded
In illustration below.
4. “If growing” bubbles appear, there is a leak. Turn gas off at
control knobs and gas source 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 Grill Service Center at 1-800-241-7548.
Safety Tips
s When grill is not in use, turn off all control knobs and gas
source.
s Never move grill while in operation or still hot.
s Use long-handled barbecue utensils to avoid burns and
splatters.
s Maximum load for side shelves is 10 lbs.
s A soup can must be attached to grease clip and emptied
after each use. Do not remove soup can until grill has
completely cooled.
s If you notice grease or other hot material dripping from grill
onto valve or hose, turn off gas supply at once. Determine
the cause, correct, clean and inspect valve and hose before
continuing. Perform a leak test.
s If you have a grill problem see the "Troubleshooting
Section".
12 • 4638234
WARNING
For Safe Use of Your Grill and to Avoid
Serious Injury:
Do not let children operate or play near grill.
Keep grill area clear and free from materials that burn.
Do not block holes in bottom or back of grill.
Check burner flames regularly.
Use grill only in well-ventilated space. NEVER use in
enclosed space such as carport, garage, porch, covered
patio, or under a surface that can catch fire.
• Do not use charcoal in a gas grill.
•
•
•
•
•
• Use grill at least 3 ft. from any
wall or surface. Maintain 10 ft.
clearance to objects that can catch
fire or sources of ignition such as
pilot lights on water heaters, live
electrical appliances, etc.
• Apartment Dwellers:
Check with management to learn the requirements and fire
codes for using a 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.
CAUTION
• Putting out grease fires by closing the lid is not
possible. Grills are well ventilated for safety reasons.
• Do not use water on a grease fire. Personal injury may
result. If a grease fire develops turn knobs and gas
source off.
• Do not leave grill unattended while preheating or
burning off food residue on high. If grill has not been
regularly cleaned a grease fire can occur that may
damage the product.
Before Your First Cookout
• Light burners, check to make sure they are lit, close the lid
and warm up grill on HIGH for 15 minutes. Curing of paint and
parts will produce an odor only on first lighting.
Ignitor Lighting
s Do not lean over grill while lighting.
1. Open lid during lighting. Turn on gas at gas source.
2. To ignite any burner, turn burner knob to HI, turn
ROTARY IGNITOR button rapidly.
3. If ignition does NOT immediately take place, turn all burner
valve knobs to OFF, wait 5 minutes, then repeat lighting
procedure.
Valve Check
• Important: Make sure gas is OFF at gas source before
checking valves. Knobs lock in OFF position. To check
valves, first push in knobs and release, knobs should spring
back. If knobs do not spring back, replace valve assembly
before using grill. Turn knobs to LOW position then turn back
to OFF position. Valves should turn smoothly.
Hose Check
After Lighting warm up on HI
• Before each use, check to see if hose is cut or worn. Replace
damaged hoses before using grill. Use only valve and hose
specified by manufacturer.
Match Lighting
s Do not lean over grill while lighting.
1. Open lid. Turn on gas at gas source.
2. Attach match to Match holder, light match.
3. Push in and turn any burner to HI. Be sure burner
lights and stays lit. Repeat on other burner.
CAUTION
Clean burner prior to use after storing, at the beginning
of the grilling season or after 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.
Typical spider webs
See following pages for specific
inside burner
cleaning instructions.
After Lighting warm up on HI.
Left side of Grill
Match lighting hole
General Grill Cleaning
CAUTION
• If burner does not light, turn knobs to OFF. Wait 5
minutes and try again. If the burner does not ignite with
valve open, gas will continue to flow out of the burner
and could accidently ignite with risk of injury.
Burner Flame Check
HIGH
• Light burner, rotate knobs
LOW
from HIGH to LOW. You
should see a smaller flame in
LOW position than seen on HIGH. Always check flame prior to
each use. If only low flame is seen refer to "Sudden drop or
low flame" in the Troubleshooting Section.
Turning Grill Off
• Turn all knobs to OFF position. Turn gas OFF at gas source.
• 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.
s Do not use citrisol, abrasive cleaners, degreasers or a
concentrated grill cleaner on plastic parts. Damage to and
failure of parts can result.
• Porcelain grate: 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.
• Stainless Steel: Wash with mild detergent or nonabrasive
cleaner and warm soapy water, wipe dry with a soft
nonabrasive cloth
Ignitor Check
• Turn gas off at gas source. Rotate ignitor button rapidly.
"Click" should be heard and spark seen each time between
collector box or burner and electrode. See "Troubleshooting" if
no click or spark.
4638234 • 13
Cleaning the Burner Assembly
Follow these instructions to clean and/or replace parts of burner
assembly or if you have trouble igniting grill.
Turn gas off at control knobs and gas source.
Remove cooking grates, burner tents and tent frames.
Under grill remove soup can from grease clip.
Beneath grill bottom remove ignitor wires by pulling down
on ceramic insulator (A).
5. Under console disengage (A) clips by lightly pushing clip on
burner tube away from you and pull down. Remove burners
and shield from grill bottom.
6. Wipe ceramic electrodes (A) with rubbing alcohol and cloth.
7. Clean burners exterior with soap and water. Lay burners on
flat surface, insert garden hose (preferably with nozzle), into
burner tubes forcing water through tubes. Make sure water
comes out of every porthole. Open clogged portholes with a
thin wire. Shake out excess water and examine portholes.
Due to normal wear and corrosion some portholes may
become enlarged, if so replace burner. If any horizontal
cracks appear from porthole to porthole or large holes (other
than portholes) are found replace burner. Use a wire brush
to clean carry-over tube.
1.
2.
3.
4.
8. If grill is to be stored, coat burners lightly with cooking oil.
Wrap in protective cover to keep insects out. If not storing
use following steps.
9. Place shield into bottom of grill then burners. Attach burners
into valves, under grill bottom reattach clips.
VERY IMPORTANT: Burner tubes must engage valve
openings as shown.
10. Attach ceramic insulators with ignitor wire to burners.
11. Reposition cooking grates, tent frames and burner tents.
Reattach soup can to grease clip under grill bottom.
12. Before cooking again on grill, follow “Burner Flame Check”.
Burner
Tube
Valve
Ceramic
Insulator
A
Clip
14 • 4638234
Cooking Chart
Food Safety
Cooking times and temperatures may vary according to specific
recipes, cooking conditions or barbecue equipment used. Take
these factors into consideration to insure best results. If you use
the indirect cooking method (lighting only one burner and placing
food on opposite side of cooking grate), allow more grilling time.
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.
Temperatures: High = 650 F° / Medium = 450 F° / Low = 300 F°
Food
Setting
Cooking Time
Beef
Hamburger ½” thick
Medium
Med: 7-10 min/Well: 10-15 min
Steak ½”
Medium-Hot
Rare: 3-6 min/Med: 6-9 min/Well: 9-12 min
Roast
Low
Rare: 18-22 min per lb/Med: 22-28 min
per lb/Well: 28-32 min per lb
Pork
Chops ½”
Medium
Well: 15-20 min
Ribs 5-6 lbs.
Low-Medium Well: 45-90 min
Roast 3-5 lbs.
Low-Medium Well: 18-23 min per lb
Ham Steak ½”
Medium-Hot
Poultry
Chicken 2½-3½ lbs.
Medium
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 safe internal temperature, and cut into food to
check for visual signs of doneness.
•
Whole poultry should reach 180 F°; breasts, 170 F°. Juices
should run clear and flesh should not be pink.
•
Hamburgers made of any ground meat or poultry should
reach 160 F°, and be brown in the middle with no pink
juices. Beef, veal and lamb steaks, roasts and chops can be
cooked to 145 F°. All cuts of pork should reach 160 F°.
•
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 F°, or until steaming hot.
12-15 min
Ham 5 lb. fully cooked Low-Medium 20 min per lb
Lamb
Chops ½”
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
6-12 min
Low
1 hr, 15 min to 1 hr, 30 min
Chicken halved or
quartered
Low
40-60 min
Turkey
Low-Medium 18-20 min per lb
Seafood
Steaks 1” thick
Medium-Hot
Well: 10-15 min
Fillets 6-8 oz.
Medium-Hot
8-12 min
Shrimp large or jumbo Low-Medium 8-12 min
Storing Your Grill
Venison
Steak 1” thick
Medium
Rare: 8-10 min/Med: 10-12 min
Burgers ½”
Medium
Rare: 10-12 min/Med: 12-15 min
Roast 3-4 lbs.
Low-Medium Rare: 20-22 min per lb/Med: 22-25 min per lb
•
•
•
•
Vegetables
Wrap vegetables in foil
•
Baking potato, whole
Low
55-60 min
Onions, whole
Low
45 min
Tomatoes, half
Medium
30-40 min
Corn, whole
Low
35-45 min
Mushrooms
Medium
15-20 min
Clean cooking grate and discard old briquets.
Store in dry location.
Cover grill if stored outdoors. Choose from a variety of grill
covers offered by Char-Broil.
Storage of grill indoors is permissible ONLY if gas source is
disconnected.
When removing grill from storage, follow “Cleaning Burner
Assembly” instructions before starting grill.
4638234 • 15
Troubleshooting
Problem
Possible Cause
Prevention/Cure
Burner will not light
using ignitor.
Wire covered with cooking
residue.
Clean wires with rubbing alcohol and clean swab.
Electrode and burner are wet.
Wipe dry with cloth.
Electrode cracked or broken,
“sparks at crack”.
Replace burner.
Wire is loose or disconnected.
Reconnect or replace ignitor wire.
Wire is shorting (sparking)
between ignitor and electrode.
Replace ignitor wire.
Bad ignitor.
Replace burner.
No gas flow.
Turn gas on at source.
Obstruction of gas flow.
Clean burner tubes.
Disengagement of burner to
valve.
Reengage burner and valve.
Is grill assembled correctly?
Check assembly steps in manual.
Flames blow out.
High or gusting winds.
Turn front of grill to face wind or increase flame height.
Flare-up.
Grease buildup.
Clean grill.
Excessive fat in meat.
Trim fat from meat before grilling.
Burner(s) will not
match light.
Excessive cooking temperature. Adjust (lower) temperature accordingly.
Persistent grease
fire (can damage
the appearance of
steel panels and
aluminum castings
on the grill).
Grease trapped by food
buildup around burner system.
Flashback...
Burner tubes are blocked.
(fire in burner tube(s)
16 • 4638234
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 tubes.