Char-Broil | 4984619 | Product guide | Char-Broil 4984619 Product guide

PRODUCT GUIDE
MODEL 463240613
Char-Broil Modular Stove Top Cart
IMPORTANT: Fill out the product record information below.
Serial Number
See rating label on grill for serial number.
Date Purchased
For support and to register your
grill, please visit us at
www.charbroil.com
If you have questions or need
assistance during assembly,
please call 1-800-241-7548.
© 2013 Char-Broil, LLC Columbus, GA 31902
Printed in China
Assembly instructions © 2013
11/20/12 • G250-001-020801
TABLE OF CONTENTS
DANGER
For Your Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Use and Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Limited Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Parts Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-20
If you smell gas:
1.
2.
3.
4.
Shut off gas to the appliance.
Extinguish any open flame.
Open lid.
If odor continues, keep away from the
appliance and immediately call your gas
supplier or your fire department.
Conversion Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-24
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-27
Registration Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Safety Symbols
The symbols and boxes shown below explain what each heading
means. Read and follow all of the messages found throughout
the manual.
WARNING
WARNING: Indicates a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
CAUTION
CAUTION: Indicates a potentially hazardous situation or
unsafe practice which, if not avoided, may result in minor
or moderate injury.
DANGER
DANGER: Indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
INSTALLER/ASSEMBLER:
Leave this manual with consumer.
CONSUMER:
Keep this manual for future reference.
WARNING
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.
WARNING
Failure to follow all manufacturer’s instructions could
result in serious personal injury and/or property damage.
CAUTION
For residential use only. Do not use for commercial
cooking.
CAUTION
Read and follow all safety statements, assembly
instructions, and use and care directions before
attempting to assemble and cook.
CAUTION
Some parts may contain sharp edges.
Wear protective gloves if necessary.
THIS GRILL IS FOR OUTDOOR USE ONLY.
2
WARNING
CALIFORNIA PROPOSITION 65
1. Combustible by-products produced when using
this product contains chemicals known to the State
of California to cause cancer, birth defects, or
other reproductive harm.
2. This product contains chemicals, including lead
and lead compounds, known to the State of
California to cause cancer, birth defects or
other reproductive harm.
Wash your hands after handling this product.
Installation Safety Precautions
• Use grill, as purchased, only with LP (propane) gas and the
regulator/valve assembly supplied. If your grill is Dual Fuel ready,
a conversion kit must be purchased for use with natural gas.
• Grill installation must conform with local codes, 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, CSA B149.1, or Propane Storage and
Handling Code, B149.2.
• 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/or
Canada only. Do not modify for use in any other location.
Modification will result in a safety hazard.
CAUTION
Grease Fires
• 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.
• If grill has not been regularly cleaned, a grease fire can
occur that may damage the product. Pay close attention
while preheating or burning off food residue to insure
that a grease fire does not develop. Follow instructions
on General Grill Cleaning and Cleaning The Burner
Assembly to prevent grease fires.
• The best way to prevent grease fires is regular cleaning
of the grill.
WARNING
Do not attempt to repair or alter the
hose/valve/regulator for any “assumed” defect. Any
modification to this assembly will void your warranty
and create the risk of a gas leak and fire. Use only
authorized replacement parts supplied by
manufacturer.
NOTE: DO NOT over tighten screws and washers that
come into contact with porcelain coated surfaces. Over
tightening may cause the porcelain coating to crack and
break, resulting in exposed metal that will be prone to rust.
3
USE AND CARE
DANGER
• NEVER store 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 improperly stored cylinder is a
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,
immediately get away from the LP
cylinder/appliance and call your fire department.
LP Cylinder Removal, Transport and Storage
•Turn OFF all control knobs and LP cylinder valve. Turn coupling
nut counterclockwise by hand only - do not use tools to
disconnect. Loosen cylinder screw beneath bottom shelf or
disconnect other retention means, then lift PL cylinder up and
and out of cart. Install safety cap onto LP cylinder 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.
•A disconnected LP cylinder in LP Cylinder Valve
storage or being transported
must have a safety cap installed (as shown).
Do not store an LP cylinder in enclosed spaces
such as a carport, garage, porch, covered
Safety
patio or other building. Never leave an LP cylinder
Cap
inside a vehicle which may become overheated
Retainer Strap
by the sun.
•Do not store an LP cylinder in an area where children play.
4
LP Cylinder
•The LP cylinder 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) or for Canada, CAN/CSA-B339,
cylinders, spheres and tubes for transportation of dangerous
goods. Transport Canada (TC). See LP cylinder collar for
marking.
•LP cylinder valve must have:
•Type 1 outlet compatible with
regulator or grill.
•Safety relief valve.
OPD Hand Wheel
•UL listed Overfill Protection
Device (OPD). This OPD safety
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 cylinder in upright position for vapor withdrawal
LP (Liquefied Petroleum Gas)
•LP gas is nontoxic, odorless and colorless when produced. For
Your Safety, LP gas has been given an odor (similar to rotten
cabbage) so that it can be smelled.
•LP gas is highly flammable and may ignite unexpectedly when
mixed with air.
LP Cylinder Filling
•Use only licensed and experienced dealers.
•LP dealer must purge new cylinder before filling.
•Dealer should NEVER fill LP cylinder more than 80% of LP
cylinder volume. Volume of propane in cylinder will vary by
temperature.
•A frosty regulator indicates gas overfill. Immediately close 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.
•To remove gas from LP cylinder, contact an LP dealer or call a
local fire department for assistance. Check the telephone
directory under “Gas Companies” for nearest certified LP
dealers.
LP Cylinder Exchange
Connecting Regulator to the LP Cylinder
•Many retailers that sell grills offer you the option of replacing
your empty LP cylinder through an exchange service. Use only
those reputable exchange companies that inspect, precision fill,
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.
1.LP cylinder must be properly secured onto grill. (Refer to
assembly section.)
•Always keep new and exchanged LP cylinders in upright
position during use, transit or storage.
•Leak test new and exchanged LP cylinders BEFORE
connecting to grill.
•Place dust cap on cylinder valve outlet whenever the cylinder is
not in use. Only install the type of dust cap on the cylinder valve
outlet that is provided with the cylinder valve. Other types of caps
or plugs may result in leakage of propane.
4.Remove the protective cap from LP cylinder valve. Always use
cap and strap supplied with valve.
2.Turn all control knobs to the OFF position.
3.Turn LP cylinder OFF by turning hand-wheel clockwise to a
full stop.
Off
Clockwise
OPD Hand Wheel
LP Cylinder Leak Test
For your safety
•Leak test must be repeated each time LP cylinder 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 tested outdoors in a well-ventilated area,
away from ignition sources such as gas fired or electrical
appliances. During leak test, keep grill away from open flames
or sparks.
•Use a clean paintbrush and a 50/50 mild soap and water
solution. Brush soapy solution onto areas indicated by arrows
in figure below.
▲ Do not use household cleaning agents. Damage to gas
train components can result.
Type 1 outlet with
thread on outside
Safety Relief Valve
Strap and Cap
Do not use a POL transport plug
(plastic part with external threads)!
It will defeat the safety feature of
the valve.
5.Hold regulator and insert nipple into LP
cylinder valve. Hand-tighten the
coupling nut, holding regulator in a
straight line with LP cylinder valve so
as not to cross-thread the connection.
Nipple has to be centered
into the LP cylinder valve.
WARNING
If “growing” bubbles appear do not use or move the LP
cylinder. Contact an LP gas supplier or your fire
department!
5
Leak Testing Valves, Hose and Regulator
1.Turn all grill control knobs to OFF.
2.Be sure regulator is tightly connected to LP cylinder.
Str
aig
ht
Hold coupling nut and regulator
as shown for proper connection
to LP cylinder valve.
3.Completely open LP cylinder valve by turning hand wheel
counterclockwise. If you hear a rushing sound, turn gas off
immediately. There is a major leak at the connection. Correct
before proceeding.
4.Brush soapy solution onto areas circled below, or other similar
fittings on your grill.
6.Turn the coupling nut clockwise and tighten to a full stop. The
regulator will seal on the back-check feature 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!
DANGER
• Do not insert any tool or foreign object into the valve
outlet or safety relief valve. You may damage the valve
and cause a leak. Leaking propane may result in
explosion, fire, severe personal injury, or death.
WARNING
• Outdoor gas appliance is not intended to be installed
in or on a boat.
• Outdoor gas appliance is not intended to be installed
in or on an RV.
• Never attempt to attach this grill to the self-contained
LP gas system of a camper trailer or motor home.
• Do not use grill until leak-tested.
• If a leak is detected at any time, STOP and call the fire
department.
• If you cannot stop a gas leak, immediately close
LP cylinder valve and call LP gas supplier or your fire
department!
6
NOTE: Sideburner
shelf fascia not
shown for clarity.
NOTE: Your grill
may NOT be
equipped with a
sideburner.
5.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.
6.Always close LP cylinder valve after performing leak test by
turning hand wheel clockwise.
Safety Tips
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 sides or back of grill.
• Check burner flames regularly, through viewing ports.
• Use grill only in well-ventilated space. NEVER use in
enclosed space such as carport, garage, porch,
covered patio, or under an overhead structure of any
kind.
• Do not use charcoal or ceramic briquets in a gas grill.
(Unless briquets are supplied with your 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.
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
Before opening LP cylinder valve, check the coupling nut for
tightness.
When grill is not in use, turn off all control knobs and LP
cylinder valve.
Never move grill while in operation or still hot.
Use long-handled barbecue utensils and oven mitts to avoid
burns and splatters.
Maximum load for sideburner and side shelf is 10 lbs.
The grease tray must be inserted into grill and emptied after
each use. Do not remove grease tray until grill has
completely cooled.
Clean grill often, preferably after each cookout. If a bristle
brush is used to clean any of the grill cooking surfaces,
ensure no loose bristles remain on cooking surfaces prior to
grilling. It is not recommended to clean cooking surfaces
while grill is hot.
If you notice grease or other hot material dripping from grill
onto valve, hose or regulator, turn off gas supply at once.
Determine the cause, correct it, then clean and inspect valve,
hose and regulator before continuing. Perform a leak test.
Keep ventilation openings in cylinder enclosure (grill cart) free
and clear of debris.
Do not store objects or materials inside the grill cart
enclosure that would block the flow of combustion air to the
underside of either the control panel or the firebox bowl.
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".
If the regulator frosts, turn off grill and LP cylinder valve
immediately. This indicates a problem with the cylinder and it
should not be used on any product. Return to supplier!
Griddle Burner Ignitor Lighting
Do not lean over griddle while lighting.
1. Turn burner control valve to the
(OFF) position.
2. Turn ON gas at LP cylinder.
3. Open lid and leave open.
4. Turn the main burner control valve knob to the position .
5. Push and hold ELECTRONIC IGNITOR button the burner lights.
Verify burner flame through match lighting hole.
6. If Ignition does not occur in 5 seconds, turn the burner
controls to the
(OFF) position, wait 5 minutes, and repeat the
lighting procedure.
▲
• Apartment Dwellers:
Check with management to learn the requirements
and fire codes for using an LP gas grill in your
apartment complex. If allowed, use outside on the
ground floor with a three (3) foot clearance from walls
or rails. Do not use on or under balconies.
• NEVER attempt to light burner with lid closed. A
buildup of non-ignited gas inside a closed grill is
hazardous.
• 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.
If ignition still not occur, follow match-lighting instructions.
WARNING: Top cover must be open when burner
is in operation.
7
WARNING
Turn controls and gas source or tank OFF when not
in use.
CAUTION
If ignition does NOT occur in 5 seconds, turn the
burner controls OFF, wait 5 minutes and repeat the
lighting procedure. If the burner does not ignite with
the valve open, gas will continue to flow out of the
burner and could accidently ignite with risk of injury.
Stove Top burner Match Lighting
1. Turn all burner control valves to the
(OFF) position.
2. Open lid and leave open. Turn ON gas at LP cylinder.
3. Place match into match holder (inside door.)
Light match, place match near burner.
4.Turn burner knob to the
(HIGH) position,
Be sure burner lights and stays lit.
5. If burner does not light, turn knob to the
(OFF) position,
wait 5 minutes, then repeat lighting procedure.
Griddle Burner Match-Lighting
▲ Do not lean over grill while lighting.
1.Turn burner control valve to the
(OFF) position.
2.Open lid and leave open. Turn ON gas at LP cylinder.
3.Place match into match holder (inside door.)
Light match, place into match lighting opening.
4.Push in and burner knob to position. Be sure
burner lights and stays lit. Verify burner flame through
match light opening.
5.If ignition does NOT occur in 5 seconds, turn the burner
control knob to
(OFF) position, wait 5 minutes, and
repeat the match lighting procedure.
Match Light Opening
Burner Flame Check
• Remove cooking grates and troughs. Light burners, rotate
knobs from the HI position to the LOW position. You should
see a smaller flame in the LOW position than seen on the
HI position. Perform burner flame check
on sideburner, also. Always check flame prior to each use. If
only low flame is seen refer to "Sudden drop or low flame" in
the Troubleshooting Section.
HI position
LOW position
Turning Griddle / Stove Top Off
• Turn all knobs to the OFF position. Turn LP cylinder off by
turning hand-wheel clockwise to a full stop.
Ignitor Check
Stove Top burner Ignitor Lighting
▲
Do not lean over grill while lighting.
1. Turn all burner control valve to the
(OFF) position
• Turn gas OFF at LP cylinder. Press and hold electronic ignitor
button. "Click" should be heard and spark seen each time
between each collector box or burner and electrode. See
"Troubleshooting" if no click or spark.
Valve Check
2. Open lid and leave open. Turn ON gas at LP cylinder.
3. Turn burner knob to the (HIGH) position, push and hold
the ELECTRONIC IGNITOR button.
4. Once burner has ignited, turn knob to desired setting.
• Important: Make sure gas is OFF at LP cylinder 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.
5. If burner does not light, turn knob to the
(OFF) position,
wait 5 minutes, then repeat lighting procedure.
Hose Check
WARNING: Top cover must be open when burner
is in operation.
8
• Before each use, check to see if hoses are cut or worn.
Replace damaged hoses before using stove top. Use only
valve/hose/regulator specified by manufacturer.
CAUTION
SPIDER ALERT!
SPIDER AND WEBS
INSIDE BURNER
If your griddle/stove top is getting hard to light
or the flame is weak, check and clean the
venturis and burners.
• Stainless steel surfaces: To maintain 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 use of an abrasive plastic cleaning
pad. Use only in direction of brushed finish to avoid damage.
Do not use abrasive pad on areas with graphics.
• Cooking surfaces: If a bristle brush is used to clean any of
the grill cooking surfaces, ensure no loose bristles remain on
cooking surfaces prior to grilling. It is not recommended to
clean cooking surfaces while grill is hot.
Storing Your Griddle / Stove Top Burner
• Clean cooking grate / griddle.
• Store in dry location.
• When LP cylinder is connected to stove top, store outdoors in a
well ventilated space and out of reach of children.
• Cover stove top if stored outdoors. Choose from a variety of grill
covers offered by manufacturer.
• Store grill indoors ONLY if LP cylinder is turned off and
disconnected, removed from grill and stored outdoors.
• When removing grill from storage, follow “Cleaning the Burner
Assembly” instructions before starting the stove top.
General Griddle / Stove Top Burner 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
on insides of grill lid and bottom. Rinse and allow to completely
air dry. Do not apply a caustic grill/oven cleaner to painted
surfaces.
• 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.
9
Cleaning the Burner Assembly
Follow these instructions to clean and/or replace parts of burner
assembly or if you have trouble igniting stove top.
1. Turn gas OFF at control knobs and LP cylinder.
2. Remove screws that hold orifice holder with the burner
venturi. Figure A
3. Remove cooking grate.
4. Remove wing nuts from inside cart to disengage it.
Figure B
5. Carefully lift up the burner enough to expose the electrode
wire. Detach wire from electrode underneath the burner
6. Carefully take out the burner to clean. Figure C
7. While cleaning, make sure that the ignitor wire is not bent
or broken.
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
venturi tube several times.
8.
9.
A
10.
Burner Venturi
(B) Use a narrow bottle brush with a flexible handle (do not
use a brass wire brush), run the brush through each
burner venturi tube several times.
(C) Wear eye protection: Use an air hose to force air into
the burner tube and out the burner ports. Check each
port to make sure air comes out each hole.
Wire brush entire outer surface of burner to remove food
residue and dirt.
Clean any blocked ports with a stiff wire such as an open
paper clip.
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 venturi must be attached with orifice
holder properly. see illustration below.
NOTE:
Remove
Screws
View from under firebox
Correct
engagement
NOTE:
Reinstall
Screws
B
12.
13.
14.
Remove three Wing Nuts
from inside cart
C
10
15.
After cleaning put the burner back into the firebox and attach
the electrode wire onto the electrode connector under the
burner.
Place burner into position and reinstall the wing nuts.
Under the firebox, attach the orifice holder with the venturi tube.
with the screws previous removed.
Replace the cooking grate.
NOTES
11
LIMITED WARRANTY
This warranty only applies to units purchased from an authorized retailer. Manufacturer warrants to the original consumer-purchaser only that this
product shall be free from defects in workmanship and materials after correct assembly and under normal and reasonable home use for the periods
indicated below beginning on the date of purchase*. The manufacturer reserves the right to require that defective parts be returned, postage and or
freight pre-paid by the consumer for review and examination.
SCOPE OF COVERAGE
Stainless Burner
All Other Parts
PERIOD OF COVERAGE
5 years from date of purchase*
1 year from date of purchase*
TYPE OF FAILURE COVERAGE
PERFORATION, MANUFACTURING,
AND MATERIAL DEFECTS ONLY
*Note: A dated sales receipt WILL be required for warranty service.
The original consumer-purchaser will be responsible for all shipping charges for parts replaced under the terms of this limited warranty.
This limited warranty is applicable in the United States and Canada only, is only available to the original owner of the product and is not transferable.
Manufacturer requires proof of your date of purchase. Therefore, you should retain your sales slip or invoice. Registering your product is not a
substitute for proof of purchase and the manufacturer is not responsible for or required to retain proof of purchase records.
This limited warranty applies to the functionality of the product ONLY and does not cover cosmetic issues such as scratches, dents, corrosions or
discoloring by heat, abrasive and chemical cleaners or any tools used in the assembly or installation of the appliance, surface rust, or the
discoloration of stainless steel surfaces. RUST is not considered a manufacturing or materials defect.
This limited warranty will not reimburse you for the cost of any inconvenience, food, personal injury or property damage.
ITEMS MANUFACTURER WILL NOT PAY FOR:
1. Shipping cost, standard or expedited, for warranty and replacement parts
2. Service calls to your home.
3. Repairs when your product is used for other than normal, single-family household or residential use.
4. Damage, failures, or operating difficulties resulting from accident, alteration, careless handling, misuse, abuse, fire, flood,
acts of God, improper installation or maintenance, installation not in accordance with electrical or plumbing codes, or use
of products not approved by the manufacturer.
5. Any food loss due to product failures or operating difficulties.
6. Replacement parts or repair labor costs for units operated outside the United States or Canada.
7. Pickup and delivery of your product.
8. Repairs to parts or systems resulting from unauthorized modifications made to the product.
9. The removal and/or reinstallation of your product.
DISCLAIMER OF IMPLIED WARRANTIES and LIMITATION OF REMEDIES
Repair or replacement of defective parts is your exclusive remedy under the terms of this limited warranty. In the event of parts availability issues,
the manufacturer reserves the right to substitute like or similar parts that are equally functional.
Manufacturer will not be responsible for any consequential or incidental damages arising from the breach of either this limited warranty or any
applicable implied warranty, or for failure or damage resulting from acts of God, improper care and maintenance, grease fire, accident, alteration,
replacement of parts by anyone other than Manufacturer, misuse, transportation, commercial use, abuse, hostile environments (inclement weather,
acts of nature, animal tampering), improper installation or installation not in accordance with local codes or printed manufacturer instructions.
THIS LIMITED WARRANTY IS THE SOLE EXPRESS WARRANTY GIVEN BY THE MANUFACTURER. NO PRODUCT PERFORMANCE
SPECIFICATION OR DESCRIPTION WHEREVER APPEARING IS WARRANTED BY MANUFACTURER EXCEPT TO THE EXTENT SET
FORTH IN THIS LIMITED WARRANTY. ANY IMPLIED WARRANTY PROTECTION ARISING UNDER THE LAWS OF ANY STATE,
INCLUDING IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR USE, IS HEREBY
LIMITED IN DURATION TO THE DURATION OF THIS LIMITED WARRANTY.
Neither dealers nor the retail establishment selling this product has any authority to make any additional warranties or to promise remedies
in addition to or inconsistent with those stated above. Manufacturer's maximum liability, in any event, shall not exceed the purchase price of the
product paid by the original consumer.
NOTE: Some states do not allow an exclusion or limitation of incidental or consequential damages, so some of the above limitations or exclusions
may not apply to you. This limited warranty gives you specific legal rights as set foth herein. You may also have other rights which vary from state
to state. In the state of California only, if refinishing or replacement of the product is not commercially practicable, the retailer selling this product or
the Manufacturer will refund the purchase price paid for the product, less the amount directly attributable to use by the original consumer-purchaser
prior to discovery of the nonconformity. In addition, in the state of California only, you may take the product to the retail establishment selling this
product in order to obtain performance under this limited warranty.
If you wish to obtain performance of any obligation under this limited warranty, you should
write to:
Consumer Relations
P. O. Box 1240
Columbus, GA 31902-1240
Consumer returns will not be accepted unless a valid Return Authorization is first acquired. Authorized returns are clearly marked on the outside of
the package with an RA number and the package is shipped freight/postage pre-paid. Consumer returns that do not meet these standards will be
refused.
12
PARTS LIST
Key
Qty Description
NOT Pictured
A
1
TOP LID
…
1
NATURAL GAS ORIFICE KIT
B
4
RUBBER BUMPER, ROUND
…
1
CASTER PIN
C
1
FIREBOX
…
1
HARDWARE PACK
D
1
BURNER
…
1
ASSEMBLY MANUAL, ENGLISH
E
1
ELECTRODE, F/ BURNER
…
1
ASSEMBLY MANUAL, SPANISH
F
1
CONTROL PANEL
G
1
HOSE VALVE REGULATOR ASSEMBLY
H
1
BEZEL, F/ CONTROL KNOB
I
1
CONTROL KNOB
J
1
IGNITER SWITCH MODULE
K
2
TOP LID HINGE, STRAIGHT
L
2
TOP LID HINGE, BENT
M
1
1
GRATE
N
LEFT SIDE CART PANEL
O
1
DOOR MAGNET ASSEMBLY
P
2
MAGNET ASSEMBLY
Q
1
RIGHT SIDE CART PANEL
R
1
BOTTOM SHELF
S
1
TANK SCREW
T
2
CASTER, LOCKING
U
2
CASTER, FIXED
V
1
CART LOWER BACK PANEL
W
1
FRONT BRACE
X
1
DOOR, NO HANDLE
Y
1
HANDLE, F/ DOOR
Z
1
MATCH HOLDER
AA
1
ELECTRONIC IGNITION MODULE
BB
1
CAP F/ EI MODULE
CC
1
TANK EXCLUSION
NOTE: Some grill parts shown in the assembly steps may differ slightly in appearance from
those on your particular grill model. However, the method of assembly remains the same.
13
PARTS DIAGRAM
C
A
M
F
B
G
E
D
K
L
CC
W
I
H
J
V
AA
O
Y
Z
BB
P
R
N
Q
T
X
U
14
S
ASSEMBLY
1
Place bottom shelf upside down. Insert Caster Pin into the caster mounting plate to lock it in place, shown A. Spin the casters
clockwise into the threads on the bottom shelf until secure. Remove the Caster Pin and repeat for remaining casters. Make
sure the two locking casters are secured at the rear and the non-locking casters are secured at the front. After all 4 casters
are secured remove the Caster Pin and save for future maintenance.
Non-locking caster (Front)
A
Locking caster (Rear)
Caster pin
Front
Bottom shelf
Rear
2
Attach side panels to bottom shelf using three 1/4-20x1/2” screws per panel.
IMPORTANT: Panel with magnet must be on Left side of bottom shelf.
1/4-20x1/2"
screw
Left side panel
Magnet
Right side panel
Front
15
3
Insert front brace between cart panels. Make sure door hinge pin is on the top side and facing the front. Secure front brace
using two 1/4-20x1/2” screws on each side.
Front brace
1/4-20x1/2"
screw
Right side panel
Left side panel
Rear
4
This step requires two people to lift and position stove top onto cart. Carefully lower the stove top onto the cart,
Attach stove top to cart with four 1/4-20x1/2" screws. Make sure the regulator and ignitor wires are hanging inside the cart.
Grill head
1/4-20x1/2"
screw
Regulator
1/4-20x1/2"
screw
Ignitor wire
Cart
16
5
Connect the wire from burner electrode into the back of Electronic ignition module, positions 1. Connect the two wires [(a) and
(b)] from switch wiring harness into the back of Electronic ignition module.
NOTE: Switch terminals are larger than electrode terminal and should only be installed in location shown as (a),(b).
Release cap and nut from electronic ignition module. Attach Electronic ignition module to front brace with the nut. Insert AAA
battery into module, negati v e (-) end first. Replace the cap.
Back of electronic ignition module
AAA battery
Front brace
Nut
(-)
1
(+)
(a) (b)
Cap
Electronic ignition module
6
On back of the stove top, attach back panel to cart side panels using four #8x3/8" self-tapping screws.
#8x3/8"self-tapping
screw
Back panel
17
7
Attach tank exclusion wire to back panel and front brace using two #8-32x3/8" screws and #8-32 nuts.
Back panel
#8-32x3/8"
screw
Tank exclusion wire
#8-32 nut
Note: some parts omitted
for clarity of illustration
#8-32 nut
Front brace
#8-32x3/8"
screw
8
Attach door handle to door using two #10-24x3/8" screws.
#10-24x3/8"
screw
Door handle
Door
18
9
10
Place cooking grate on the stove top as shown, align grate legs into
matching slots in the stove top.
Insert hinge pin on bottom of door into hole in bottom shelf. Press upper hinge pin in front brace, align hinge hole on top of
door and release hinge pin into door.
Front brace
PRESS
Top of
door
Hinge pin
on bottom
of door
Bottom shelf
19
LP CYLINDER IS SOLD SEPARATELY. Fill and leak check the cylinder before attaching to grill and regulator (see Use & Care
section). Once cylinder has been filled and leak checked, place cylinder into hole in bottom shelf. Make sure cylinder valve
is facing front of grill. Secure cylinder with cylinder screw under bottom shelf.
See Use & Care section of this manual to perform the burner Flame Check and for important safety instructions before using.
11
Cylinder screw at rear of cart
Cylinder screw
Always keep LP cylinders in upright position during
use, transport and storage.
CAUTION
Regulator
LP Cylinder
(not included)
Cylinder valve must face to front of cart once
tank is attached. Failure to install cylinder
correctly may allow gas hose to be damaged
in operation, resulting in the risk of fire.
12
OPTIONAL
Attaching the Griddle Cart to your full size Commercial Series grill.
1. Remove the RH side shelf and brackets from your Grill:
2. Attach the magnet assemblies to your grill:
a
b
c
2a. From outside the grill, insert the magnet shaft.
.2b. From inside the grill, place the spring on the shaft,
.followed by the washer.
2c. Secure the magnet assembly with the hairpin clip.
3. Attach the Griddle Cart to you Grill.
20
4. Complete!
Consumer must purchase Natural Gas Conversion Kit 4984619 to convert this grill to natural
gas. Use the following instructions instead of instructions found in conversion kit
Main Burner Conversion
1
Make sure all Control Knobs are in the OFF position, LP Tank Valve is closed, Tank is disconnected from Regulator and
removed from Grill.
Remove cooking grates or griddle plate.
Your grill may differ from illustration shown. This portion of the manual covers a variety of grill styles. Use pictures as
reference only. Not all steps will apply to your grill conversion.
2
Remove screws that hold orifice holder with the burner venturi.
Burner Venturi
View from under firebox
3
Unscrew Orifice from Orifice Holder using the Orifice Removal Tool provided with Kit. Save removed Orifice and Orifice
Removal Tool for converting back to LP Tank Gas. These grill valve are designed to work with Natural Gas once Orifice is
removed. Replace Main Burner LP Orifice with Natural Gas Orifice supplied in hardware pack.
Orifice Holder
Remove LP Orifice
Orifice Removal Tool
Install NG Orifice
21
4
Pull the Burner Control Knob off of Valve Stem.
Remove Screws and Washers that secure the Bezel to the Control Panel. Save removed Bezel for converting back to LP
Tank Gas.
Install new Natural Gas Bezel provided with Kit (see illustration below) in place of old Bezel, on Control Panel and secure
using previously removed Screws and Washers. Assure proper alignment with Control Knob before fully tightening.
Note: The new bezel will limit the rotation of the Control Knob in order to properly control gas flow to your grill.
Press Control Knob back onto Valve Stem. Make adjustments to Bezel for free movement of Control Knob.
Install bezel with “OFF” at top
Valve Stem
Bezels
Screws
Main Burner
Control Knobs
5
Under the firebox, attach the orifice holder with the venturi tube with the screws previous removed.
Correct engagement
NOTE: Reinstall Screws
22
Natural Gas Hose Conversion
6
Using a wrench, not provided, remove LP Regulator Hose Assembly from Manifold Connection. Save removed LP Manifold
Connection for converting back to LP Tank Gas.
Your Grill may differ from illustration shown.
Manifold Connection
LP Regulator Hose Assembly
Manifold Connection
Natural Gas Hose Assembly
23
WARNING
Do not use hard metal piping of any kind to connect this
type of grill to 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.
4. When the quick disconnect socket and the gas hose are connected,
a valve in the socket opens automatically to permit full gas flow.
When the gas hose is disconnected, the valve in the socket instantly
and positively shuts off the flow of gas. Because the valve in the
socket positively shuts off the flow of gas, the grill can be
disconnected from the gas source by disconnecting the gas hose
from the quick disconnect socket. The socket should be left attached
to the gas source (house piping). Figure C, below, shows properly
connected hose and socket.
Connecting Your Grill to the Natural Gas Source.
1. A professionally-installed shut-off valve between the supply piping
and the socket is recommended, but not required, by the National
Fuel Gas Code. Socket connection must be made outdoors.
2. Coat the gas supply pipe nipple with gas resistant pipe dope or
approved teflon tape. Screw socket onto gas supply pipe (house gas
source) as shown in Figure A below, and wrench-tighten.
Figure C
CAUTION
The quick disconnect socket should never be connected
to the grill. Direction of gas flow is indicated on the
socket.
Quick disconnect socket
With proper assembly, the gas hose cannot be removed without
pushing the quick disconnect sleeve back. To disconnect, push
sleeve back and pull plug out of sleeve (this automatically shuts off
gas).
House piping
Please Note: Hose and assembly are C.S.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.
Figure A
3. Pull back the sleeve on the quick disconnect socket and insert the
unattached end of the gas hose into the socket. Release the sleeve
and continue pushing the hose into the socket until the sleeve snaps
into the locked position. See Figure B.
Gas hose
Sleeve
Figure B
24
The appliance and its individual shut off valve must be
disconnected from the gas supply piping system during any
pressure testing on that system at test pressures in excess of 1/2
psig (3.5kPa).
The appliance must be isolated from the gas supply piping system
by closing its individual manual shutoff valve during any pressure
testing of the gas supply piping system at test pressures equal to
or less than 1/2 psi (3.5kPa).
DANGER: If a gas leak cannot be stopped, or a fire occurs due to gas leakage, call the fire department.
Emergencies
Possible Cause
Prevention/Solution
Gas leaking from
cracked/cut/burned
hose.
• Damaged hose.
• Turn off gas at LP cylinder or at source on natural gas systems. If
anything but burned, replace valve/hose/regulator. If burned,
discontinue use of product until a plumber has investigated cause
and corrections are made.
Gas leaking from LP
cylinder.
• Mechanical failure due to rusting or
mishandling.
• Replace LP cylinder.
Gas leaking from LP
cylinder valve.
• Failure of cylinder valve from
mishandling or mechanical failure.
• Turn off LP cylinder valve. Return LP cylinder to gas supplier.
Gas leaking between
LP cylinder and
regulator connection.
• Improper installation, connection not
tight, failure of rubber seal.
• Turn off LP cylinder valve. Remove regulator from cylinder and
visually inspect rubber seal for damage. See LP Cylinder Leak Test
and Connecting Regulator to the LP Cylinder.
Fire coming through
control panel.
• Fire in burner tube section of burner due
to blockage.
• Turn off control knobs and LP cylinder valve. Leave lid open to
allow flames to die down. After fire is out and grill is cold, remove
burner and inspect for spider nests or rust. See Natural Hazard
and Cleaning the Burner Assembly pages.
Grease fire or
continuous excessive
flames above cooking
surface.
• Too much grease buildup in burner area.
• Turn off control knobs and LP cylinder valve. Leave lid open to
allow flames to die down. After cooling, clean food particles and
excess grease from inside firebox area, grease tray, and other
surfaces.
Possible Cause
Prevention/Solution
GAS ISSUES:
• Trying to light wrong burner.
• See instructions on control panel and in Use and Care section.
• Burner not engaged with control valve.
• Make sure valves are positioned inside of burner tubes.
• Obstruction in burner.
• Ensure burner tubes are not obstructed with spider webs or other
matter. See cleaning section of Use and Care.
• No gas flow.
• Make sure LP cylinder is not empty. If LP cylinder is not empty,
refer to “Sudden drop in gas flow.”
• For a grill equipped with the AUTO-CLEAN™ feature, make sure
the AUTO-CLEAN™ valve is set to “Grill”
• Vapor lock at coupling nut to LP cylinder.
• Turn off knobs and disconnect coupling nut from LP cylinder.
Reconnect and retry.
• Coupling nut and LP cylinder valve not
fully connected.
• Turn the coupling nut approximately one-half to three-quarters
additional turn until solid stop. Tighten by hand only - do not use
tools.
Troubleshooting
Problem
Burner(s) will not light
using ignitor.
(See Electronic Ignition
Troubleshooting also)
Continued on next
page.
ELECTRICAL ISSUES:
• Electrode cracked or broken; “sparks at
crack.”
• Replace electrode(s).
• Electrode tip not in proper position.
Main Burners:
• Tip of electrode should be pointing toward gas port opening on
burner. The distance should be 1/8” to 1/4”. Adjust if necessary.
Sideburner:
• Tip of electrode should be pointing toward gas port opening on
burner. the distance should be 1/8” to 3/16”. Adjust if necessary.
• Wire and/or electrode covered with
cooking residue.
• Clean wire and/or electrode with rubbing alcohol and clean swab.
• Wires are loose or disconnected.
• Reconnect wires or replace electrode/wire assembly.
• Wires are shorting (sparking) between
ignitor and electrode.
• Replace ignitor wire/electrode assembly.
• Dead battery.
• Replace with a new alkaline battery.
25
Troubleshooting (continued)
Problem
Possible Cause
Prevention/Solution
Burner(s) will not light
using ignitor.
(See Electronic Ignition
Troubleshooting also)
ELECTRONIC IGNITION:
• No spark, no ignition noise.
• See Section I of Electronic Ignition System.
• No spark, some ignition noise.
• See Section II of Electronic Ignition System.
• Sparks, but not at electrode or at full
strength.
• See Section III of Electronic Ignition System.
Burner(s) will not
match light.
• See “GAS ISSUES:” on previous page.
• Match will not reach.
• Use long-stem match (fireplace match).
• Improper method of match-lighting.
• Out of gas.
• See “Match-Lighting” section of Use and Care.
• Check for gas in LP cylinder.
• Excess flow valve tripped.
• Turn off knobs, wait 30 seconds and light grill. If flames are still low,
turn off knobs and LP cylinder valve. Disconnect regulator.
Reconnect regulator and leak-test. Turn on LP cylinder valve, wait
30 seconds and then light grill.
• Vapor lock at coupling nut/LP cylinder
connection.
• Turn off knobs and LP cylinder valve. Disconnect coupling nut from
cylinder. Reconnect and retry.
• High or gusting winds.
• Turn front of grill to face wind or increase flame height.
• Low on LP gas.
• Refill LP cylinder.
• Excess flow valve tripped.
• Refer to “Sudden drop in gas flow” above.
• Grease buildup.
• Clean burners and inside of grill/firebox.
• Excessive fat in meat.
• Trim fat from meat before grilling.
• Excessive cooking temperature.
• Adjust (lower) temperature accordingly.
Persistent grease fire.
• Grease trapped by food buildup around
burner system.
• Turn knobs to OFF. Turn gas off at LP cylinder. Leave lid in position
and let fire burn out. After grill cools, remove and clean all parts.
Flashback...
(fire in burner tube(s)).
• Burner and/or burner tubes are blocked.
• Turn knobs to OFF. Clean burner and/or burner tubes. See burner
cleaning section of Use and Care.
Unable to fill LP
cylinder.
• Some dealers have older fill nozzles
with worn threads.
• The worn nozzles don’t have enough “bite” to engage the valve. Try
a second LP dealer.
One burner does not
light from other
burner(s).
• Grease buildup or food particles in
end(s) of carryover tube(s).
• Clean carry-over tube(s) with wire brush.
AUTO-CLEAN™
Possible Cause
Prevention/Solution
Sudden drop in gas
flow or low flame.
Flames blow out.
Flare-up.
(If Equipped)
Timer does not work
(Green light does not
flash)



Dead Battery
Batteries installed incorrectly.
Knob Position did not start the Clean
Cycle



Replace batteries
Install batteries correctly.
Push Knob in to start the clean cycle. (Green LED should begin to
flash)
No LED’s will illuminate

Dead Battery

Replace batteries
Red LED next to battery
symbol is illuminated

Low Battery Strength

Prepare to replace batteries (NOTE: Clean cycle will operate with
a weak battery.
26
Troubleshooting - Electronic Ignition
Problem (Ignition)
Check Procedure
Prevention/Solution
• Check battery orientation.
• Install battery (make sure that “+” and “–”
connectors are oriented correctly, with “+” end up
and “–” end down.)
• Has battery been used
previously?
• Replace battery with new alkaline battery.
• Button assembly not
installed properly.
• Check to insure threads are
properly engaged. Button
should travel up and down
without binding.
• Unscrew button cap assembly and reinstall, making
sure threads are aligned and engaged fully.
• Faulty spark module.
• If no sparks are generated
with new battery and good
wire connections, module is
faulty.
• Replace spark module assembly.
• Are output connections on
and tight?
• Remove and reconnect all output connections at
module and electrodes.
• Output lead
connections not
connected.
• Are output connections on
and tight?
• Remove and reconnect all output connections at
module and electrodes.
• Arcing to grill away
from burner(s).
• If possible, observe grill in
dark location. Operate
ignition system and look for
arcing between output wires
and grill frame.
• If sparks are observed other than from burner(s),
wire insulation may be damaged. Replace wires.
• Weak battery.
• All sparks present but weak
or at slow rate.
• Replace battery with a new alkaline battery.
• Electrodes are wet.
• Has moisture accumulated
on electrode and/or in burner
ports?
• Use paper towel to remove moisture.
• Electrodes cracked or
broken “sparks at
crack”.
• Inspect electrodes for
cracks.
• Replace cracked or broken electrodes.
Possible Cause
SECTION I
• Battery not installed
No sparks appear at
properly.
any electrodes when
Electronic Ignition Button
is pressed; no noise can
• Dead battery.
be heard from spark
module.
SECTION II
• Output lead
No sparks appear at
connections not
any electrodes when
Electronic Ignition Button connected.
is pressed; noise can
be heard from spark
module.
SECTION III
Sparks are present
but not at all
electrodes and/or not
at full strength
27
NOTES
28
NOTES
29
NOTES
30
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Veuillez enregistrer votre produit à l'adresse:
www.charbroil.com/register
(If you register online, you do not need to send in this registration card.)
(Si registra en línea, no es necesario enviar esta tarjeta de registro.)
(Si vous enregistrez votre produit en ligne, il n'est pas nécessaire d'envoyer la carte
d'enregistrement.)
PLEASE FILL OUT THIS CARD AND ATTACH A COPY OF YOUR SALES RECEIPT. RETURN IT WITHIN10 DAYS OF PURCHASE.FOR WARRANTYSERVICEPROOF OF PURCHASE
WILL BE REQUIRED.THIS WARRANTYIS NON-TRANSFERABLE.
LLENE ESTA TARJETA Y DEVUELVALADENTRO DE LOS 10 DIAS DE LA COMPRA.PARA EL SERVICIODE GARANTIAES NECESARIOQUE PRESENTESU COMPROBANTEDE
COMPRA.CONSERVELA FACTURA.ESTA GARANTIAES INTRANSFERIBLE.
VEUILLEZCOMPLETERCETTE CARTE ET LA RETOURNERDANS LES 10 JOURS SUIVANTL’ACHAT. POUR OBTENIRLE SERVICESOUS GARANTIE,UNE PREUVED’ACHAT DOIT
ETRE PRESENTEE.VEUILLEZCONSERVERVOTRE FACTURE. LA PRESENTEGARANTIEN’EST PAS TRANSFERABLE.
~ PLEASE PRINT ~ IMPRIMAPOR FAVOR ~ S'IL VOUS PLAÎT IMPRIMER~
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Initial | Inicial | Initiale
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Address (number & street) | Dirección (número y calle) | Adresse (numéro et rue)
Apt Number | Nº de apart | Nº d’appt.
City | Cludad | Ville
Zip Code | Código Zip | Code Postal
State | Estado | Province
*❷ E-mail Address | Dirección de correo electrónico | Adresse électronique
* ❸ Phone Number | Número telefónico | Numéro de téléphone
*❹ Model Number | Número de modelo | Numéro de modèle
STICKERON PRODUCT
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❻
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❼
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❽
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❾
Your Gender | Sexo | Sexe:
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❿
1.
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3.
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5.
6.
Which product are you registering?
¿Qué producto está registrando?
Quel produit enregistrez-vous?
 Gas Grill | Parrilla a gas | Gril au gaz
 Electric Grill | Parrilla eléctrica | Gril électrique
 Smoker | Ahumador | Fumoir
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*❺Attachcopyofyour
salesreceipthere.
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desurecibode
compra
Veuillezattacherune
copiedevotrereçu
ici.
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31
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