Char-Broil 463611011 User manual

PRODUCT GUIDE

MODEL 46361 t 0t t

463611211

Sears Model No. 16118

Krnart item No, 415.16118110

KSN No. 02579795-2

IMPORTANT: Fill out the product record information below.

Serial Number

Date Purchased

Seeratinglabelongrillforserialnumber.

Forsupportandto registeryour

grill,pleasevisit usat

www.charbroil.com

Ifyouhavequestionsorneed

assistanceduringassembly,

pleasecall1-800-241-7548.

Estimated assembly time: 45 minutes

The following are trademarks registered by W.C. Bradley Co. in the U.S. Patent and Trademark Office: Caldera@; Charcoal2Go®; Char-Broil@; American Gourmet®;

Bandera®; Brush Hawg®; CB 940®; Char-Diamonds@; Char-Broil Charcoal/Gas®; Everybody Grills®; Grill 2 Go®; Grill 2 Go® Express@; Grill Lovers®; Infrared

Grilling That's All About U®; Keepers of the Flame®; Magneto@; New Braunfels Smoker Company®; Patio Bistro@; Patio Caddie®; Patio Kitchen®; Pro-Sear®;

RED@; Quantum@; Santa Fe@; Sear and Grill@; Sierra@; Signature Series®; Sure2Burn@; The Big Easy@; U@; Wild West Tradition@; and the following marks:

The following are trademarks of W.C. Bradley Co.:America's Legendary Barbeque CompanyTM; Advantage SeriesTM; Auto-Clean TM ;Chef Tested TM;Commercial

Series TM;Designer Series TM ;; Diamond Flame TM;Double ChefTM; Everybody Outside TM ; FastStartTM; FlavorMaster TM ; Front Avenue TM ; Grill 2 Go® Advantage TM;

Grill 2 Go® IceTM; Hog and Yard BirdTM; H20 SmokerTM; Infrared. Grilling's Juicy Little SecretTM; Incredible Taste. Infallible ResultsTM; Infrared InsideTM; Let's Grill

Something TogetherTM; LonghornTM;; Precision FlameTM; Quick2BurnTM; QuickSetTM; Ready When You AreTM; Season, Set, And SavorTM; Sizzle On The GrilITM;

SureFireTM; TorchforkTM;TrentinoTM; Universal Grill PartsTM;You Bring the Party TM TEC TMis a trademark of Tec Infrared Grills.

Protected under oneor moreof the following U,S, Patents:5,421,319;5,458,309; 5,579,755;5,996,573;6,114,666;6,135,104;6,209,533;6,331,108; 6,484,900;6,595,197;6,640,803;6,729,873;6,792,935; 6,951,213;

6,935,327;D405,643;D406,005;D406,009; D413,043;D413,229;D414,982;D415,388;D416,164;D416A41; D417,587;D417,588;D422,516; D423,274;D423,876;D428,303;D430,772;D435,396;D436,004;D438,059;

D438,060;D438,427; D439,110;D442,505; D443,179;D443,354;D443,464;D448,614;D448,615; D448,616;D448,975;D449A92; D451,759;D454,028; D454,031;D455,205;D455,206;D456,202;D460,312; D460,313;

D461,359; D465,123; D465,693; D466,439; D477,501; D478,472; D480,914; D491,410; D494,009; D494,413; D498,523; D500,359;D504,048; D535,000; D551A89; D553A30; D562,619; D562,628; D613,116

Canada:D97,504;D99,355;D102,037;D104,200;D108,377;2,315,567;OtherPatentsPending,@2010W.C.BradleyCompany

@2010Char-Broil,LLC Columbus,GA 31902 Printedin China Assemblyinstructions@2010 10/21/10 QG31%001-010801

For Your Safety .................................... 2-3

Grilling Guide ...................................... 4-7

Use and Care .................................... 8-13

Limited Warranty.................................... 14

Parts List.......................................... 15

Parts Diagram...................................... 16

Assembly ....................................... 17-24

Troubleshooting.................................. 25-26

Registration Card ................................... 27

Safety Symbols

The symbols and boxesshown below explain what each heading

means. Read and follow all ofthe messages found throughout

the manual.

WARNING: Indicatesan potentiallyhazardoussituation

which, if not avoided, could result in death or serious injury.

CAUTioN

CAUTION: Indicatesa potentiallyhazardoussituationor

unsafe practicewhich, if not avoided, may result in minor

or moderateinjury,

DANGER: Indicatesan imminentlyhazardous situation

which, if not avoided,will resultin death or serious injury.

If you smell gas:

1. Shut off gas to the appliance.

2. Extinguish any open flame.

3. Open lid.

4. If odor continues, keep away from the

appliance and immediately call your gas

supplier or your fire department.

1. Do not store or use gasoline or other

flammable liquids or vapors in the vicinity of

this or any other appliance.

2. An LP cylinder not connected for use shall not

be stored in the vicinity of this or any other

appliance.

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 beforeattempting

to assemble and cook.

|NSTALLER/ASSEMBLER:

Leavethis manualwith consumer.

CONSUMER"

Keepthis manualfor future reference.

WARNING-

Failureto follow all manufacturer's instructionscould result

in serious personal injuryand/or property damage.

CAUTION,"

Some partsmay containsharpedges- especiallyas noted

in the manual!Wear protectivegloves if necessary.

CALIFORNIAPROPOSITION65

1.Combustionby-productsproducedwhenusing

thisproductcontainchemicalsknowntotheStateof

Californiatocausecancer,birthdefects,andother

reproductiveharm.

2.Thisproductcontainschemicals,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. A conversion kit for dual fuel

grills must be purchased for usewith 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, CSAB149.1, or Propane Storage and

Handling Code, B149.2, or the Standard for Recreational

Vehicles,ANSI A 119.2/NFPA1192,and CSAZ240 RV Series,

Recreational Vehicle Code,as applicable.

• 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, CSAC22.1. Keep any electrical cords and/or

fuel supply hoses away from any hotsurfaces.

• This grill issafety certified for use in the United States and/or

Canada only. Donot modifyfor use in any other location.

Modification will result in a safety hazard.

CAUTION

Using pots larger than 6 quarts in capacity could

exceed weight limit of the

side burner shelf

or side shelf,

resulting in failure

of grill cart

components.

Do not attempt to repair or alter the

hoseNalve/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.

First Time Use

Read yourAssembly Manual and ensure the grill is puttogether

properly. Removeall Point-of-Purchase advertising material from

all grill surfaces beforefirst use. We recommend operating your

grill on its highest setting for 15-20 minutes prior to your first use.

This aids in removing theoils used during manufacturing.

Lava Rock /Briquettes

This gas grill has been designed, engineered, and tested to be

used with flame tamers or heat distribution plates to provide

more even heating, improve the cleaning process, and reduce

flare-ups. The addition of after marketlava rocks, charcoal, or

briquettes of any type will cause poor combustion and increase

the likelihood of a grease fire, and is not recommended. Using

briquettes, lava rock,or charcoal in this grill will void your

warranty. Forextra smoke flavor,we recommend using a

smoker box with wood chips.

Temperature

The temperature gauge in the hood of your new grill measures

air temperature. The air temperature inside your grill will never

be as hotas the temperature at the cooking surface.

Note: Since 1995,all regulators (the part that attaches to the gas

tank to regulatethe flow of gas) haveincluded a safety feature

that restrictsgas flow in theevent of a gas leak. You can

inadvertently activate this safety feature without having a gas

leak. This typically occurs when you turn on the gas using the

grill control knob beforeyou turn on the LP tank valve. If the gas

regulator safety feature activates, the grill will only reach

temperatures between 250°F and 300°F evenwith all burners on

the high setting.

Regulator Coupling Nut

If your grill is not getting hotter than 250°F to 300°F these

steps should be taken first to reset the gas regulator safety

device:

1.Open the grill lid.

2. Turnoff all knobs on the control panel in front.

3. Turnoff the tank knob.

4. Disconnect the regulator from the LP tank.

5. Wait 30 seconds.

6. Reconnect the regulator to the LP tank.

7. Slowly open the LP tank knob all the way. Do notput

excessive force on the valve at the full open position to avoid

damaging the valve.

8. Turnon the appropriate control knob and lightthe grill per the

instructionson the control panel.

An illustration ofthis process is includedin this Product Guide.

See Troubleshooting section for additional information.

Pre-HeatingYour Grill

Just like your home oven, your grill should be pre-heated to

provide optimum performance. Pre-heat the grill on high for 10-

15 minutes-longer ifweather conditions require. Please refer to

the lighting instructions inside the Product Guide if you have

questions about how to light your grill. A match-light chain and

hole is providedfor your convenience.

Outdoorgrillingisreallyquitesimple.You'llsucceedwith

burgers,dogs,orsteaksusuallyonyourveryfirsttry.With

experience,youwilllearnhowtoworkwithyourgrill,creating

moreimaginativemealsallthetime.Thisknowledgemakesup

theartofgrilling.Beforeyoustartgrilling,organizeyourfood

accordingtocookingtechniqueandrequiredcookingtime,and

optimizetheuseofyourgrillingarea.

DirectCooking

Directcookinginvolvesgrillingyourmeatdirectlyoverhighheat.

Itisperfectforsearingsteaks,chops,andothersmallerpiecesof

meatandvegetablesthatquicklymaketheirwaytothetable.

RotisserieCooking

Rotisseriecookingisbestfor'round'meat,suchaslargeroasts,

wholepoultry,andpork.Itgenerallyrequiresanaccessorymotor

andspitrodthatallowsthemeattobeturnedataconstant

speed.Rotisseriecookingisbestdoneinfrontofaspecial

rotisserieburner,orutilizinganindirectcookingburner

arrangement.Apancanbeplacedunderneaththemeattocatch

greaseandfooddrippings,andhelpsminimizeclean-up.

IndirectCooking

Indirectcookingutilizesselectburnerstocirculateheat

throughoutthegrill,withoutdirectcontactbetweenthemeatand

theflame.Themeatisplacedovertheburnerthatis'off'.This

methodisgenerallyusedtoslowcooklargecutsofmeatand

poultry.Apancanbeplacedunderneaththemeattocatch

greaseandfooddrippings,andhelpsminimizeclean-up. FoodSafety

Foodsafetyisaveryimportantpartofenjoyingtheoutdoor

cookingexperience.Tokeepfoodsafefromharmfulbacteria,

followthesefourbasicsteps:

Clean: Wash hands, utensils, and surfaces with hotsoapy water

before and after handling raw meat.

Separate: Separate raw meats 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 killbacteria. Use a

thermometer to ensure proper internal food temperatures.

Chill: Refrigerate prepared foods and leftovers promptly.

Cookingonyournewgrillisahands-onexperience,anditis

recommendedtoremainoutsidewithyourgrillwhilecooking.

Grillingcanbeaffectedbymanyexternalconditions.Incold

weather,youwillneedmoreheattoreachanidealcooking

temperature,andgrillingmaytakelonger.Themeat'sinternal

temperatureandthicknesscanalsoaffectcookingtimes.Cold

andthickermeatswilltakelongertocook.

InternalMeatTemperatures

Meatcookedonagrilloftenbrownsveryfastontheoutside.

Therefore,useameatthermometertoensureithasreached

safeinternaltemperatures.

USDA Recommended Safe Minimum

Internal Temperatures

Beef, Veal, Lamb, Steaks, & Roasts 145 ° F

Fish 145 ° F

Pork 160 ° F

Beef, Veal, Lamb Ground 160 ° F

Egg Dishes 160 ° F

Turkey, Chicken & Duck Whole, 165 ° F

Pieces & Ground

Please refer to the IJSDAfor complete, up-to-date information.

Our internaltemperature chart is based on USDA standards for

meat doneness. Check it out at www.isitdone_gD2

Sauces

Sauces containing sugars and fats can cause flare-ups, and your

food may burn. Ingeneral, apply these sauces during the final

10 minutesof cooking. Keep in mind, use of excessive sauces

or glazes will also require extra cleaning afterwards.

Marinades and Rubs

Toenhance the flavor of grilled foods, a liquid marinadeor dry

rub can be used prior to cooking. Meat can be either soaked or

injected with liquid marinade up to 24 hours prior to grilling. Dry

rubs can be applied directly to the meat immediately before

grilling.

Wood Chips

For extra smoke flavor when grilling, try adding wood chips.

Soak the chips in water for approximately 30 minutes before

adding to a smoke box or pan. Placesmoke boxor pan on top of

the cooking grate above the flame. Turn grill on high untilthe

wood starts to smoke. Reduce heat to desired temperature for

cooking, and placefood on cooking grate as desired. Close lid to

retain more smoke. Hardwood varieties that work particularly

well with grilled foods includeAlder,Apple, Cherry, Grapevines,

Hickory, Mesquite, Oak, Rosemary and Sassafras.

Skewers

Metal skewers should be flat,with long handles. Round skewers

allow food to roll when turned, so it may not cook as evenly. Use

metal skewers when cooking meat kabobs. Wooden skewers

should be soaked in water for an hour before use, and are best

usedfor quick cooking foods such as vegetables and fruits.

Utensils

Use tongs or a spatula to handle the food instead of a fork, and

don'tturn the food too

often. Piercing thefood

with a fork will release

juices that you want in

the meat, and may

cause flare-ups.

WhyClean?

We'veallheardthesaying,'anounceofpreventioniswortha

poundofcure.'Thisisgreatadvicewhenitcomestokeeping

yourgrillclean.

RoutineCare

Periodiccleaningofthisgrillisnecessary,

asgrillfirescanoccurwhengreaseand

fooddebriscollectinthebottomofthegrill.

Aftereachuse,removeanyremaining

foodparticlesfromthecookinggrateand

insideofthegrillusingagrillbrush.Do

thisafterthegrillhascooleddown,yetis

stillwarm.Itismucheasiertocleanfood

particleswhilewarmthisstillpresent,than

afterthefoodparticleshavecompletely

cooledandhardened.Thisgrillisnot

designedtobe'burnedoff'byclosingthe

lidandturningtheburnersonHighforan

extendedtime.Theexcessiveheat

generatedcancauseleftovergreaseto

catchfire,andcancausepermanent

damagetoyourgrill.

GeneralCleaning

Plastic parts: Wash with warm soapy water and wipe dry. Do not

use 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

glass cleaner. Use non-abrasive scouring powderfor stubborn

stains.

Painted surfaces: Wash with mild detergent or non-abrasive

cleaner and warm water. Wipe drywith a soft non-abrasive cloth.

Stainless steel surfaces: Stainless steel can rust under certain

conditions. This can be caused byenvironmental conditions

such as chlorineor salt water, or improper

cleaning tools such as wire or steel

wool. It can also discolor due to heat,

chemicals, or grease build-up. To

maintain your grill's high quality

appearance, wash with mild detergent

and warm water,or use a stainless

steel grill cleaner. 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

areaswith graphics.

Cooking surfaces: If a bristle brush is used to cleanany 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 Grill

• Clean cooking grates.

• Store grill in dry location.

• When LP cylinder isconnected to grill, store outdoors in a well

ventilated space and out of reachof children.

• Cover grill ifstored outdoors. Choose from a variety of grill

covers offered by manufacturer.

• Store grill indoors ONLYif LP cylinder is turned off,

disconnected, and removed from grill. Never store LP cylinder

indoors.

• When removing grill from storage, follow the 'Cleaning the

BurnerAssembly' instructions in the Use and Caresection of

the Product Guide.

Critters

Spiders like to make their homes in the venturi tubes of grills.

These must be inspected and cleaned regularly to ensure there

are no blockages. Refer to the Use and Care portion of this

Product Guide for complete information.

• NEVERstore a spare LP cylinder under or near

the appliance or in an enclosed area.

• Never fill a cylinder beyond 80%full.

• An over filled or improperlystored cylinder is a

hazard due to possible gas release from the

safety relief valve. This couldcause an intense

fire with risk of property damage, serious injury or

death.

If you see, smell or hear gas escaping,

immediatelyget away from the LP

cylindedappliance and call your fire department.

LP Cylinder Removal, Transport and Storage

•Turn OFFall control knobs and LP cylinder valve. Turn coupling

nutcounterclockwise by hand only - do notuse tools to

disconnect. Loosen cylinder screw beneathbottom shelf, then

lift LP cylinder up and out of cart. Installsafety cap onto LP

cylinder valve.Always use capand strap supplied with valve.

Failure to use safety cap as directed may result in serious

personal injuryand/or property damage.

•Adisconnected LP cylinder in LPCylinder

storage or being transported

must havea safety cap installed (as shown).

Do not store an LP cylinder in enclosed spaces

such as a carport, garage, porch, covered

patio or other building. Never leavean LP cylinder Safety

inside a vehicle which may become overheated Cap

by the sun. RetainerStrap

•Do notstore an LP cylinder in an area where children play.

LP Cylinder

•The LP cylinder used with your grill must meet the

following requirements:

•Use LPcylinders 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

regulatoror grill.

•Safety reliefvalve.

•ULlisted Overfill Protection OPDHandWheel

Device (OPD). This OPD safety

feature is identified by a unique triangular hand wheel. Use

only LP cylinders equipped with this type of valve.

•LPcylinder 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.

•LPgas is highly flammableand may ignite unexpectedly when

mixedwith 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. Volumeof propane in cylinder will vary by

temperature.

•Afrosty regulator indicates gas overfill. Immediately close LP

cylinder valve and call local LP gas dealer for assistance.

•Do not releaseliquid propane (LP) gas into the atmosphere.

This is a hazardous practice.

•Toremove 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 companiesthat 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.

•Always keep newand 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

notin use. Only install the type ofdust cap on the cylinder valve

outlet that is providedwith the cylinder valve. Other types of caps

or plugs may result in leakage of propane.

LP Cylinder Leak Test

For your safety

•Leak test must be repeated each time LP cylinder isexchanged

or refilled.

•Do notsmoke 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 ignitionsources such as gas fired or electrical

appliances. Duringleak test, keep grill away from open flames

or sparks.

•Use a clean paintbrush and a 50/50 mild soap and water

solution. Brush soapy solution onto areas indicated byarrows

in figure below.

ADo not use householdcleaning agents. Damage to gas

train components can result.

1.LP cylinder mustbe properly secured onto grill. (Refer to

assembly section.)

2.Turn all control knobs to the OFF position.

3.TurnLP cylinder OFF by turning hand-wheel clockwise to a

full stop.

4.Remove the protective cap from LP cylinder valve.Always use

cap and strap supplied with valve.

OPDHandWheel

j Type1 outlet with

threadon outside

SafetyReliefValve

Strapand Cap

Do not use a POLtransport plug

(plastic part with external threads)!

It will defeat the safety feature of

the valve.

5.Hold regulatorand insert nipple into LP

cylinder valve. Hand-tightenthe

coupling nut, holding regulator in a

straight line with LP cylinder valve so

as not to cross-thread the connection.

Nipplehasto be centered

intothe LP cylinder valve.

If"growing"bubblesappear do notuseor move the LP

cylinder.Contact an LPgas supplieroryour fire

department!

Holdcoupling nut and regulator

asshown for properconnection

to LP cylinder valve.

Leak Testing Valves, Hose and Regulator

1.Turn all grill control knobs to OFF.

2.Be sure regulator istightly connected to LP cylinder.

3.Completely open LP cylinder valve 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 clockwiseand tighten to a full stop. The

regulatorwill seal on the back-checkfeature in the LP cylinder

valve, resulting in some resistance.An additional one-half to

three-quarters turn is required to complete the

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

NOTE:

If you cannot complete the connection, disconnect regulatorand

repeat steps 5 and 6. If you are still unable to completethe

connection, do not use this regulator!

Do not insertany tool or foreignobject into thevalve

outlet or safety relief valve. You maydamagethe valve

and cause a leak. Leakingpropane may result in

explosion,fire, severepersonal injury,or death.

Outdoorgas appliance is not intendedto beinstalled

in or on a boat.

Outdoorgas appliance is not intendedto beinstalled

in or on an RV.

,Never attemptto attach this grill to theself-contained

LPgas system of a campertrailer or motorhome.

,Do not use grill until leak-tested.

,If a leak is detectedat any time, STOPand callthe fire

department.

,If you cannot stop a gas leak,immediately close

LPcylindervalve and call LPgas supplieror yourfire

department!

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 LPcylinder valve after performing leak test by

turning hand wheel clockwise.

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