Char-Broil 640-174667113 User manual

PRODUCT GUIDE

Kenmore Mode| No, 415.t6121801

Kmart item No, 640-174667113

IMPORTANT: Fill out the product record information below.

Serial Number Seeratinglabelongrillforserialnumber.

Date Purchased

Forsupportandto registeryour

grill,pleasevisit usat

www.charbroil.com

Ifyouhavequestionsorneed

assistanceduringassembly,

pleasecall1-800-241-7548.

Estimated assembly time: 35-40 minutes

The following are trademarks registered by W.C. Bradley Co. in the U.S. Patent and Trademark Office: Char-Broil®; America's Legendary Barbeque Company®;

American Gourmet®; Banders®; BrushHawg®; CB940®; Char-Diamonds®; Char-Broil Charcoal/Gas®; DiamondFlame®; Everybody Grills®; Everybody Outside®;

FastStart®; Fireball®; Firenzy®; FlavorMaster®; Grill2Go®; Grill2Go® Express®; Grill Lovers®; H20 Smoker@; Keepers of the Flame®; New Braunfels Smoker

Company@; Oklahoma Joe's®; Patio Bistro@; Patio Caddie®; Patio Kitchen®; Precision Flame®; Quantum@; Santa Fe@; Sear and Grill@; Sierra@; Signature

Series@; The Big Easy@;The Minute Grill@;Trentino@; Wild West Tradition@; and the following marks:

TM TM TM TM TM TM

The following are trademarks of W.C. Bradley Co.: Commercial Series ; Designer Series ; Grill2Go@ Advantage ; Longhorn ; Double Chef ; QuickSet ;

TM TM TM TM TM

Ready When YouAre ; Hog and Yard Bird ;You Bring the Party ; SureFire ;Universal Grill Parts

TEC is a trademark of Tec Infrared Grills.

Protected under oneor moreofthe following U.S.Patents:4,989,579; 5,421,319; 5,458,309;5,579,755; 5,996,573;6,114,666; 6,135,104;6,209,533; 6,279,566;6,331,108; 6,484,900; 6,526,876;6,595,197;6,640,799; 6,640,803; 6,729,873;6,739,473; 6,749,424;

6,863,t00; 6,935,327; 6,951,213;6792,935;7,047,590;D364,535;D372,637;D373,70t ;D377,735;D383,035; D397,9t0; D405,643;I}406,005; D4Od,OO9;I}413,043;D4t3,229; I}414,982; D4t5,388; I}4t6,164; D4t6,441; I}417,587;D417,588; D422,516;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;D447,384; D447,385; D447,909;D448,610;D448,614;D448,6t5; D448,616;D448,975;D449,492;D450,544; D451,759;D454,028;

D454,03t; Ii)455,205;D455,206;D456,202;D456,222;D456,223;I}457,789; D458,520;D458,760;D458,802; D459,088; I}459,148 D459,149;D459,16t; I}459,163; D459,586;D459,943;D460,312;D460,313;1}460,318;D461,359;D465,123;D465,693;D466,307;

D466,439;D466,752;D473,4t4; Ii)474,371;D477,498;D477,50t; D477,504; D477,506; I}477,746; D478,471;D478,472;D480,914;D49t,4t0; I)494,009; D494,4t3; D498,523;D500,359;D504,048;D530,098; D535,000; Canada: 87,743;87,744; 97,504; 99,355;

102,037; 104,2OO;2,315,567;2,336,036;France: O10231 ;0tO,422;0t 0,590; O10,849;1,089,646;Germany:1,089,646;South Korea:384,565;China:99,127,066.5;UnitedKingdom:2,099,402;1,089,646.OtherPatents Pending.

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

Use and Care .................................... 4-10

Grilling Guide .................................... 11-14

Limited Warranty.................................... 15

Parts List.......................................... 16

Parts Diagram...................................... 17

Assembly ....................................... 18-28

Troubleshooting.................................. 29-30

Registration Card ................................... 31

Safety Symbols

The symbols and boxes shown below explain what each heading

means. Read and follow all ofthe messages found throughout

the manual.

WARNING: Indicatesan potentiallyhazardous situation

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

CAUTION

CAUTION: Indicatesa potentiallyhazardoussituationor

unsafe practicewhich, if notavoided, 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.

INSTALLER/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 containsharp edges- especially as noted

in the manual!Wear protectivegloves if necessary.

CALiFORNiAPROPOSiTiON65

1.Combustionby-productsproducedwhenusing

thisproductcontainchemicals known to the State of

California to cause cancer, birth defects, and 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. A conversion kit must be

purchased for use with naturalgas.

• 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, CSA C22.1. 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 wilt result in a safety hazard.

CAUTIO.

Using pots larger than 6 quarts in capacity could _,

exceed weight limit of the

resulting in failure s

of grill cart _'_

components.

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 agas leak and fire. Use only

authorized replacement parts supplied by

manufacturer.

•NEVERstore aspare LP cylinder under or near the

appliance or in an enclosed area.

•Never fill a cylinder beyond 80%full.

• ifthe information in two points above is not

followed exactly, afire causing death or serious

injury may occur.

• An over filled or improperlystored cylinder isa

hazard due to possible gas release from the safety

relief valve. This could cause an intense fire with

risk of property damage, serious injury or death.

• ifyou see, smell or hear gas escaping, immediately

get 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 not use 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 have a 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 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.

*LPcylinder valve must have:

,Type 1 outlet compatible with

regulatoror grill.

,Safety reliefvalve.

,UL listed 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.

,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)

*LPgas is nontoxic, odorless and colorless when produced. For

Your Safety, LPgas 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

*Useonly licensed and experienced dealers.

*LPdealer must purge new cylinder before filling.

*Dealer should NEVER fill LP cylinder more than 80% of LP

cylinder volume. Volumeof propane in cylinder wilt 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.

,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

•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 new and exchanged LP cylinders in upright

position during use, transit or storage.

•Leak test new and exchanged LP cylinders BEFORE

connecting to grill.

Connecting Regulator to the LP Cylinder

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

assembly section.)

2.Turn all control knobs to the OFF position.

3.Turn LP 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.

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 notuse 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 household cleaning agents. Damage to gas

train components can result.

Safety Relief Valve

OPD Hand Wheel

//- Type1outlet with

threadon outside

Strapand Cap

Do not use a POL transport 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 LPcylinder valve.

If"growing"bubblesappear do notuseor move the LP

cylinder.Contact an LPgas supplieror your fire

department!

Holdcoupling nut and regulator

asshownfor properconnection

to LPcylindervalve.

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!

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.

Do not insertany tool or foreignobject into the valve

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 the self-contained

LPgas system of a campertrailer or motorhome.

. Do not usegrill until leak-tested.

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

department.

. If you cannotstop 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. Callfor replacement

parts.

6.Always close LPcylinder valve after performing leak test by

turning hand wheel clockwise.

zL zL

For Safe Use Of Your Grill And To Avoid Serious

Injury:

*Do notlet children operate or play near grill.

•Keep grill area clear and free from materialsthat burn.

•Do notblock holes in bottom or back of grill.

•Check burner flames regularly.

•Use grill only inwell-ventilated space. NEVER use in

enclosed space such as carport, garage, porch, covered

patio, or under an overhead structure of any kind.

•Do notuse charcoal or ceramic briquets ina gas grill.

(Unless briquets are supplied with your grill.)

•Use grillat least 3ft. from any wall or surface. Maintain

10 ft. clearance to objects that can catch fire or sources of

ignitionsuch as pilot lights on water heaters, live electrical

appliances, etc.

*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 floorwith a three (3) foot

clearance from walls or rails. Donot 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 tank out of correct position

specified in assembly instructions.

•Always close LP tank valve and remove coupling nut

before moving LP tank from specified operation

position.

Safety Tips

,& Beforeopening LP cylinder valve, check the coupling nutfor

tightness.

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

cylinder valve.

,& If the outdoor cooking gas appliance is not in use, the gas

must be turned off at the supply cylinder. Storage of an

outdoor cooking gas appliance indoorsis permissible only if

the cylinder is disconnected and removed from the appliance.

,& Never move grill while in operation or still hot.

,& Use long-handled barbecue utensils and oven mitts to avoid

burnsand splatters.

,& Maximum load for side shelves is 10 Ibs.

,& The grease cup must be inserted into grease clip and

emptied after each use. Do not remove grease cup 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 recommendedto clean cooking surfaces

while grill is hot.

,& If you notice grease or other hot material dripping from grill

onto valve, hoseor regulator, turn off gas supply at once.

Determinethe cause, correct it, then clean and inspect valve,

hoseand regulator before continuing. Perform a leak test.

,& The regulator may make a humming or whistling noiseduring

operation. This will notaffect safety or use of grill.

,& Onlyuse the pressure regulator and hose assembly supplied

with this grill. Replacement pressure regulator and hose

assemblies must be specified or supplied by Char-Broil, LLC.

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

,& If the regulator frosts, turn off grill and LP cylinder valve

immediately.This indicatesa problemwith the cylinder and it

should notbe used on any product. Return to supplier!

CAUTION

Putting out grease fires by closing the lid is not

possible. Grills are well ventilated for safety

reasons.

Do not use water ona grease fire. Personal injury

may result. If a grease fire develops, turn knobs

and LP cylinder off.

Do not leave grill unattended while preheating or

burning off food residue on HI. If grill has not been

regularly cleaned, a grease fire can occur that may

damage the product.

ignitor Lighting

ADo not lean over grill while lighting.

1. TurnOFF gas burner control valves.

2. TurnON gas source or tank.

3. Open lidduring lighting.

4. Toignite, turn left knob to,_ HIGH.

5. Push IGNITOR button rapidly.

6.If ignitiondoes NOT occur in 5 seconds, turn the burner

controls OFF,wait 5 minutes and repeat the lighting

procedure.

7. Toignite right burner,turn knob to _.

If ignitordoes notwork, follow matchlighting instructions.

After Lighting: Turn knobs to HI position for warm-up.

CAUTioN

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

minutes, and try again. Always close valve during the 5

minute waiting period, if the burner does not ignite with

the valve open, gas will continue to flow out of the burner

and could accidentally ignite with risk of injury.

Match-Lighting

ADo not lean over grill while lighting.

1.Open lid during lighting.

2.Place match into match holder (hanging from side of cart).

3.Push in and turn left knob to Jl: HIGH position. Be sure

burner lights and stays lit.

4.Light right burner by pushing knob in and turning to _ HIGH

position.

Sideburner Ignitor Lighting

1. Turn OFF gas burner control valves.

2. Turn ONgas source or tank.

3. Turn sideburner knobto HI.and push IGNITORbutton rapidly.

4. If sideburner does NOT light, turn knob to OFF,

wait 5 minutes, then repeat lighting procedure.

Sideburner Match Lighting

1. Turn on gas at LP tank.

2. Hold lit match to any port on

the burner.Push in and turn

sideburner knob to _. Be

sure burner lights and stays lit.

Before Your First Cookout

•Light burners, check to make sure they are lit, close the lid and

warm up grill on HIGHfor 15 minutes. This curing of paint and

partswill produce an odor only on first lighting.

Burner Flame Check

•Light burner, rotateknobs from HIGHto LOW.You should see

a smaller flame in LOW position than seen on HIGH.Always

check flame prior to each use. If only lowflame is seen refer to

"Sudden drop or low flame" in the Troubleshooting Section,

Hose Check

•Beforeeach use, check to see if hoses are cut,worn or kinked.

Replace damaged hoses before using grill. Use only

valve/hose/regulator specified in the Parts List.

Normal Kinked

Hose Hose

Turning Grill Off

•Turn all knobs to OFF position.Turn LP tank off byturning

OPD handwheel clockwise to a full stop.

Ignitor Check

•Turn gas off at LP tank. Press and hold ignitor button. "Click"

should be heard and spark seen each time between collector

box or burner and electrodes. See "Troubleshooting" if no click

or spark.

Valve Check

•Important: Make sure gas is off at LP tank before checking

valves. Knobs lock in OFF position. Tocheck 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 LO position then turn back to OFF position.

Valves should turn smoothly.

General Grill Cleaning

•Keepthe outside of your grill looking new by cleaning it once a

month with warm soap and water or a non-abrasive cleaner. If

you don't havea grill cover, wipe off dust and grime before

starting your grill.

• Coating the cooking gridswith spray-on cooking oil will keep the

food from sticking and make clean up easier.After cooking,

scrape the grates with a long handled, brass wire bristle brush.

•Check inside the grill bottom for grease build upand clean

often, especially after cooking fatty meat.

•Do not mistake brown or black accumulation of grease and

smoke for paint. Apply a strong solution of detergent and water

or use a grill cleanerwith scrub brush on insides of grill lid and

bottom. Rinse and allow to completely air dry. Do not apply a

caustic grill/oven cleanerto painted surfaces.

•Plated wire grates: Wash grates with concentrated grill

cleaner or use soap and water solution. Dry thoroughly and

store indoors between cookouts.

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

,A. Do not use citrisol, abrasive cleaners, degreasers or a

concentrated grill cleaner on plastic parts. Damage to and

failure of parts can result.

•Porcelain grates: Because of glass-like composition, most

residue can be wiped away with baking soda/water solution or

specially formulated cleaner. Use non-abrasive scouring

powder for stubborn stains.

•Painted surfaces: Wash with mild detergent or nonabrasive

cleaner and warm soapy water.Wipe dry with a soft

nonabrasive cloth.

•Stainless steel surfaces: Tomaintain your grill's high quality

appearance, wash with mild detergent and warm soapy water

and wipe drywith a soft cloth after each use. Baked-ongrease

deposits may require the use of an abrasive plastic cleaning

pad. Use only in direction of brushed finish toavoid damage.

Do not use abrasive pad on areas with graphics.

• Cooking surfaces: If a bristle brush isused to cleanany of

the grill cooking surfaces, ensure no loose bristles remain on

cooking surfaces prior to grilling. It is not recommendedto

clean cooking surfaces while grill is hot.

Iz l cAuT,o.Iz l

SPIDER ALERT!

GAS COLLECTOR

VALVE AIR VENTURI

SHUTTER

If you notice that your grill is getting hard to light or that the

flameisn't asstrong as itshould be,take the time to checkand

clean theventuri's.

LIFTOUT

BURNERASSEMBLY

REMOVE

BURNER

CLIPS

CLEAN OUT SPIDER WEBS

VENTURI INSIDEVENTURI

Insomeareasofthecountry,spidersor smallinsectshavebeen

knowntocreate"flashback"problems.Thespidersspinwebs,build

nestsandlayeggsin thegrill'sventuritube(s)obstructingtheflowof

gastotheburner.Thebacked-upgascanignitein theventuribehind

thecontrolpanel.Thisis knownasa flashbackanditcandamage

yourgrilland evencauseinjury.

Topreventflashbacksandensuregoodperformancetheburnerand

venturiassemblyshouldberemovedfromthegrilland cleaned

beforeusewheneverthegrillhasbeenidleforanextendedperiod.

,,. j

Cleaning the Burner Assembly

Follow these instructions to clean and/or replace parts of burner

assembly or if you have trouble ignitinggrill.

1. Turn gas off at control knobs and LP cylinder.

2. Remove cooking grate and heattent.

3. Under grill remove grease cup, disconnect ignitorwire from

burner.

4. Inside grill remove burner assembly (A), clean ceramic

portion of electrode with rubbing alcohol and a swab.

5. Clean outside of burner with soap and water. Lay burner

upside down on flat surface, insert garden hose to force

water through tubes. Make sure water comes out of all

burner holes. Open clogged holes with a thinwire. Shake

out excess water and examine holes. Due to normal wear

and corrosion some holes may become enlarged. Ifany

large cracks or holesare found replace burner.

6. If grill is to be stored, coat burner lightly with cooking oil.

Wrap in protective cover to keep insects out.

7. If notstoring grill after cleaning, replace burner intogrill

bottom.

VERY IMPORTANT: Burner tubes must re-engage valve

openings, See illustration (A).

8. Reattach ignitorwire to electrode.

9. Reposition heat tent and cooking grate. Reattach clean

grease cup to grease clip.

10. Before cooking again on grill, perform a "Leak Test'and

"Burner Flame Check".

Correctburner-to-valveengagement

BurnerTube

Valve

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