Char-Broil 463440109 4 Burner Liquid Propane Gas Grill Owner’s Manual

June 17, 2024
Char-Broil

Char-Broil 463440109 4 Burner Liquid Propane Gas Grill

Char-Broil-463440109-4-Burner-Liquid-Propane-Gas-Grill-
product

Product Information

Specifications

  • Model: 463440109
  • Estimated assembly time: 45 minutes
  • TM REVISION: 00
  • Printed in China

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: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
  • CAUTION: Indicates a potentially hazardous situation or unsafe practice which, if not avoided, may result in minor or moderate injury.
  • DANGER: Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.

Important Safety Instructions
Please read and follow all safety statements, assembly instructions, and use and care directions before attempting to assemble and cook.

  • WARNING: Do not store or use gasoline or other flammable liquids or vapours in the vicinity of this or any other appliance.
  • WARNING: 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 it for commercial cooking.
  • WARNING: Failure to follow all manufacturer’s instructions could result in serious personal injury and/or property damage.
  • WARNING: Combustion by-products produced when using this product contain chemicals known to the State of California to cause cancer, birth defects, and other reproductive harm. This product also 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.
  • 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 the manufacturer.
  • CAUTION: Using pots larger than 6 quarts in capacity could exceed the weight limit of the side burner shelf, failing grill cart components.

Product Usage Instructions

To disconnect an LP cylinder from the grill:

  1. Ensure that the gas is shut off to the appliance.
  2. Extinguish any open flame.
  3. Open the lid.
  4. If the gas odor continues, keep away from the appliance and immediately call your gas supplier or fire department.
  5. Loosen the cylinder screw beneath the bottom shelf.
  6. Lift the LP cylinder up and out of the cart.
  7. Install the safety cap onto the LP cylinder valve. Always use the cap and strap supplied with the valve. Failure to use the safety cap as directed may result in serious personal injury and/or property damage.

FAQ

  • Can I use this grill for commercial cooking?
    No, this grill is for residential use only. It is not suitable for commercial cooking.

  • What should I do if I smell gas?
    If you smell gas, follow these steps: 1) Shut off gas to the appliance. 2) Extinguish any open flame. 3) Open the lid. 4) If the odour continues, keep away from the appliance and immediately call your gas supplier or fire department.

  • Can I store flammable liquids near this grill?
    No, do not store or use gasoline or other flammable liquids or vapours in the vicinity of this or any other appliance.

  • What should I do if I suspect a defect in the hose/valve/regulator?
    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 the manufacturer.

IMPORTANT:
Fill out the product record information below.

  • 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.

Estimated assembly time: 45 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®; Bandera®; 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:

The following are trademarks of W.C. Bradley Co.: Commercial Series™; Designer Series™; Grill2Go® Advantage™; Longhorn™; Double Chef™; QuickSet™; Ready When You Are™; Hog and Yard Bird™; You Bring the Party™; SureFire™; Universal Grill Parts™

TEC™ is a trademark of Tec Infrared Grills.

Protected under one or more of the 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; 6,863,100; 6,935,327; 6,951,213; 6792,935; 7,047,590; D364,535; D372,637; D373,701; D377,735; D383,035; D397,910; D405,643; D406,005; D406,009 ; D413,043; D413,229; D414,982; D415,388; D416,164; D416,441; D417,587; 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; D448,615; D448,616; D448,975; D449,492; D450,544; D451,759; D454,028; D454,031; D455,205; D455,206; D456,202; D456,222; D456,223; D457,789; D458,520; D458,760; D458,802; D459,088; D459,148 D459,149; D459,161; D459,163; D459,586; D459,943; D460,312; D460,313; D460,318; D461,359; D465,123; D465,693; D466,307; D466,439; D466,752; D473,414; D474,371; D477,498; D477,501; D477,504; D477,506; D477,746; D478,471; D478,472; D480,914; D491,410; D494,009; D494,413; D498,523; D500,359; D504,048; D530,098; D535,000; Canada: 87,743; 87,744; 97,504; 99,355; 102,037; 104,200; 2,315,567; 2,336,036; France: 010,231; 010,422; 010,590; 010,849; 1,089,646; Germany: 1,089,646; South Korea: 384,565; China: 99,127,066.5; United Kingdom: 2,099,402; 1,089,646. Other Patents Pending.

© 2008 W.C. Bradley Company.

Safety Instruction

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: Indicates an potentially hazardous situation which, if not avoided, could result in death or serious injury.
  • CAUTION: Indicates a potentially hazardous situation or unsafe practice which, if not avoided, may result in minor or moderate injury.
  • DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

DANGER

If you smell gas:

  • 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.

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.

CAUTION
For residential use only. Do not use for commercial cooking.

THIS GRILL IS FOR OUTDOOR USE ONLY.

CAUTION:
Read and follow all safety statements, assembly instructions, and use and care directions before attempting to assemble and cook.

INSTALLER/ASSEMBLER:
Leave this manual with the consumer.

CONSUMER:
Keep this manual for future reference.

  • WARNING:
    Failure to follow all manufacturer’s instructions could result in serious personal injury and/or property damage.

  • CAUTION:
    Some parts may contain sharp edges – especially as noted in the manual! Wear protective gloves if necessary.

WARNING

CALIFORNIA PROPOSITION 65

  1. Combustion by-products produced when using this product contain chemicals 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 natural gas.
  • Grill installation must conform with local codes, or in the 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, or the Standard for Recreational Vehicles, ANSI A 119.2/NFPA 1192, and CSA Z240 RV Series, Recreational Vehicle Code, as applicable.
  • All electrical accessories (such as rotisserie) must be electrically grounded per 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. The modification will result in a safety hazard.

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 the manufacturer.

CAUTION
Using pots larger than 6 quarts in capacity could exceed the weight limit of the side burner shelf, resulting in the failure of grill cart components.

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 overfilled or improperly stored cylinder is a hazard due to possible gas release from the safety relief valve. This could cause an intense fire with a 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 the LP cylinder valve. Turn the coupling nut counterclockwise by hand only – do not use tools to disconnect. Loosen cylinder screw beneath the bottom shelf, then lift LP cylinder up and out of the cart. Install safety cap onto LP cylinder valve. Always use a cap and strap supplied with a valve. Failure to use the safety cap as directed may result in serious personal injury and/or property damage.
  • A disconnected LP cylinder in 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 leave an LP cylinder inside a vehicle that may become overheated by the sun.
  • Do not store 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 a 20 lb. (9 kg.) capacity maximum.
  • LP cylinders must be constructed and marked by 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.
  • 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 vapour withdrawal and include a collar to protect the LP cylinder valve. Always keep LP cylinders in an upright position during use, transit or storage.

LP cylinder in an upright position for vapour withdrawal

LP (Liquefied Petroleum Gas)

  • LP gas is nontoxic, odourless and colourless when produced. For Your Safety, LP gas has been given an odour (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 the new cylinder before filling.

  • Dealer should NEVER fill LP cylinder more than 80% of LP cylinder volume. The volume of propane in the cylinder will vary by temperature.

  • A frosty regulator indicates gas overfill. Immediately close the LP cylinder valve and call the 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 the LP cylinder, contact an LP dealer or call a local fire department for assistance. Check the telephone directory under “Gas Companies” for the 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 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.
  • Always keep new and exchanged LP cylinders in an upright position during use, transit or storage.
  • Leak test new and exchanged LP cylinders BEFORE connecting to grill.

LP Cylinder Leak Test

For your safety

  • The leak test must be repeated each time the LP cylinder is exchanged or refilled.
  • Do not smoke during the 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 the grill away from open flames or sparks.
  • Use a clean paintbrush and a 50/50 mild soap and water solution. Brush the soapy solution onto areas indicated by arrows in the figure below.
  • Do not use household cleaning agents. Damage to gas train components can result.

WARNING
If “growing” bubbles appear do not use or move the LP cylinder. Contact an LP gas supplier or your fire department!

Connecting Regulator to the LP Cylinder

  1. LP cylinder must be 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.
    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.

  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 an 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 the 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 the LPcylinder valve and call LP gas supplier or your fire department!

Leak Testing Valves, Hose and Regulator

  1. Turn all grill control knobs to OFF.
  2. Be sure the regulator is tightly connected to the LP cylinder.
  3. Completely open the LP cylinder valve by turning the hand wheel counterclockwise. If you hear a rushing sound, turn the gas off immediately. There is a major leak at the connection. Correct before proceeding.
  4. Brush the soapy solution onto the areas circled below.Char-Broil-463440109-4-Burner-Liquid-Propane-Gas-Grill-fig- \(13\)
  5. If “growing” bubbles appear, there is a leak. Close the LP cylinder valve immediately and retighten connections. If leaks cannot be stopped do not try to repair. Call for replacement parts.
  6. Always close the LP cylinder valve after performing the leak test by turning the hand wheel clockwise.

WARNING
For Safe Use of Your Grill and to Avoid Serious Injury:

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

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

  • Do not block holes in the sides or back of the grill.

  • Check burner flames regularly.

  • Use the grill only in a well-ventilated space. NEVER use in an enclosed space such as a 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 a grill at least 3 ft. from any wall or surface. Maintain 10 ft. clearance to objects that can catch fire or sources of ignition such as pilot lights on water heaters, live electrical appliances, etc.

  • Apartment Dwellers:
    Check with management to learn the requirements and fire codes for using 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 the burner with the lid closed. A buildup of non-ignited gas inside a closed grill is hazardous.

  • Never operate the grill with the LP cylinder out of the correct position specified in assembly instructions.

  • Always close the LP cylinder valve and remove the coupling nut before moving the LP cylinder from the specified operation position.

Safety Tips

  • Before opening the LP cylinder valve, check the coupling nut for tightness.
  • When the grill is not in use, turn off all control knobs and LP cylinder valves.
  • Never move the grill while in operation or still hot.
  • Use long-handled barbecue utensils and oven mitts to avoid burns and splatters.
  • The maximum load for the sideburner and side shelf is 10 lbs.
  • The grease tray must be inserted into the grill and emptied after each use. Do not remove the grease tray until the grill has completely cooled.
  • Clean the 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 the cooking surfaces before grilling. It is not recommended to clean cooking surfaces while the grill is hot.
  • If you notice grease or other hot material dripping from the grill onto the valve, hose or regulator, turn off the gas supply at once. Determine the cause, correct it, and then clean and inspect the valve, hose and regulator before continuing. Perform a leak test.
  • Keep ventilation openings in the 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 the safety or use of the grill.
  • If you have a grill problem see the “Troubleshooting Section”.
  • If the regulator frosts, turn off the 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!

CAUTION

  • Putting out grease fires by closing the lid is not possible. Grills are well-ventilated for safety reasons.
  • Do not use water on a grease fire. Personal injury may result. If a grease fire develops, turn the knobs and LP cylinder off.
  • Do not leave the grill unattended while preheating or burning off food residue on HI. If the grill has not been regularly cleaned, a grease fire can occur that may damage the product.

Ignitor Lighting

Do not lean over the grill while lighting.

  1. Turn OFF the gas burner control valves.
  2. Turn ON the gas source or tank.
  3. Open the lid during lighting.
  4. To ignite, turn the IGNITION BURNER knob to HIGH.
  5. Push and hold the ELECTRONIC IGNITION button.
  6. If ignition does NOT occur in 5 seconds, turn the burner controls OFF, wait 5 minutes and repeat the lighting procedure.
  7. Ignite other burners by turning the knob . If the ignitor does not work, follow match lighting instructions. After Lighting: Turn knobs to the HIGH position for warm-up.

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.

Match-Lighting
Do not lean over the grill while lighting.

  1. Open lid. Turn on the gas at the LP cylinder.
  2. Place lit match into match holder (hanging from cart side panel), light burner on the right or left side of the grill.
  3. Push in and turn the far right or far left burner knob to HIGH. Be sure the burner lights and stays lit.
  4. Light adjacent burners in sequence by pushing knobs in and turning to HIGH.

Sideburner Ignitor Lighting

Do not lean over the grill while lighting.

  1. Turn OFF the gas burner control valves.
  2. Turn ON the gas source or tank.
  3. To ignite the SIDEBURNER, open the sideburner cover.
  4. Turn the side burner knob to . Push and hold the ELECTRONIC IGNITION button.
  5. If the sideburner does NOT light, turn the knob to OFF, wait 5 minutes, and then repeat the lighting procedure.

Sideburner Match Lighting

  1. Open sideburner lid. Turn on gas at LP cylinder.
  2. Place a lit match near the burner.
  3. Turn the sideburner knob to .
    Be sure the burner lights and stays lit.

Burner Flame Check

Remove cooking grates and flame tamers. Light burners, rotate knobs from HIGH to LOW. You should see a smaller flame in the LOW position than seen on the HIGH. 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.

  • Turning Grill Off

Turn all knobs to position. Turn the LP cylinder off by turning the hand wheel clockwise to a full stop.

  • Ignitor Check
    Turn the gas off at the LP cylinder. Press and hold the electronic ignitor button. “Click” should be heard and a spark seen each time between the collector box or burner and electrode. See “Troubleshooting” if no click or spark.

Valve Check

Important:
Make sure the gas is off at the LP cylinder before checking the valves. Knobs lock in position. To check valves, first push in knobs and release, knobs should spring back. If the knobs do not spring back, replace valve assembly before using grill. Turn knobs to LOW position then turn back to position. Valves should turn smoothly.

Hose Check

Before each use, check to see if the hoses are cut or worn. Replace damaged hoses before using the grill. Use only the valve/hose/regulator specified by the manufacturer.

General Grill Cleaning

  • Do not mistake brown or black accumulation of grease and smoke for paint. Interiors of gas grills are not painted at the factory (and should never be painted). Apply a strong solution of detergent and water or use a grill cleaner with scrub brush 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.

  • 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.

CAUTION

SPIDER ALERT!

In some areas of the country, spiders or small insects have been known to create “flashback” problems. The spiders spin webs, build nests and lay eggs in the grill’s venturi tube(s) obstructing the flow of gas to the burner. The backed-up gas can ignite in the venturi behind the control panel. This is known as a flashback and it can damage your grill and even cause injury.

To prevent flashbacks and ensure good performance the burner and venturi assembly should be removed from the grill and cleaned before use whenever the grill has been idle for an extended period.

Storing Your Grill

  • Clean cooking grates.

  • Store in a dry location.

  • When the LP cylinder is connected to the grill, store it outdoors in a well-ventilated space and out of reach of children.

  • Cover the grill if stored outdoors. Choose from a variety of grill covers offered by the manufacturer.

  • Store grill indoors ONLY if LP cylinder is turned off and disconnected, removed from the grill and stored outdoors.

  • When removing the grill from storage, follow the “Cleaning the Burner Assembly” instructions before starting the grill.

Cleaning the Burner Assembly
Follow these instructions to clean and/or replace parts of the burner assembly or if you have trouble igniting the grill.

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

  2. Remove cooking grates and flame tamers.

  3. Remove screws and carryover tubes from the rear of the burners.

  4. Remove the screw and washers to disengage the burner from a bracket on the firebox.

  5. Remove the screws to detach the electrode from the burner. The electrode should remain in the firebox.

  6. Carefully lift each burner up and away from valve openings.
    We suggest three ways to clean the burner tubes. Use the one easiest for you.

    • Bend a stiff wire (a lightweight coat hanger works well) into a small hook. Run the hook through each burner tube several times.
    • Use a narrow bottle brush with a flexible handle (do not use a brass wire brush), and run the brush through each burner tube several times.
    • 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 of each hole.
  7. Wire brush the entire outer surface of the burner to remove food residue and dirt.

  8. Clean any blocked ports with a stiff wire such as an open paper clip.

  9. Check the burner for damage, due to normal wear and corrosion some holes may become enlarged. If any large cracks or holes are found replace the burner.
    VERY IMPORTANT: Burner tubes must reengage valve openings. See illustrations at right.

  10. Attach electrode to burner.

  11. Carefully replace burners.

  12. Attach burners to brackets on the firebox.

  13. Reposition carryover tubes and attach them to burners. Replace flame tamers and cooking grates.Char-Broil-463440109-4-Burner-Liquid-Propane-Gas-Grill-fig- \(23\)

GRILLING GUIDE

Getting Started

First Time Use
Read your Assembly Manual and ensure the grill is put together properly. Remove all Point-of-Purchase advertising material from all grill surfaces before first use. We recommend operating your grill on its highest setting for 15-20 minutes prior to your first use. This aids in removing the oils 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 market lava 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. For extra 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 hot as the temperature at the cooking surface.

Note:
Since 1995, all regulators (the part that attaches to the gas tank to regulate the flow of gas) have included a safety feature that restricts gas flow in the event 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 before you 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 even with all burners on the high setting.

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. Turn off all knobs on the control panel in front.
  3. Turn off 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 not put excessive force on the valve at the fully open position to avoid damaging the valve.
  8. Turn on the appropriate control knob and light the grill per the instructions on the control panel.

An illustration of this process is included in this Product Guide. See the Troubleshooting section for additional information.

Pre-Heating Your 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 if weather 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 are provided for your convenience.

Grilling 101

Outdoor grilling is really quite simple. You’ll succeed with burgers, dogs, or steaks usually on your very first try. With experience, you will learn how to work with your grill, creating more imaginative meals all the time. This knowledge makes up the art of grilling. Before you start grilling, organize your food according to cooking technique and required cooking time, and optimize the use of your grilling area.

Direct Cooking
Direct cooking involves grilling your meat directly over high heat. It is perfect for searing steaks, chops, and other smaller pieces of meat and vegetables that quickly make their way to the table.

Indirect Cooking
Indirect cooking utilizes select burners to circulate heat throughout the grill, without direct contact between the meat and the flame. The meat is placed over the burner that is ‘off’. This method is generally used to slow cook large cuts of meat and poultry. A pan can be placed underneath the meat to catch grease and food drippings, and helps minimize clean-up.

Rotisserie Cooking
Rotisserie cooking is best for ’round’ meat, such as large roasts, whole poultry, and pork. It generally requires an accessory motor and spit rod that allows the meat to be turned at a constant speed. Rotisserie cooking is best done in front of a special rotisserie burner, or utilizing an indirect cooking burner arrangement. A pan can be placed underneath the meat to catch grease and food drippings, and helps minimize clean-up.

Char-Broil-463440109-4-Burner-Liquid-Propane-Gas-Grill-fig-
\(29\)

Food Safety
Food safety is a very important part of enjoying the outdoor cooking experience. To keep food safe from harmful bacteria, follow these four basic steps:

  • Clean: Wash hands, utensils, and surfaces with hot soapy water before and after handling raw meat.
  • 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 kill bacteria. Use a thermometer to ensure proper internal food temperatures. Chill: Refrigerate prepared foods and leftovers promptly.
Tips & Tricks

Cooking on your new grill is a hands-on experience, and it is recommended to remain outside with your grill while cooking. Grilling can be affected by many external conditions. In cold weather, you will need more heat to reach an ideal cooking temperature, and grilling may take longer. The meat’s internal temperature and thickness can also affect cooking times. Cold and thicker meats will take longer to cook.

Internal Meat Temperatures
Meat cooked on a grill often browns very fast on the outside. Therefore, use a meat thermometer to ensure it has reached safe internal temperatures.

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, Pieces & Ground| 165° F

Please refer to the USDA for complete, up-to-date information. Our internal temperature chart is based on USDA standards for meat doneness. Check it out at www.isitdoneyet.gov.

Sauces
Sauces containing sugars and fats can cause flare-ups, and your food may burn. In general, apply these sauces during the final 10 minutes of cooking. Keep in mind, the use of excessive sauces or glazes will also require extra cleaning afterwards.

Marinades and Rubs
To enhance the flavor of grilled foods, a liquid marinade or 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 flavour when grilling, try adding wood chips. Soak the chips in water for approximately 30 minutes before adding them to a smoke box or pan. Place a smoke box or pan on top of the cooking grate above the flame. Turn the grill on high until the wood starts to smoke. Reduce heat to the desired temperature for cooking, and place food on the cooking grate as desired. Close the lid to retain more smoke. Hardwood varieties that work particularly well with grilled foods include Alder, 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 used for quick cooking foods such as vegetables and fruits.

Utensils
Use tongs or a spatula to handle the food instead of a fork, and don’t turn the food too often. Piercing the food with a fork will release juices that you want in the meat, and may cause flare-ups.

Cleaning Your Grill

Why Clean?
We’ve all heard the saying, ‘an ounce of prevention is worth a pound of cure.’ This is great advice when it comes to keeping your grill clean.

Routine Care
Periodic cleaning of this grill is necessary, as grill fires can occur when grease and food debris collect in the bottom of the grill. After each use, remove any remaining food particles from the cooking grate and inside of the grill using a grill brush. Do this after the grill has cooled down, yet is still warm. It is much easier to clean food particles while warmth is still present, than after the food particles have completely cooled and hardened. This grill is not designed to be ‘burned off’ by closing the lid and turning the burners on High for an extended time. The excessive heat generated can cause leftover grease to catch fire, and can cause permanent damage to your grill.

General Cleaning

  • 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 powder for stubborn stains.
  • Painted surfaces: Wash with mild detergent or non-abrasive cleaner and warm water. Wipe dry with a soft non-abrasive cloth.
  • Stainless steel surfaces: Stainless steel can rust under certain conditions. This can be caused by environmental conditions such as chlorine or 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 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 before grilling. It is not recommended to clean cooking surfaces while grill is hot.

Storing Your Grill

  • Clean cooking grates.
  • Store the grill in a dry location.
  • When the LP cylinder is connected to the grill, store it outdoors in a well-ventilated space and out of reach of children.
  • Cover the grill if stored outdoors. Choose from a variety of grill covers offered by the manufacturer.
  • Store the grill indoors ONLY if the LP cylinder is turned off, disconnected, and removed from the grill. Never store the LP cylinder indoors.
  • When removing the grill from storage, follow the ‘Cleaning the Burner Assembly’ instructions in the Use and Care section 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.

LIMITED WARRANTY

This warranty only applies to units purchased from an authorized retailer. The 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

| PERIOD OF COVERAGE|

TYPE OF FAILURE COVERAGE

---|---|---
Burner| 2 years from the date of purchase| PERFORATION, MANUFACTURING, AND MATERIAL DEFECTS ONLY
All Other Parts| 1 year from date of purchase

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. The 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 discolouring 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 labour 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. The 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 by 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 THE MANUFACTURER EXCEPT TO THE EXTENT OUTLINED 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. The 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 forth 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 before the discovery of the nonconformity. In addition, in the state of California only, you may take the product to the retail establishment selling this product to obtain performance under this limited warranty.

If you wish to obtain the 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 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.

PARTS LIST

Key Qty Description
A 1 FIREBOX
B 4 TUBE BURNER
C 1 ELECTRODE, MAIN BURNER
D 3 CARRY OVER TUBE
E 1 CONTROL PANEL, MAIN
F 1 ELECTRONIC MODULE, W/BUTTON
G 1 BUTTON, F/ ELECTRONIC MODULE
H 1 VALVE/ HOSE/ REGULATOR
I 5 BEZEL F/ KNOB
J 5 CONTROL KNOB
K 1 GRILL LID
L 1 LOGO PLATE
M 1 TEMPERATURE GAUGE
N 2 LID BUMPER, RECTANGLE
O 1 GRILL LID HANDLE
P 1 TOP LID HARDWARE
Q 4 HEAT TENT
R 3 COOKING GRATE
S 1 SWING AWAY GRID
T 1 LEFT SIDE SHELF
U 1 DRIP PAN F/ SIDEBURNER
V 1 SIDEBURNER LID
W 1 CONTROL PANEL F/ LEFT SHELF
X 1 SIDEBURNER GRATE
Y 1 SIDEBURNER
Z 1 ELECTRODE, F/ SB
AA 1 RIGHT SIDE SHELF
BB 1 CONTROL PANEL F/ RIGHT SIDE SHELF
CC 1 CART, RIGHT SIDE
DD 1 MATCH HOLDER
EE 1 CART, LEFT SIDE
FF 1 FRONT PANEL
GG 1 BOTTOM SHELF
HH 1 AXLE ROD
II 2 WHEEL
JJ 1 GREASE CUP
--- --- ---
KK 1 CLIP, F/ GREASE CUP
LL 1 TANK EXCLUSION
MM 2 LEG EXTENDER
NN 1 WING SCREW F/ TANK
OO 2 LID BUMPER, ROUND
PP 1 WIRE, F/ SIDEBURNER
QQ 1 HEAT SHIELD F/ EI MODULE

NOT Pictured

1 VENTURI CLIP F/ SB
1 HARDWARE PACK
1 ASSEMBLY MANUAL, ENGLISH
1 ASSEMBLY MANUAL, SPANISH

NOTE:
Some grill parts shown in the assembly steps may differ slightly in appearance from those on your particular grill model. However, the methood of assembly remains the same.

PARTS DIAGRAM

Char-Broil-463440109-4-Burner-Liquid-Propane-Gas-Grill-fig-
\(37\)

ASSEMBLY

  1. Place legs as shown. The left leg assembly has large holes on the ends of the legs. Hook tank exclusion wire into right and left leg assembliesChar-Broil-463440109-4-Burner-Liquid-Propane-Gas-Grill-fig- \(38\)

  2. Place the bottom shelf with a cut-out hole for the LP tank next to the legs with axle holes. Attach to right and left leg assemblies with 1/4″-20×1-1/2″ screws and 1/4″-20 flange nuts.Char-Broil-463440109-4-Burner-Liquid-Propane-Gas-Grill-fig- \(39\)

  3. Attach the front panel to the cart with #8-32×3/8″ sheet metal screws.Char-Broil-463440109-4-Burner-Liquid-Propane-Gas-Grill-fig- \(40\)

  4. Turn the assembly upside down. Insert the axle rod into the wheel, Axle Spacer, legs and other Axle Spacer and wheel. Attach with (1) 8mm flat washer and hitch pin.Char-Broil-463440109-4-Burner-Liquid-Propane-Gas-Grill-fig- \(41\)

  5. Stand the cart upright. This step requires two people to lift and position the grill head onto the cart. Carefully lower the grill head onto the cart. Make sure the regulator hose is hanging outside the cart. Attach with 1/4″-20×1/2″ machine screws.Char-Broil-463440109-4-Burner-Liquid-Propane-Gas-Grill-fig- \(42\)

  6. Hook the side wall of the shelf over support brackets on the side of the firebox (A). Inside the firebox insert 7×15 fibre washers and 1/4 -20×1/2″ machine screws as shown (B). Attach the shelf with flange nuts on each side. (C).Char-Broil-463440109-4-Burner-Liquid-Propane-Gas-Grill-fig- \(43\)

  7. Attach fascia to the firebox with #8-32×3/8″ sheet metal screws.Char-Broil-463440109-4-Burner-Liquid-Propane-Gas-Grill-fig- \(44\)

  8. The hook side wall of the sideburner shelf over support brackets on the side of the firebox (A). Inside the firebox insert 7×15 fibre washers and 1/4 -20×1/2″ machine screws as shown (B). Attach sideburner shelf with flange nuts on each side. (C).Char-Broil-463440109-4-Burner-Liquid-Propane-Gas-Grill-fig- \(45\)

  9. Attach fascia to the firebox with #8-32×3/8″ sheet metal screws.Char-Broil-463440109-4-Burner-Liquid-Propane-Gas-Grill-fig- \(46\)

  10. Attach the sideburner bezel and valve with #8-32×3/8″ machine screws (A). Place the sideburner on the shelf. Make sure the valve is inside the sideburner tube. Attach the sideburner with wing nut (B). Hook burner clip to sideburner tube and around manifold. Attach the sideburner ignitor wire (C) Press the sideburner control knob onto the valve stem (D). Place grate onto sideburner shelf (E).Char-Broil-463440109-4-Burner-Liquid-Propane-Gas-Grill-fig- \(47\)

  11. Place heat tents over burners by inserting tabs into slots in front of the firebox. The opposite ends of heat tents rest on pins in the back of the firebox.Char-Broil-463440109-4-Burner-Liquid-Propane-Gas-Grill-fig- \(48\)

  12. Place cooking grates onto grate rests.

    • Insert the ends of the Swing Away pivot wire into holes in the sides of the grill lid. Insert ends of Swing Away leg wire into holes in the sides of the firebox.
    • NOTE: Pivot and leg wires, running side-to-side, should be under wires running front-to-back. If pivot and leg wires are on top,
    • Swing Away is installed upside-down.
    • Unscrew the ignitor cap and place the AAA battery into the ignitor slot with the positive end (+) facing outward. Screw the ignitor cap onto the ignitor.Char-Broil-463440109-4-Burner-Liquid-Propane-Gas-Grill-fig- \(49\)
  13. Hang the grease cup clip from the bottom of the firebox and place the grease cup into the grease clip.Char-Broil-463440109-4-Burner-Liquid-Propane-Gas-Grill-fig- \(50\)
    CAUTION
    Failure to install the grease cup clip and cup will cause hot grease to drip from the bottom of the grill with a risk of fire or property damage.

  14. LP tank is sold separately. Use only with an OPD (over-fill protection device) equipped LP tank. Fill and leak check before attaching to grill and regulator. Place LP tank into hole in bottom shelf with tank collar opening facing to side as shown. Finger tighten tank thumbscrew to hold LP tank securely in place.
    See the Use and Care section to correctly Leak Test and perform the Burner Flame CheckChar-Broil-463440109-4-Burner-Liquid-Propane-Gas-Grill-fig-
\(51\)

    • CAUTION
      Failure to install the tank correctly may allow the gas hose to be damaged in operation, resulting in the risk of fire.

EMERGENCIES:
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.

Gas leaking from LP cylinder.

Gas leaking from LP cylinder valve.

Gas leaking between LP cylinder and regulator connection.

Fire coming through the control panel.

Grease fire or continuous excessive flames above the cooking surface.

| •Damaged hose.

•Mechanical failure due to rusting or mishandling.

•   Failure of cylinder valve from mishandling or mechanical failure.

•Improper installation, connection not tight, failure of rubber seal.

•   Fire in burner tube section of burner due to blockage.

•   Too much grease buildup in the burner area.

| •Turn off gas at the LP cylinder or at the source on natural gas systems. If anything but burned, replace the valve/hose/regulator. If burned, discontinue the use of the product until a plumber has investigated the cause and corrections are made.

•Replace LP cylinder.

•   Turn off the LP cylinder valve. Return LP cylinder to gas supplier.

•Turn off the LP cylinder valve. Remove regulator from the cylinder and visually inspect the rubber seal for damage. See LP Cylinder Leak Test and Connecting Regulator to the LP Cylinder.

•Turn off control knobs and LP cylinder valve. Leave the lid open to allow the flames to die down. After the fire is out and the grill is cold, remove the burner and inspect for spider nests or rust. See Natural Hazard and Cleaning the Burner Assembly pages.

•   Turn off control knobs and LP cylinder valve. Leave the lid open to allow the flames to die down. After cooling, clean food particles and excess grease from inside the firebox area, grease tray, and other surfaces.

Troubleshooting

Problem Possible Cause Prevention/Solution

Burner(s) will not light using an ignitor.

(See Electronic Ignition Troubleshooting also)

Continued on the next page.

| GAS ISSUES:

•   Trying to light the wrong burner.

•   Burner not engaged with control valve.

•   Obstruction in burner.

•   No gas flow.

•   Vapor lock at coupling nut to LP cylinder.

•   Coupling nut and LP cylinder valve not fully connected.

ELECTRICAL ISSUES:

•Electrode cracked or broken; “sparks at crack.”

•Electrode tip not in proper position.

•Wire and/or electrode covered with cooking residue.

•Wires are loose or disconnected.

•Wires are shorting (sparking) between the ignitor and electrode.

•Dead battery.

| •   See instructions on the control panel and in the Use and Care section.

•   Make sure valves are positioned inside burner tubes.

•   Ensure burner tubes are not obstructed with spider webs or other matter. See the cleaning section of Use and Care.

•   Make sure the LP cylinder is not empty. If the LP cylinder is not empty, refer to “Sudden drop in gas flow.”

•   Turn off the knobs and disconnect the coupling nut from the LP cylinder. Reconnect and retry.

•   Turn the coupling nut approximately one-half to three-quarters additional turn until solid stop. Tighten by hand only – do not use tools.

•   Replace electrode(s).

Main Burners:

• The tip of the electrode should be pointing toward the gas port opening on the burner. The distance should be 1/8” to 1/4”. Adjust if necessary.

Sideburner:

• The tip of the electrode should be pointing toward the gas port opening on the burner. the distance should be 1/8” to 3/16”. Adjust if necessary.

•Clean wire and/or electrode with rubbing alcohol and a clean swab.

•Reconnect wires or replace electrode/wire assembly.

•Replace ignitor wire/electrode assembly.

•Replace with a new AA-size alkaline battery.

REV00

Burner(s) will not light using ignitor.

(See Electronic Ignition Troubleshooting also)

| ELECTRONIC IGNITION:

•No spark, no ignition noise.

•No spark, some ignition noise.

•Sparks, but not at electrode or at full strength.

| •   See Section I of Electronic Ignition System.

•   See Section II of Electronic Ignition System.

•   See Section III of Electronic Ignition System.

---|---|---
Burner(s) will not match light.| •See “GAS ISSUES:” on the previous page.

•Match will not reach.

•Improper method of match-lighting.

| •Use long-stem match (fireplace match).

•See the “Match-Lighting” section of Use and Care.

Sudden drop in gas flow or low flame.| •Out of gas.

•Excess flow valve tripped.

•Vapor lock at coupling nut/LP cylinder connection.

| •Check for gas in the LP cylinder.

•Turn off the knobs, wait 30 seconds and light the grill. If flames are still low, turn off the knobs and LP cylinder valve. Disconnect regulator.

Reconnect regulator and leak test. Turn on the LP cylinder valve, wait 30 seconds and then light the grill.

•Turn off knobs and LP cylinder valve. Disconnect the coupling nut from the cylinder. Reconnect and retry.

Flames blow out.| •High or gusting winds.

•Low on LP gas.

•Excess flow valve tripped.

| •Turn the front of the grill to face the wind or increase the flame height.

•Refill LP cylinder.

•Refer to “Sudden drop in gas flow” above.

Flare-up.| •Grease buildup.

•Excessive fat in meat.

•Excessive cooking temperature.

| •Clean burners and the inside of the grill/firebox.

•Trim fat from meat before grilling.

•Adjust the (lower) temperature accordingly.

Persistent grease fire.| •Grease trapped by food buildup around the burner system.| •Turn knobs to OFF. Turn the gas off at the LP cylinder. Leave the lid in position and let the fire burn out. After the 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 the 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 another burner (s).| •Grease buildup or food particles in end(s) of carryover tube(s).| •Clean carry-over tube(s) with wire brush.

Troubleshooting – Electronic Ignition

Problem (Ignition)| Possible Cause| Check Procedure| Prevention/Solution
---|---|---|---
SECTION I

No sparks appear at any electrodes when the control knob is turned ; no noise can be heard from the spark module.

| ****

•Battery not installed properly.

•Dead battery.

•Button assembly not installed properly.

•Faulty spark module.

| ****

•Check battery orientation.

•Has the battery been used previously?

•Check to ensure threads are properly engaged. The button should travel up and down without binding.

•If no sparks are generated with a new battery and good wire connections, the module is faulty.

| •Install battery (make sure that “+” and “–” connectors are oriented correctly, with “+” end up and “–” end down.)

•Replace battery with new AA-size alkaline battery.

•Unscrew the button cap assembly and reinstall, making sure threads are aligned and engaged fully.

•Replace spark module assembly.


SECTION II

No sparks appear at any electrodes when the control knob is turned on ; noise can be heard from the spark module.

| •Output lead connections not connected.| •Are output connections on and tight?| •Remove and reconnect all output connections at the module and electrodes.


SECTION III

Sparks are present but not at all electrodes and/or not at full strength

| ****

•Output lead connections not connected.

•Arcing to grill away from burner(s).

•Weak battery.

•Electrodes are wet.

•Electrodes cracked or broken “sparks at crack”.

| ****

•Are output connections on and tight?

•If possible, observe the grill in a dark location. Operate the ignition system and look for arcing between output wires and the grill frame.

•All sparks present but weak or at a slow rate.

•Has moisture accumulated

on electrode and/or in burner ports?

•Inspect electrodes for cracks.

| •Remove and reconnect all output connections at the module and electrodes.

•If sparks are observed other than from burner(s), wire insulation may be damaged. Replace wires.

•Replace the battery with a new AA-size alkaline battery.

•Use a paper towel to remove moisture.

•Replace cracked or broken electrodes.

Please register your product online at:
www.charbroil.com/register

(If you register online, you do not need to send in this registration card.)

PLEASE FILL OUT THIS CARD AND ATTACH A COPY OF YOUR SALES RECEIPT. RETURN IT WITHIN 10 DAYS OF PURCHASE. FAILURE TO RETURN MAY AFFECT YOUR WARRANTY COVERAGE. FOR WARRANTY SERVICE PROOF OF PURCHASE WILL BE REQUIRED. THIS WARRANTY IS NON-TRANSFERABLE. LLENE ESTA TARJETA Y DEVUELVALA DENTRO DE LOS 10 DIAS DE LA COMPRA. SI NO LA DEVUELVE, PUEDE VERSE AFECT ADA SU COBERTURA DE GARANTIA. PARA EL SERVICIO DE GARANTIA ES NECESARIO QUE PRESENTE SU COMPROBANTE DE COMPRA. CONSERVE LA FACTURA. ESTA GARANTIA ES INTRANSFERIBLE. VEUILLEZ COMPLETER CETTE CARTE ET LA RETOURNER DANS LES 10 JOURS SUIVANT L’ACHAT. LA COUVERTURE DE VOTRE GARANTIE POURRAIT EN ETRE AFFECTEE SI VOUS NE LE FAITES PAS. POUR OBTENIR LE SERVICE SOUS GARANTIE, UNE PREUVE D’ACHAT DOIT ETRE PRESENTEE. VEUILLEZ CONSERVER VOTRE FACTURE. LA PRESENTE GARANTIE N’EST PAS TRANSFERABLE.

Char-Broil-463440109-4-Burner-Liquid-Propane-Gas-Grill-fig-
\(52\)

Here’s what you can find atwww.charbroil.com

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  • And much more!

Please visit us at www.charbroil.com and click on the Buy Online link to find grilling tools and accessories, maintenance items, covers, grill parts, Char-Broil® grills and cookers, and of course, the famous Oklahoma Joe’s° sauces, rubs, and marinades. We also have a Special Offers section, so be sure to check often for special deals.

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  • Charbroil.com also offers online customer support for Char-Broil® products.

Thank you for your support, and HAPPY GRILLING!

www.charbroil.com
For all your grilling needs!

References

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