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Char-Broil 466271509 Product Manual

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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
© 2008 Char-Broil, LLC Columbus, GA 31902
PRODUCT GUIDE
MODEL 466271509
IMPORTANT: Fill out the product record information below.
Serial Number
Date Purchased
For support and to register your
grill, please visit us at
www.charbroil.com
If you have questions or need
assistance during assembly,
please call 1-888-430-7870.
Estimated assembly time: 30 minutes
®
®
Printed in China
See rating label on grill for serial number.
Assembly instructions © 2008
12/23/08 • 80019079
TM REVISION 00

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Summary of Contents for Char-Broil 466271509

  • Page 1 1-888-430-7870. Estimated assembly time: 30 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®;...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS DANGER For Your Safety ........2-3 If you smell gas: Use and Care .
  • Page 3 WARNING CAUTION CALIFORNIA PROPOSITION 65 Using pots larger than 6 quarts in capacity could 1. Combustion by-products produced when using exceed weight limit of the this product contain chemicals known to the State of side burner shelf, California to cause cancer, birth defects, and other resulting in failure reproductive harm.
  • Page 4 LP Cylinder USE AND CARE •The LP cylinder used with your grill must meet the following requirements: DANGER •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. •...

  • Page 5: For Your Safety

    LP Cylinder Exchange Connecting Regulator to the LP Cylinder 1.LP cylinder must be properly secured onto grill. (Refer to •Many retailers that sell grills offer you the option of replacing your empty LP cylinder through an exchange service. Use only assembly section.) those reputable exchange companies that inspect, precision fill, 2.Turn all control knobs to the OFF position.
  • Page 6 Leak Testing Valves, Hose and Regulator 1.Turn all grill control knobs to OFF. 2.Be sure regulator is tightly 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.
  • Page 7 Safety Tips WARNING  Before opening LP cylinder valve, check the coupling nut for tightness.  When grill is not in use, turn off all control knobs and LP For Safe Use of Your Grill and to Avoid Serious cylinder valve. ...
  • Page 8 Burner Flame Check WARNING •Remove cooking grates and flame tamers. Light burners, rotate knobs from HIGH to LOW. You should see a smaller flame in Turn controls and gas source or tank OFF when not LOW position than seen on HIGH. Perform burner flame check in use.
  • Page 9 Cleaning the Burner Assembly CAUTION Follow these instructions to clean and/or replace parts of burner assembly or if you have trouble igniting grill. 1. Turn gas off at control knobs and LP cylinder. SPIDER ALERT! 2. Remove cooking grates and flame tamers. 3.
  • Page 10 Grill Halogen Light LIGHT OPERATION INSTRUCTIONS 1. Make sure light switch on the control panel is in the “OFF” position. 2. Connect adapter plug to an extension cord, then put the extension cord plug into the outlet on the wall. 3.
  • Page 11 Cleaning the Lens 1. Prior to cleaning, make sure the light switch is in the “OFF” position and the AC adaptor is disconnected from the power supply. 2. Do not clean the glass lens when warm. Allow to cool before cleaning. Sudden change in temperature may cause cracking of the glass lens.

  • Page 12: Limited Warranty

    LIMITED WARRANTY This warranty only applies to units purchased from an authorized retailer. Manufacturer warrants to the original consumer-purchaser only that this product shall be free from defects in workmanship and materials after correct assembly and under normal and reasonable home use for the periods indicated below beginning on the date of purchase*.

  • Page 13: Parts List

    PARTS LIST Key Qty Description Key Qty Description BOTTOM SHELF TOWEL BAR TANK SCREW, F/ BOTTOM SHELF TOP LID, OUTER INNER LINER, F/ TOP LID TANK GAUGE HANDLE F/ TOP LID DISPLAY, F/ TANK GAUGE RECTANGULAR BUMPER, F/ TOP LID CASTER, LOCKING LOGO PLATE CASTER, FIXED...

  • Page 14: Parts Diagram

    PARTS DIAGRAM...

  • Page 15: Assembly

    ASSEMBLY Attach the two locking casters at the rear of the bottom shelf and the two fixed casters at the front. Use the provided caster wrench to fully tighten casters. Fixed caster Locking caster Bottom shelf Rear Attach side panels to bottom shelf using three 1/4-20x1/2” 1/4-20x1/2”...
  • Page 16 Place lower back panel between side panels at rear of bottom shelf. Make sure the slots are positioned as shown (A). Secure lower back panel to side panels using four 1/4-20x1/2” screws, 7mm lock washers, and 7mm flat washers. 7mm flat washer 1/4-20x1/2”...
  • Page 17 On back of grill, place upper back panel between side panels and above lower back panel. Secure upper back panel, in lower holes, using one 1/4-20x1½” screw, 7mm lock washer, and 7mm flat washer on each side. Do not fully tighten screws until side shelf installation is complete in later steps. Light wire must be inside of the cart.
  • Page 18 Inside the cart left, fix Light wires with one Hose clip and secure it to the upper back panel using one #8-32x3/8” screw, 4mm flat washer, 4mm lock washer and #8 nut, shown A/B. Connect Adapter wire harness and Light wire harness. Fix Adapter wires with one clip(w/two holes) and secure it to the lower back panel using two #8-32x3/8”...
  • Page 19 Attach towel bar to the right side shelf using two 1/4-20x1/2” screws, 7mm lock washers, 7mm flat washers, shown A. Insert flange on right side shelf into side shelf brackets on side of firebox, shown B. Attach rear of shelf using one 1/4-20x3/4” screw, 7mm flat washer, 7mm lock washer, and 1/4” nut in upper hole; using one 1/4-20x1½”...
  • Page 20 Insert flange on left side shelf into side shelf brackets on side of firebox, shown A. Attach rear of shelf using one 1/4-20x3/4” screw, 7mm flat washer, 7mm lock washer and 1/4” nut in upper hole; and using 1/4-20x1½” screw, 7mm lock washer, 7mm flat washer in lower hole, shown B/C. Attach front of shelf and fascia using two 1/4-20x3/4”...
  • Page 21 Insert front brace under control panel and between cart side panels. Make sure door hinge pins are on the top side and facing the front. Secure using two 1/4-20x1½” screws, 7mm lock washers, and 7mm flat washers on each side. NOTE: MAKE SURE THAT THE FRONT BRACE IS MOUNTED IN THE MOST DOWNWARD POSITION WHEN ASSEMBLED TO CART.
  • Page 22 Insert sideburner burner into left shelf. The stud on bottom of burner fits into rear small hole in sideburner drip pan on shelf, shown A. Secure burner to sideburner drip pan with one Wing nut, shown B. Under sideburner shelf, attach sideburner ignitor wire to electrode.
  • Page 23 Place sideburner grate onto sidebruner shelf. Sideburner grate Inside of cart, insert rear heat shield tabs(without holes) into three slots between upper and lower back panels, shown A. Attach shield tabs under front brace with three #8x3/8” self-tapping screws. Then insert left and right grease tray rails into slots beneath grease tray opening in rear upper panel.
  • Page 24 Inside of cart, insert end of tank wire (without hole) into back of lower back panel. Attach other end to bottom of front brace with a #8x3/8” self-tapping screw. Front brace #8x3/8” self-tapping screw Tank wire end of tank wire Inside of cart, insert tank exclusion wire ends into lower back panel.
  • Page 25 Release the cap and nut from electronic ignition module. Attach electronic ignition module and heat shield to the cart right side panel with the nut, shown A. – Insert AA battery into ignition module, negative ( ) end first. Then put on the cap, shown B. Connect each of the wires from the main burner electrodes, and sideburner electrode into the back of the electronic ignition module.
  • Page 26 Insert hinge pin on bottom of doors into hole in bottom shelf. Press upper hinge pin in front brace, align hinge hole on top of door, and release hinge pin into door. PRESS Top of door Hinge pin on bottom of door Left door Right door...
  • Page 27 Place cooking grates onto the firebox as shown. Insert the two wire ends at rear of warming rack into holes in back of firebox. Front wires of warming rack rest on sides of firebox. Cooking grate On back of grill, slide grease tray into opening in upper back panel. CAUTION Failure to install grease tray will cause hot grease to drip from bottom...
  • Page 28 Inside of the cart, put two AA batteries in the tank gauge shelf. Some components not shown for illustration purposes. Tank gauge shelf LP CYLINDER IS SOLD SEPARATELY. Fill and leak check the cylinder before attaching to grill and regulator (see Use & Care section).

  • Page 29: Troubleshooting

    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 •Damaged hose. •Turn off gas at LP cylinder or at source on natural gas systems. If cracked/cut/burned anything but burned, replace valve/hose/regulator.
  • Page 30 Troubleshooting (continued) Problem Possible Cause Prevention/Solution ELECTRONIC IGNITION: Burner(s) will not light using ignitor. •No spark, no ignition noise. • See Section I of Electronic Ignition System. (See Electronic Ignition Troubleshooting also) •No spark, some ignition noise. • See Section II of Electronic Ignition System. •Sparks, but not at electrode or at full •...
  • Page 31 Troubleshooting - Electronic Ignition Problem (Ignition) Possible Cause Check Procedure Prevention/Solution SECTION I No sparks appear at •Battery not installed •Check battery orientation. •Install battery (make sure that “+” and “–” any electrodes when properly. connectors are oriented correctly, with “+” end up and “–”...
  • Page 32 NOTES...
  • Page 33 NOTES...
  • Page 34 NOTES...
  • Page 35 REGTEMP REV00...