Char-Broil 463620409 Product Manual

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PRODUCT

GUIDE

MODEL

463620409

iMPORTANT: Fill out the product record information below,

Serial Number

Date Purchased

See ratinglabel on grill for serialnumber,

Forsupportandto registeryour

grill, pleasevisit us at

www.charbroil.com

If you havequestionsor need

assistanceduringassembly,

pleasecall 1-800-241-7548.

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®; Amedcan

Gourmet®; Bandera®;

BrushHawg®;

CB940®; Char-Diamonds®;

Char-Broil Charcoal/Gas®;

DiamondFlame®;

Everybody

Gdlls®; 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 SeriesTM; Designer SeriesTM; Gdll2Go® Advantage TM LonghornTM; Double CheffM;

QuickSetTM; Ready When You AreTM; Hog and Yard BirdTM; 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;

D4t6,164;

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:

D477A98;

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;

I04,200;

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.

TM REViSiON 00

Printedin China

Rev.02 • 08-02-08 • 80012081

Table of Contents

Summary of Contents for Char-Broil 463620409

Page 1 If you havequestionsor need assistanceduringassembly, pleasecall 1-800-241-7548. 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®; Amedcan Gourmet®; Bandera®; BrushHawg®; CB940®; Char-Diamonds®;...
Page 2 For Your Safety ........If you smell gas: Grilling Guide ........Use and Care ........8-13 1. Shut off gas to the appliance. Limited Warranty ........2. Extinguish any open flame. 3. Open lid. Parts List .......... 4. If odor continues, keep away from the Parts Diagram ........
Page 3: California Proposition
CALiFORNiA P ROPOSiTiON 65 1.Combustion by-products produced whenusing this productcontain 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.
Page 4 Temperature The temperature gauge in the hood of your new grill measures First Time Use air temperature. The air temperature inside your grill will never be as hot as the temperature at the cooking surface. Read your Assembly Manual and ensure the grill is put together properly.
Page 5: Rotisserie C Ooking
Rotisserie C ooking Rotisserie cooking isbest f or'round' meat, such aslarge roasts, whole poultry, andpork.Itgenerally requires anaccessory motor Outdoor grilling i sreally q uite simple. You'll succeed with and spitrodthatallows t hemeat tobeturned a ta constant burgers, dogs, o rsteaks u sually o nyour v ery first t ry.With speed.
Page 6 Wood Chips For extra smoke flavor when grilling, try adding wood chips. Cooking onyour n ew grill i sahands-on experience, anditis Soak the chips in water for approximately 30 minutes before recommended toremain o utside w ithyour g rill w hile cooking. adding to a smoke box or pan.
Page 7: Routine Care
Cooking surfaces: If a bristle brush is used to clean any of the grill cooking surfaces, ensure no loose bristles remain on cooking WhyClean? surfaces prior to grilling. It is not recommended to clean cooking We've a llheard t hesaying, 'anounce o fprevention isworth a surfaces while grill is hot.
Page 8 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. • NEVER store a spare LP cylinder under or near the •...
Page 9 LP Tank Exchange Connecting Regulator To The LP Tank • Many retailers that sell grills offer you the option of replacing 1. LP tank must be properly secured onto grill. (Refer to your empty LP tank through an exchange service. Use only assembly section.) those reputable exchange companies that inspect, precision fill, 2.
Page 10 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 11 Safety Tips A Before opening LP cylinder valve, check the coupling nut for tightness. A When grill is not in use, turn off all control knobs and LP ForSafeUseOf Your Grill And To Avoid Serious cylinder valve. Injury: A Never move grill while in operation or still hot. A Use long-handled barbecue utensils and oven mitts to avoid * Do not let children operate or play near grill.
Page 12 Burner Flame Check • Light burner, rotate knobs from HIGH to LOW. You should see a smaller flame in LOW position than seen on HIGH. Always check flame prior to each use. If only low flame is seen refer to Turn controls and gas source or tank OFF when not "Sudden drop or low flame"...
Page 13 cAuTioN Cleaning the Burner Assembly Follow these instructions to clean and/or replace parts of burner assembly or if you have trouble igniting grill. Turn gas off at control knobs and LP cylinder. SPIDER ALERT! Remove cooking grate and heat tent. Under grill remove grease cup, disconnect ignitor wire from burner.
Page 14 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 15 Part # Description Part # Description FIREBOX BOWL 80017400 HARDWARE PACK 80012080 GRILL LID 80012067 80012081 ASSEMBLY MANUAL, ENGLISH LOGO PLATE 80005765 HOSE/VALVE/REGULATOR ASSY 80017966 CONTROL PANEL, MAIN 80017954 BURNER 80012070 ELECTRODE/COLLECTOR 80017659 SIDE SHELF 80012073 MOUNTING BRACKET, F/SIDE 80017760 SHELF, BACK MOUNTING BRACKET, F/SIDE 80017761...
Page 17 Left Leg PlaceupperLeft leg as shown. NOTE:Left front and left back legsdo not haveleg extenders. In front,attachupperleg, side braceand left front leg (curve)with #10-24x1-1/4"machine screw and#10-24flange nut. Attachsupportbracketin thirdhole from bottomof leg with a hinge pinsand hitchpins (A). UpperLeg,Left HitchPin Qty.2 Side Brace Left BackLeg...
Page 18 Front Panels Lay front legs down on the floor. Slidefront panel underlegs.Attachwith #10-24x2"Machine screws and #10-24flange nuts. #10-24x2"MachineScrew Qty.4 #10-24 FlangeNut Qty.4 Attachback braceswith #10-24x1-1/4"Machine screws and#10-24flange nuts. Wheels Back Braces to Cart Turnassemblyupsidedown. Insertaxlerod intowheel,legsand otherwheel.Attachwith a wheelbushingand hitchpin. Attachall in secondhole. HitchPin Qty.1 Wheel...
Page 19 Control Panel and Firebox Supports Standcart upright. In front,slidecontrolpanelbetweenleft and rightlegs, attachcontrolpanelwith #10-24x2"Machine screws. and#10-24flange nuts. Tightenall screws. ControlPanel #10-24x2" MachineScrews Qty.4 #10-24FlangeNut Qty.4 Insetmainburnervalveand hosebetweenleftfirebox supportand side brace, attachvalve/hose/regulator assembly to control Valve/Hose/Regulatorand Ignitor. panelwith #10-24x1/2"Machine screws. Attachignitorto controlpanel usingthe stampednutthat's provided.NOTE:If your grill comes with Snap-in ignitor,please see Option.
Page 20 Hooktank exclusionwires ontofront panelbrackets,attachotherend to back bracewith #8-32x3/8"Sheet Metal Screws. #8-32x3/8"SheetMetal Screw Qty.2 Heat Shield Attachheat shieldwith #10-24x1/2"Machine screws and#10-24flange nuts Tank Retainer Inserttank retainerinto sidebraceand securewith #10-24x3/8" WingScrew. #10-24xl/2" MachineScrew Qty.2 HeatShield #10-24FlangeNut Qty.2 #10-24x3/8" WingScrew Qty.1...
Page 21 Burner and Firebox and Control Knobs Placeburnerassemblyintofirebox.Fastenthe burnerassembly to the fireboxusing 5x15Fiber Washers and #10-24x Y2" Machine Screws. Inserttwo #10-24x1-1/4"Machine Screws from outerfirebox,then fastenwith two #10-24 FlangeNuts and 5x15 Fiber Washersfrom inner.Repeaton the otherside(A). Placefireboxontocart (upperlegs). Makesurethe venturitube are locatedunderneathHeatShield.Makesureburnertubes are correctlyengaged.If burneris not levelfrom left to right, adjustthe two screwsattachingvalveto controlpanel.Attachignitorwire to ignitor(B).
Page 22 Shelves insertmountingbracketsinto shelf supportswith #8-32x3/8"Sheet Metal Screw andSide Shelf Bushing (A). Attachmountingbracketsto front of leg with 1/4"-20x1/2"Machine Screws, Backof leg with 1/4"-20x1-1/4"screw and1/4"-20 FlangeNuts (B). Repeatabove steps for another side. MountingBracket 1/4"-20xl/2" MachineScrew Qty.4 1/4"-20x1-1/4" MachineScrew #8-32x3/8"SheetMetalScrew Qty.4 1/4"-20FlangeNut Qty.4 #8-32x3/8"Sheet SideShelf Bushing MetalScrew...
Page 23 Lower Hinges Attachlowerhingesto back of fireboxusing#10-24xl/2" MachineScrews, 5x15 FiberWashers and #10-24Flange Nuts. The centerfiat portionof the hingeshouldbe at the bottom(seeinset). #10-24xl/2" 5x15 #10-24 MachineScrew FiberWasher FlangeNut LowerHinge Qty.4 Qty.8 Qty.4 Centerflat portion of hinge on bottom. Lid Handle and Upper Hinges Attachhandleto lid with 7x15fiber washers and 1/4"-20Wing Nuts.
Page 24 Place lid assembly onto firebox, aligning hinges. Upper Hinges fit inside lower hinges. Secure using two hinge pins and hitch pins. NOTE: Tighten the hinges screws after installing the hinge pins. HingePin Qty.2 HitchPin Qty.2 Heat Tent Place heat tent into firebox. Align the slots on heat tent to heat tent support screws. Heat Tent Cooking Orate Placegrateintofirebox.
Page 25 Hanggreasecup clipfrom bottomof firebox andplacegreasecupinto greaseclip CAUTION Failure to install grease cup clip and cup will cause hot grease to drip from bottom of grill with risk of fire or property damage. Tank collar opening must face to front of grill. Loosen wing nuts from tank retainer bracket. Set bottom of tank into notches of tank bracket.
Page 26: Gas Issues
EMERGENCIES; if a gas leak cannot be stopped, or a fire occurs due to gas leakage, call the fire department. Gas leakingfrom • Damaged hose. • Turnoff gas at LP cylinderor at sourceon naturalgassystems.If cracked/cut/burned anythingbutburned,replacevalve/hose/regulator. If burned, hose. discontinueuseof productuntila plumberhas investigated cause and correctionsare made.
Page 27 Troubleshooting (continued) Burner(s)will not light ELECTRONICIGNITION: • See SectionI of ElectronicIgnitionSystem. using ignitor. ° No spark, no ignition noise. (See Electronic Ignition Troubleshooting also) ° No spark, some ignitionnoise. • See SectionII of ElectronicIgnitionSystem. • See SectionIII of ElectronicIgnitionSystem. ° Sparks, but not at electrode or at full strength.
Page 31 Pleaseregisteryour productonlineat: (if you register online, you do not need to send in this registration card.) PLEASE FiLL OUTTHiS CARD AND ATTACH A COPYOF YOUR SALES RECEIPT. RETURNiT WiTHiN 10 DAYS OF PURCHASE.FAILURETO RETURNMAY AFFECT YOUR WARRANTYCOVERAGE.FORWARRANTYSERVICE PROOFOF PURCHASEWiLL BE REQUIRED. THiS WARRANTY iS NON=TRANSFERABLE. LLENEESTATARJETAY DEVUELVALA DENTRODE LOS 10 DIAS DE LA COMPRA.
Page 32 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 specials deals.

Char-Broil 463620409 Product Manual

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Summary of Contents for Char-Broil 463620409

Page 3: California Proposition

Page 5: Rotisserie C Ooking

Page 7: Routine Care

Page 26: Gas Issues