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Char-Broil 415.16112010 Product Manual

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PRODUCT
GUIDE
Sears
item
No, 161 t2
Sears
Mode|
No. 415.16112010
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: Caldera®; Charcoal2Go®;
Char-Broil@; America's Legendary
Barbeque
Company®; American
Gourmet®;
Bandera®;
Brush Hawg®; CB 940®; Char-Diamonds@;
Char-Broil Charcoal/Gas@;
Everybody Grills@; Everybody
Outside®;
FastStart®;
Grill 2 Go®; Grill 2 Go® Express@; Grill Lovers@; Infrared Grilling That's All About U®; Keepers of the Flame®; New Braunfels Smoker
Company®;
Patio Bistro®; Patio Caddie®; Patio Kitchen®; Pro-Sear@; RED®; Quantum@; Santa Fe@; Sear and Grill@; Sierra@; Signature Series@; Sure2Burn@;
The Big Easy@; Trentino@; U@; Wild West Tradition®; and the following marks:
,._i
®
AUT®-CL_AN'_
The following are trademarks of W.C. Bradley Co.: Advantage Series TM ; Auto-Clean TM ;Chef Tested TM ;Com mercial Series TM ; Designer Series TM ;; Diamond Flame TM ;
Double ChefTM; Fireball TM;FirenzyTM ; FlavorMasterTM ;FrontAvenueTM; Grill 2 Go@AdvantageTM; Hog and Yard Bird TM;H20 SmokerTM; Infrared. Grilling's Juicy Little
SecretTM; Incredible
Taste. Infallible ResultsTM; Infrared InsideTM; InsureTM; Let's Grill Something
TogetherTM; Lev-AlertTM; LonghornTM; MagnetoTM; Precision
FlameTM; Quick2BurnTM; QuickSetTM; Ready When You AreTM; Season, Set, And SavorTM; Sizzle On The GrilITM; Signature
SeriesTM; SureFireTM; The Minute
Grill
TM
;TorchforkTM; Universal Grill PartsTM; You Bring the Party
TM
TEC
TM
is a trademark of Tec Infrared Grills.
Protected underone or more of the following U.S. Patents: 5,421,3t9; 5,458,309;5,579,755; 5,996,573; 6,135,104;6,279,566; 6,33t,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; 6,792,935;6,951,213; 7,047,590;
7,516,693;D364,535; D372,637; D373,701;D377,735; D383,035; D397,9t0; D405,643;D406,OO5; D 406,OO9 ; D413,043;D413,229; D414,982; D415,388;D416,164; D4t6,441; D4t7,587; D417,588; D422,516; D423,274;D423,876; D428,303; D430,772;D435,396;
D436,004; [:)438,059;[:)438,060; D 438A27; [:)439,11 O; D442,505;D443,179; D443,354; D443A64; D447,384;D447,385; D447,909; D448,6t0; D448,614;D448,615; D448,616; D448,975; D449A92; D450,844; D451,759; D454,028; D454,03t; D455,205; D455,206;
D456,202; D456,222; D456,223;D457,789; D458,520; [:)458,760;D458,802; D459,088; D459,148D459,149; D459,161; D459,163;D459,586; [:)459,943;D460,3t2; D460,3t3; D460,3t8; D46t,359; D465,123; D465,693; D466,307; D466A39; D466,752; D473At4;
D474,371; D477A98; D477,50t; D477,504; D477,506; D477,746; D478A71; D478A72; D480,914; D491A10; D494,009; D494At3; D49&523; D500,359; D504,048; D530,098; D535,OOO; Canada:D97,504;D99,355; D102,037; D104,2OO;DtOS,377; 2 ,315,567;
France:D010,231;DOt 0 ,422;D010,590;D0t0,849; 1,089,646;South Korea:384,565; United Kingdom:2,099,402.OtherPatents Pending. @2009 W.C.Bradley Company
@2009 Char-Broil,LLC Columbus,GA 31902
Printed in China
Assembly instructions@ 2009
Model 463723310
10/23/09 • G305-001-210801

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  • Page 1 D474,371; D477A98; D477,50t; D477,504; D477,506; D477,746; D478A71; D478A72; D480,914; D491A10; D494,009; D494At3; D49&523; D500,359; D504,048; D530,098; D535,OOO; Canada:D97,504;D99,355; D102,037; D104,2OO;DtOS,377; 2 ,315,567; France:D010,231;DOt 0 ,422;D010,590;D0t0,849; 1,089,646;South Korea:384,565; United Kingdom:2,099,402.OtherPatents Pending. @2009 W.C.Bradley Company @2009 Char-Broil,LLC Columbus,GA 31902 Printed in China...
  • 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

    CAUTION CALIFORNIA P ROPOSITION 65 Using pots larger than 6 quarts in capacity could 1.Combustion by-products produced whenusing exceed weight limit of the side burner shelf this productcontainchemicalsknownto the Stateof California to causecancer, b irth defects,andother or side shelf, reproductive harm. resulting in failure 2.This productcontainschemicals, including lead...
  • 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 •LP cylinders must be constructed and marked in accordance the appliance or in an enclosed area.
  • Page 9 LP Cylinder Exchange Connecting Regulator to the LP Cylinder •Many retailers that sell grills offer you the option of replacing 1.LP cylinder must be properly secured onto grill. (Refer to 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 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 A Only use 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. A If you have a grill problem see the "Troubleshooting Section". A If the regulator frosts, turn off grill and LP cylinder valve immediately.
  • Page 12 Sideburner Match Lighting Ignitor Lighting 1. Turn OFF all burner control valves. A Do not lean over grill while Eghting. 2. Open sideburner lid (if equipped). 1. Turn OFF gas burner control valves. Turn ON gas at LP cylinder. 2 Turn ON gas at LP cylinder. 3.
  • Page 13 * Plated wire grates: Wash grates with concentrated grill Cleaning the Burner Assembly cleaner or use soap and water solution. Dry thoroughly and Follow these instructions to clean and/or replace parts of burner store indoors between cookouts. assembly or if you have trouble igniting grill. , Plastic parts: Wash with warm soapy water and wipe dry.
  • Page 14 This warranty only applies to units purchased from an authorized retailer. ManuPacturer warrants to the original cunsumer-purchaser only that this product shall be fiec 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: Right Side Shelf

    il! i IIIIIIIIIIllli ii LEFT FRONTLEG, CURVED MOUNTING BRACKET, F/SHELF, (LF/RB) LEFT BACK LEG, STRAIGHT MOUNTING BRACKET, F/SHELF, (RF/LB) SIDE BRACE LEFT SIDE SHELF F/SB MATCH HOLDER DRIP PAN F/SB UPPER LEG SIDEBURNER SUPPORT BRACKET ELECTRODE W/ WIRE, F/SB RETAINER CLIP RIGHT FRONT LEG, CURVED LID F/SB RIGHTBACK LEG, STRAIGHT...
  • Page 16 R_-_...
  • Page 17 Left Leg Place one upper leg as shown. NOTE: Left front and left back legs do not have leg extenders. In front, attach upper leg, side brace and left front leg (curve) with #10-24x1-1/4" machine screw and #10-24 flange nut. Tighten screw. In back, attach upper leg, side brace and left back leg (straight) with #10-24x1-1/4"...
  • Page 18 Upper and lower Front Panel and Top brace Lay front legs down on the floor. Fit upper front panel between legs. Attach with 2" hinge pins and hitch pins through the 3rd hole down from the top of the leg, and the bottom hole of the top front panel. _Attach lower front panel with #10-24x2"...
  • Page 19 Tank Exclusion Hook tank exclusion wires onto lower front panel brackets, attach other ends to back brace with #8-32x3/8" sheet metal screws. #8-32X3/8" #8-32X3/8" Sheet Metal Screw Sheet Metal Screw Qty. 2 Loosen screws to adjust upper and front panels to line up Tank Exclusion Wire Back Brace...
  • Page 20 Control Panel and Firebox Support ill] Stand cart upright. In front, fit control panel between left and right legs. Insert #10-24x2" machine screws to hold panel in place. Place upper firebox supports onto screws making sure angle side is facing the front and attach with #10-24 flange nuts. See the insert for correct placement.
  • Page 21 Heat Shield Attach heat shield with #10-24x1/2" machine screws and #10-24 flange nuts. Tank Retainer Insert tank retainer into side brace and secure with #10-24x3/8" wing screw. #10-24xl/2" #10-24 Machine Screw Flange Nut Qty.2 Qty. 2 #10-24x3/8" Wing Screw Qty.1 Front Panel Handle and Condiment basket Attach front panel handle to upper front panel using #10-24 flange nuts (A).
  • Page 22 Burner, Firebox and Control Knobs Place burner assembly into firebox. Fasten the burner assembly to the firebox using 5x15 fiber washers and #10- 24x1/2" machine screws (A). i_ Insert #10-24x1-1/4" machine screws from outside firebox, then fasten with #10-24 flange nuts and 5x15 fiber washers from inside (A).
  • Page 23 Right Side Shelf and Side Burner Support Shelf I 3 Insert mounting brackets into Right Side Shelf Support, and secure with #10-24x1/2" machine screws (A). Insert mounting brackets into Side Burner Shelf Support, and secure with #10-24x1/2" machine screws (B) and (C). Attach the sideburner lid to side burner shelf with #10-24 nuts and shoulder bolts.
  • Page 24 Sideburner Attach sidebumer valve with #8-32x3/8" machine screws. Place sideburner into shelf (A). Make sure valve is inside sideburner tube (B). Attach sideburner with #8-32 wing nut and 5x9 fiber washer (A). :_Hook sideburner clip to sideburner tube and around manifold. Attach sideburner ignitor wire to ignition module. (B) [i Press control knob onto valve stem and sideburner grate onto shelf (C).
  • Page 25 Lower Hinges [ Attach lower hinges to back of firebox using #10-24x1/2" machine screws, 5x15 fiber washers and #10-24 flange nuts. The center flat portion of the hinge should be at the bottom (see inset). 5x15 #10-24xl/2" Fiber Washer ..Machine Screw #10-24xl/2"...
  • Page 26 Attach Lid Place lid assembly onto firebox, aligning hinges. Hinges on lid fit inside hinges on firebox. Secure using two hinge pins and hitch pins. Hitch Pin Qty. 2 Hinge Pin Qty. 2 Heat Tent and Cooking Grate Place heat tent inside firebox onto support screws. Place cooking grate into firebox.
  • Page 27 Grease Cup and Grease Cup Clip Hang grease cup clip from bottom of firebox and place grease cup into grease cup clip. grease cup Failure to install clip and cup will cause hot grease to drip from bottom of grill with risk of fire or property damage.

  • Page 28: Troubleshooting

    EIVlERGENCIIES= if a gas leak cannot be stopped, or a fire occurs due to gas leakage, call the fire department. Gasleakingfrom , Damagedhose. , Turnoff gas at LP cylinderor at sourceon naturalgassystems.If cracked/cut/burned anythingbut burned,replacevalve/hose/regulator. If burned, hose. discontinueuseof productuntila plumberhas investigated cause and corrections are made.

  • Page 29: Electronic Ignition

    Troubleshooting (continued) ELECTRONIC IGNITION: Burner(s)will not light usingignitor. • Nospark,no ignitionnoise. • SeeSectionI of ElectronicIgnitionSystem. (See ElectronicIgnition Troubleshooting a lso) • Nospark,someignitionnoise. • SeeSectionII of ElectronicIgnitionSystem. , Sparks,but notat electrodeor at full • SeeSectionIII of ElectronicIgnitionSystem. strength. Burner(s)will not • See"GAS ISSUES:"on previouspage. matchlight.

  • Page 30: Troubleshooting - Electronic Ignition

    Troubleshooting - Electronic Ignition SECTION I Nosparksappearat • Batterynot installed , Checkbatteryorientation. • Installbattery(makesurethat "+"and "-" anyelectrodeswhen properly. connectorsare orientedcorrectly, w ith "+"end up ElectronicIgnitionButton and "-" enddown.) is pressed;no noise can be heardfromspark , Deadbattery. , Has batterybeen used •...
  • Page 31 Please registeryourproductonline at: (if you register online, you do not need to send in this registration card,) PLEASEFiLL OUT THiS CARDAND ATTACH A COPYOF YOUR SALES RECEIPT. RETURN iT WiTHiN t0 DAYS OF PURCHASE.FAILURETO RETURN MAYAFFECT YOUR WARRANTYCOVERAGE.FORWARRANTYSERVICE PROOFOF PURCHASEWiLL BE REQUIRED. THiS WARRANTYiS NON-TRANSFERABLE. LLENE ESTATARJETAY DEVUELVALA DENTRODE LOS 10 DIAS DE LACOMPRA.
  • Page 32 In addition to the online store, charbroil.com offers you a wealth of information regarding Char-Broil ® gas, charcoal, electric, and new infrared grills and cookers. Be sure to check out our many grilling recipes and don't forget to sign up for our exciting...

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