Char-Broil 415.161209 Product Manual
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Char-Broil 415.161209 Product Manual

Char-Broil 415.161209 Product Manual

Gas grill
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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:
The following are trademarks of W.C. Bradley Co.: Advantage Series™; Auto-Clean™;Chef Tested™; Commercial Series™; Designer Series™;; Diamond Flame™;
Double Chef™; Fireball™; Firenzy™; FlavorMaster™;Front Avenue™; Grill 2 Go® Advantage™; Hog and Yard Bird™; H20 Smoker™; Infrared. Grilling's Juicy Little
Secret™; Incredible Taste. Infallible Results™; Infrared Inside™; Insure™; Let's Grill Something Together™; Lev-Alert™; Longhorn™; Magneto™; Precision
Flame™; Quick2Burn™; QuickSet™; Ready When You Are™; Season, Set, And Savor™; Sizzle On The Grill™; Signature Series™; SureFire™; The Minute
Grill™;Torchfork™; Universal Grill Parts™; You Bring the Party™
Protected under one or more of the following U.S. Patents: 5,421,319; 5,458,309; 5,579,755; 5,996,573; 6,135,104; 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; 6,792,935; 6,951,213; 7,047,590;
7,516,693; 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; D423,274; 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:D97,504;D99,355; D102,037; D104,200;D108,377; 2,315,567;
France:D010,231;D010,422;D010,590;D010,849; 1,089,646; South Korea: 384,565; United Kingdom: 2,099,402. Other Patents Pending. © 2009 W.C. Bradley Company
© 2009 Char-Broil, LLC Columbus, GA 31902
®
®
TEC™ is a trademark of Tec Infrared Grills.
Printed in China
PRODUCT GUIDE
Sears Item No. 16120
Sears Model No. 415.16120901
KSN No. 640-174093112
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 1-800-241-7548.
Estimated assembly time: 35-40 minutes
Assembly instructions © 2009
Model 463611810 463612010
See rating label on grill for serial number.
®
10/22/09 • G211-001-090801
•

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Summary of Contents for Char-Broil 415.161209

  • Page 1 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®;...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS For Your Safety ........2-3 Grilling Guide.
  • Page 3 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.

  • Page 4: Grilling Guide

    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.
  • Page 5 GRILLING GUIDE – 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.
  • Page 6 GRILLING GUIDE – 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.

  • Page 7: Grilling Guide

    GRILLING GUIDE – 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.

  • Page 8: Use And Care

    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 over filled or improperly stored cylinder is a hazard due to possible gas release from the safety relief valve.
  • Page 9 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"...
  • Page 10 Hold coupling nut and regulator as shown for proper connection to LP cylinder valve. 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.
  • Page 11 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. If you have a grill problem see the "Troubleshooting Section". If the regulator frosts, turn off grill and LP cylinder valve immediately.
  • Page 12 Ignitor Lighting Do not lean over grill while lighting. Turn OFF gas burner control valves. Turn ON gas at LP cylinder. Open lid during lighting. To ignite, turn left knob to the HI position. Push IGNITOR button rapidly. 6. If ignition does NOT occur in 5 seconds, turn the burner controls OFF, wait 5 minutes and repeat the lighting procedure.

  • Page 13: Spider Alert

    • Plated wire grates: Wash grates with concentrated grill cleaner or use soap and water solution. Dry thoroughly and store indoors between cookouts. • 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.

  • Page 14: 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 15: Parts List

    PARTS LIST Key Qty Description 4 CART LEG, LOWER 1 MATCH HOLDER 2 CART LEG 1 BACK BRACE 1 FRONT PANEL 2 WHEEL 2 AXLE BOLT 1 SUPPORT BRACKET 2 LEG EXTENDER 1 FIREBOX 1 CONTROL PANEL VALVE/HOSE/REGULATOR ASSEMBLY 2 KNOB 1 IGNITOR 1 BURNER 1 ELECTRODE/COLLECTOR...

  • Page 16: Parts Diagram

    PARTS DIAGRAM...

  • Page 17: Assembly

    ASSEMBLY Cart legs, Lower cart legs, Front panel and Back brace. Insert lower cart legs into cart legs, make sure the holes for tank exclusion wire face inside, and the holes on lower cart legs are aligned to the lower holes on cart legs. Position leg assemblies as shown below. Attach front panel and back brace to legs using eight 1/4’’-20x2’’...
  • Page 18 Control Panel Attach control panel / HVR assembly to firebox with two #10-24x1/2’’ machine screws, 5x15 fiber washers and #10-24 flange nut. #10-24x1/2’’ Machine Screw Qty.2 #10-24 Flange Nut Qty.2 Burner Place burner assembly into firebox. Make sure burner tubes are correctly engaged with valves. Fasten the burner assembly to the firebox using 5x15 fiber washers and #10-24x1/2’’...
  • Page 19 Turn cart upright. Place cart in the upright position. Place firebox assembly onto cart, making sure that regulator hose hangs inside cart and control panel overlaps front panel. Secure firebox to cart using four #10-24x1-1/4’’ machine screws, 5x15 fiber washers and #10-24 wing nuts. Front Tank Exclusion Grid Attach tank exclusion grid to lower cart legs with four #8-32x3/8’’...
  • Page 20 Side Shelf Arm Slide shelf arms into leg assemblies and secure with one push fastener per arm. Side Shelf Attach side shelves to shelf arms using four 1/4’’-20x2’’ carriage bolts and four 1/4’’-20 tee knobs per shelf. 1/4’’-20 Tee Knob Qty.8 1/4’’-20x2’’...
  • Page 21 Lower Hinges Attach lower lid hinges to back of firebox using two #10-24x1/2’’ machine screws, #10-24 flange nuts and four 5x15 fiber washers per hinge. The center flat portion of the hinge should be at the bottom (see insert below). #10-24 #10-24x1/2’’...
  • Page 22 Place lid assembly onto firebox, aligning hinges. Hinges on lid fit inside hinges on firebox. Secure using two hinge pins and two hitch pins. Cooking Grate and Heat Tent Place heat tent into firebox. Align the slots on heat tent to heat tent support screws. Place cooking grate into firebox.
  • Page 23 Grease Cup and Grease Cup Clip Hang grease cup clip from bottom of firebox and place grease cup into grease cup clip. Grease Cup Clip Grease Cup Tank Retainer Wire Attach tank retainer wire to left side support brace using one 1/4’’-20x1-1/4’’ carriage bolt and one 1/4’’-20 tee knob. Do not fully tighten until LP cylinder is installed.
  • Page 24 LP CYLINDER IS SOLD SEPARATELY. Fill and leak check the cylinder before attaching to grill and regulator (see Use & Care section). Once cylinder has bee filled and leak checked, place cylinder into notches in tank support bracket. Make sure cylinder valve is facing front of grill.

  • Page 25: Troubleshooting

    EMERGENCIES: If a gas leak cannot be stopped, or a fire occurs due to gas leakage, call the fire department. Emergencies Possible Cause Gas leaking from •Damaged hose. cracked/cut/burned hose. Gas leaking from LP •Mechanical failure due to rusting or cylinder.

  • Page 26: Troubleshooting

    Troubleshooting (continued) Problem Possible Cause Burner(s) will not light PIEZO PUSH-BUTTON AND ROTARY: using ignitor. •Push-button sticks at bottom. •Rotary knob rotates without clicking. •Sparking between ignitor and electrode. Burner(s) will not •See “GAS ISSUES:” on previous page. match light. •Match will not reach.

  • Page 27: Registration Card

    Warranty Registration Department P.O. Box 1240 Columbus, GA 31902-1240...

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640-174093112

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