Char-Broil Classic C-59G4 Product Manual
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Char-Broil Classic C-59G4 Product Manual

Char-Broil Classic C-59G4 Product Manual

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© 2013 Char-Broil, LLC Columbus, GA 31902
PRODUCT GUIDE
MODEL 463252113
Classic C-59G4
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.
Printed in China
See rating label on grill for serial number.
Assembly instructions © 2013
03/14/13 • G651-001-260801

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Summary of Contents for Char-Broil Classic C-59G4

  • Page 1 PRODUCT GUIDE MODEL 463252113 Classic C-59G4 IMPORTANT: Fill out the product record information below. Serial Number See rating label on grill for 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.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS DANGER For Your Safety ........2-3 If you smell gas: Grilling Guide.

  • Page 3: Grease Fires

    WARNING CAUTION Using pots larger than 6 quarts in capacity could CALIFORNIA PROPOSITION 65 exceed weight limit of the 1. Combustible by-products produced when using side burner shelf this product contains chemicals known to the State or side shelf, of California to cause cancer, birth defects, or resulting in failure other reproductive harm.

  • Page 4: Grilling Guide

    Temperature - Convective Grills ONLY. GRILLING GUIDE – Getting Started The temperature gauge in the hood of your new grill measures air temperature. The air temperature inside your grill will never First Time Use 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 Cooking GRILLING GUIDE – Grilling 101 Rotisserie cooking is best for 'round' meat, such as large roasts, whole poultry, and pork. It generally requires an accessory motor Outdoor grilling is really quite simple. You'll succeed with and spit rod that allows the meat to be turned at a constant burgers, dogs, or steaks usually on your very first try.
  • Page 6 Wood Chips GRILLING GUIDE – Tips & Tricks For extra smoke flavor when grilling, try adding wood chips. Cooking on your new grill is a hands-on experience, and it is Soak the chips in water for approximately 30 minutes before recommended to remain outside with your grill while cooking.
  • Page 7 Gear Trax Painted surfaces: Wash with mild detergent or non-abrasive accessories. Please visit charbroil.com for a complete list cleaner and warm water. Wipe dry with a soft non-abrasive cloth. of Gear Trax accessories. *Available on most models.

  • Page 8: Use And Care

    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 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 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. Injury: ▲...
  • Page 12 Ignitor Lighting SEAR Burner Ignitor Lighting ▲ ▲ Do not lean over grill while lighting. Do not lean over grill while lighting. Turn OFF gas burner control valves. Turn OFF gas burner control valves. Turn ON gas at LP cylinder. Turn ON gas at LP cylinder.

  • Page 13: Ignitor Check

    General Grill Cleaning Burner Flame Check • Do not mistake brown or black accumulation of grease and • Remove cooking grates and flame tamers. Light burners, rotate smoke for paint. Interiors of gas grills are not painted at the knobs from HIGH to LOW. You should see a smaller flame in factory (and should never be painted).

  • Page 14: Spider Alert

    3. Remove carryover tubes and burners. CAUTION Detach electrode from burner. NOTE: Removal/Detachment method will depend on the burner configuration. See different configurations in illustrations below. SPIDER ALERT! 5. 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.

  • Page 15: 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 16: Parts List

    PARTS LIST Qty Description Qty Description FIREBOX FRONT DOOR BRACE MAIN BURNER-TUBE BURNER LEFT DOOR MAIN BURNER-BAR BURNER RIGHT DOOR ELECTRODE, F/ TUBE BURNER HANDLE, F/ DOOR ELECTRODE, F/ BAR BURNER REAR BRACE CARRY OVER TUBE TANK EXCLUSION WIRE CONTROL PANEL, MAIN GREASE TRAY ELECTRONIC IGNITION MODULE GREASE PAN...

  • Page 17: Parts Diagram

    PARTS DIAGRAM...

  • Page 18: Assembly

    ASSEMBLY • Attach bottom shelf to left and right side panels with 1/4-20x2-3/8" machine screws and 1/4-20 flange nuts. The cut out hole for LP cylinder should be on left side. Right Side Panel For Front Door Brace Assembly Left Side Panel 1/4-20x2-3/8"...
  • Page 19 • Hook tank exclusion wires onto the holes on back brace, attach other ends to bottom shelf with #8x3/8" sheet metal screws. Back Brace #8x3/8" Sheet Metal Screw Qty. 2 Metal Tab • Place front door brace as shown. Attach to left and right side panels with 1/4-20x2-3/8" machine screws and 1/4-20 flange nuts. 1/4-20 Flange Nut Qty.
  • Page 20 • Turn assembly upside down. • Insert Caster Pin into the caster mounting plate to lock it in place, shown A. Spin the caster clockwise into the threads on the legs until secure. Remove the Caster Pin and repeat for remaining casters. Make sure the two locking casters are secured at the rear and the non-locking casters are secured at the front.
  • Page 21 • Stand cart upright. • This step requires two people to lift and position grill head onto cart. • Carefully lower the grill head onto the cart. Make sure the regulator hose is hanging outside the cart. Attach with 1/4-20x1/2” screws.
  • Page 22 • Hook the right side shelf to firebox by the pre-assembled screws (A). • Inside firebox, insert 7mm fiber washer and 1/4-20x1/2" screw as shown (B). • Attach shelf with 1/4-20x1/2" screw and 1/4-20 flange nuts, and fasten the two pre-assembled screws (C). Right Side Shelf 1/4-20 1/4-20x1/2"...
  • Page 23 • Hook the left side shelf to firebox by the pre-assembled screws (A). • Inside firebox, insert 7mm fiber washer and 1/4-20x1/2" screw as shown (B). • Attach shelf with 1/4-20x1/2" screw and 1/4-20 flange nuts, and fasten the two pre-assembled screws (C). Left Side Shelf Fiber Washer 1/4-20x1/2"...
  • Page 24 • Attach sideburner bezel and valve with #8-32x3/8" Stainless Steel screws. (A). • Place sideburner into shelf. Make sure valve is inside sideburner tube. Attach sideburner with wing nut (B). Hook venturi clip to sideburner tube and around manifold. Attach sideburner ignitor wire to ignitor as shown (C). •...
  • Page 25 • Attach handles to doors with #10-24x1/2" machine screws, 5mm flat washers and 5mm lock washers . • Insert hinge pin on bottom shelf into hole in door. Press upper hinge pin in front door brace, align hinge hole on top of door, and release hinge pin into door.
  • Page 26 • Place heat tents over tube burners by inserting tabs into slots in front of firebox. Opposite ends of heat tents rest on pins in back of firebox. NOTE: There is no heat tent over sear burner. Sear Burner • Place cooking grates onto grate rests.
  • Page 27 • Attach heat shield to grease tray with #8x3/8" sheet metal screws (A). • Place grease pan into grease tray, then place the tray into the cart (B). Heat Shield #8x3/8" Grease Tray Sheet Metal Screw Qty. 4 CAUTION Failure to install grease tray and grease pan will cause hot grease to drip from bottom of grill with risk of fire or property damage.

  • Page 28: Troubleshooting

    DANGER: 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 29 Troubleshooting (continued) Problem Possible Cause Prevention/Solution Burner(s) will not light ELECTRONIC IGNITION: 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. •...

  • Page 30: Troubleshooting

    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 Electronic Ignition Button and “–”...

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Classic c-59g4 463252113

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