Char-Broil 463631009 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.

PRODUCT GUIDE

MODEL 463631009

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

Printed in China

See rating label on grill for serial number.

Rev. 03 • 07-28-08 • 80017802

TM REVISION 00

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Summary of Contents for Char-Broil 463631009

Page 1 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®; 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®;...
Page 2: Table Of Contents
TABLE OF CONTENTS DANGER For Your Safety ........2-3 If you smell gas: 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
Temperature GRILLING GUIDE – Getting Started 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 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 Cooking surfaces: If a bristle brush is used to clean any of the GRILLING GUIDE – Cleaning Your Grill grill cooking surfaces, ensure no loose bristles remain on cooking Why Clean? surfaces prior to grilling. It is not recommended to clean cooking surfaces while grill is hot.
Page 8: Use And Care
LP Cylinder USE AND CARE • The LP cylinder used with your grill must meet the following requirements: • Use LP cylinders only with these required measurements: 12" DANGER (30.5cm) (diameter) x 18" (45.7 cm) (tall) with 20 lb. (9 kg.) capacity maximum.
Page 9 LP Tank Exchange Connecting Regulator To The LP Tank 1. LP tank must be properly secured onto grill. (Refer to • Many retailers that sell grills offer you the option of replacing 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 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 Burner Flame Check WARNING • 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: Spider Alert
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! Remove cooking grate and heat tent Under grill remove grease cup, disconnect ignitor wire from burner.
Page 14: Limited Warranty
LIMITED WARRANTY STATEMENT – LIMITED WARRANTY REV. 102-1 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 NOT PICTURED : FIREBOX BOWL GR I L L LID Key Qty Description LOGO PLATE … HARDWARE PACK HOSE/ VALVE R E G ULATOR … ASSEMBLY MANUAL, ENGLISH ASSY CONTR O L PANEL, MAIN BURNER ELECTRODE/COLLECTOR BOX SIDE SHELF RIGHT TOOL H O L DER, F/SIDE SHELF...
Page 16: Parts Diagram
PARTS DIAGRAM...
Page 17: Assembly
ASSEMBLY Left leg Attach upper left leg onto lower left leg with #10-24x1-1/4’’ Machine screw and #10-24 Wing nut. NOTE: Lower Left Leg has notches on tank support Upper left leg Lower left leg #10-24X1-1/4” Machine Screw Qty.1 Tank support Tank support #10-24 Wing Nut...
Page 18: Assembly
Front Panel Lay front legs down on the floor Fit front panel between legs. Attach with #10-24x2’’ Machine screws and #10-24 Wing nuts. #10-24 Front panel Wing Nut Qty.4 #10-24x2” Machine Screw Qty.4 Back Braces to Cart Attach back braces with #10-24x1-1/4’’ Machine screws and #10-24 Wing nuts. Wheels Turn assembly upside down.
Page 19 Control Panel Stand cart upright In front, slide control panel between left and right legs, attach control panel with #10-24X2’’ Machine screws and #10-24 Wing nuts. Control panel #10-24 Wing Nut Qty.4 #10-24x2” Machine Screw Qty.4 Valve/Hose/Regulator and Ignitor Attach valve/hose/regulator assembly to control panel with #10-24x1/2’’ Machine screws. Attach ignitor to control panel using the stamped nut that’s provided.
Page 20 Tank exclusion wire Hook tank exclusion wires onto front panel brackets, secure other end to back brace using #8-32X3/8’’ Sheet metal screws. #8-32X3/8’’ Sheet Metal Screw Qty.2 Tank exclusion wire Qty.2 Heat Shield Attach heat shield with #10-24x1/2’’ Machine screws and #10-24 Wing nuts. Heat shield #10-24 Wing Nut...
Page 21 Burner ,Firebox and Control Knob Place burner assembly into firebox. Fasten the burner assembly to the firebox using 5x15 Fiber washers and #10-24x1/2’’ Machine screws. Insert #10-24x1-1/4’’ Machine screws from outside the firebox, then fasten with #10-24 Flange nuts and 5x15 Fiber washers from the inside( A ).
Page 22 Tank Retainer Insert tank retainer into side brace ( left side when looking at front ) and secure with #10-24X2-1/8’’ Carriage bolt, #10-24 Wing nuts and 5x10 Flat washers . #10-24 Wing Nut Qty.2 #10-24x2-1/8” Carriage Bolt Qty. 2 5x10 Flat Washer Qty.2 Shelves Attach mounting brackets to front of leg with 1/4’’-20x1/2’’...
Page 23 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). #10-24 Flange nut Qty.4 Center flat portion of hinge on bottom #10-24X1/2”...
Page 24 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 Place heat tent inside firebox onto support screws. Place cooking grate onto firebox. Cooking Grate Heat Tent...
Page 25 Insert ends of Swing Away pivot wire into holes in sides of grill lid. Insert ends of Swing Away leg wire into holes in sides of firebox. NOTE: Pivot and leg wires, running side-to-side, should be under wires running front-to-back. If pivot and leg wires are on top, swing away is installed upside-down.
Page 26 Hang grease cup clip from bottom of firebox and place grease cup into grease clip Grease Cup Clip CAUTION Grease Cup 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.
Page 27: 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 28: Troubleshooting
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. •...
Page 29 NOTES...
Page 30 NOTES...

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