Char Broil 4639071 User Manual GAS GRILL Manuals And Guides L0803637

CHAR-BROIL Grill, Gas Manual L0803637 CHAR-BROIL Grill, Gas Owner's Manual, CHAR-BROIL Grill, Gas installation guides

User Manual: Char-Broil 4639071 4639071 CHAR-BROIL GAS GRILL - Manuals and Guides View the owners manual for your CHAR-BROIL GAS GRILL #4639071. Home:Lawn & Garden Parts:Char-Broil Parts:Char-Broil GAS GRILL Manual

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4
_J

O
8_

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#

To installer
manual

with

To consumer:

or person
grill

assembling

for future

grill:

Leave

this

reference.

Keep this manual

for future

reference.

4
@

S
_=

L__

Read this manual before cooking on grill Failure to follow all
manufacturer's
instructions
could result in serious personal
injury
and/or property damage

®
®

FOR YOUR SAFETY
t.

Do not store or use gasoline
or other flarnmablevapors
and liquids in the vicinity of this or any other appliance.
2. An LP Tank not connected
for use shali not be stored in
the vicinity

of this or any other appJiance.

FOR YOUR SAFETY
If you smell gas:
1. Shut off gas to the appliance.
2. Extinguish
any open flame.
3. Open lid.
4. If odor continues,
immediately
your fire department.

call your gas supplier

Call Grill Service
Center
For Help And Parts
• if you need help or warranty parts call _1-800-241.7548 or send a FAX to
1-706-576-6355
Business hours Open 24 hours- Seven days a week
, To order non-warranty replacement parts or accessories (grill cover, cleaners,
paint) call 1-800-993-2677or send a FAX to 1-706-565-2t21

Important:

Fit! out Warranty

Information

Warranty

below

Information

Model Number
UPC (oncarton) Label Lot # GG
Serial Number

DatePurchased

_._,_

o For residential use only Do not use for commercial cooking

Installation

Safety

Precautions

This grill is designed for use with LP (propane) gas using the regulator/valve
assembly supplied
° Grill installation must conform with local codes, or in their absence with National
Fuel Gas Code, NFPA 54 / ANSI Z223,1 or CANICGA-B149.2 Propane
Installation Code. Handling and storage of LP cylinders must conform to LP Gas
Code NFPA/ANSI 5& Grill is not for use in or on recreational vehicles andlor boats
, All electrical accessories (such as rotisserie) must be electrically grounded in
accordance with local codes, or National Electrical Code, ANSI / NFPA 70 or
Canadian Electrical Code, CSA C22.!, Keep any electrical cords andlor fuel
supply hoses away from.any hot surfaces
• This grill is safety certified for use in the United States and CanadaonIy Do not
modify for use in any other location Modification will result in a safety hazard.
Safety Symbols
• The symbols and boxes shown below explain what each heading means Read and
follow all of the messages found throughout the manual,

o WARNING: Be alert to the possibility of serious bodily injury .if the
instructions are not followed

Be sure to read and carefuly follow all of

z.........................
..........

_-,,,,_,,

,,,, ,

,lu,

i
I

J
I

....i,l,,,_,,,ii r,_

CAUTI©II

o CAUTION: Indicates a potentialy hazardous situation which, if not
avoided, may result in minor or moderate injury

CHAR-BROIL
e,FLAVORMASTER%
MASTERFLAME2
_,HeatWave'_,CoolingZone1000", SabeP,Pafo
Caddie
"_,Sierra"-'_,
SignatureSeries_,SwingAway
_;,H20 Smo_e_,andPatoKtchen`_areregisteredtrademarks
of W C BradteyCo PrecisionFlame",SureFire",StackRack'",FastStart
's,Tit Tank",WideBody",and Patio
Bisl;d', arelradernarksof WC BradieyCoGrils protectedforW C. BradteyCo.underoneormoreoflhese
US Paenls:4,989,579;
4,955,358;5,220,764;
5,42t,319;5.441,226;
5,566,606;5,931,t49; D291,768;
D341,292Assemblt, [nstructons© 1999WC BradleyCo, All RightsResewed
3

Table

of Contents

ForYourSafety...............................................................................................................
2
CallGfi!lServiceCenterForHelpAnd Parts..............................................................
2
Warrantylnforrnation
..................................................................................................
2
Installation
SafetyPrecautions...................................................................................
3
SafetySymbols............................................................................................................
3
TableofContents.......................................................................................................
4
Warranty's.............................................................................................................
5
ConnectlngTheRegulatorToThe LPTank ..............................................................
6,7
LeakTest ............................................................................................................
8, 9
ForSafe Use OfYourGrill ..........................................................................................
10
Safety]qps...............................................................................................................
!!
BeforeYourFirstCookout.........................................................................................
11
IgnitorLighting
ForFrontControlGrills..........................................................................
11
MatchLighting
...........................................................................................................
12
IgnitorLightingForSideControIGrilis........................................................................
12
IgnitorLightingForHeatWaveRotisserieGrills-MainBurners...................................12
MatchLighting..........................................................................................................
12
IgnitorLightingforHeatWaveRotisserieBurner.........................................................
13
MatchLighting..........................................................................................................
13
IgnitorLightingTheSidebumer...............................................................................
13
MatchLighting
............................................................................................................
13
BurnerFlameCheck
13
TurningGriltOff.............................................................................................................
13
IgnitorCheck.............................................................................................................
14
ValveCheck.............................................................................................................
14
HoseCheck..............................................................................................................
14
LPTankFitling............................................................................................................
14
LPTankRemovat,TransportAndStorage...............................................................
15
LPTank ...................................................................................................................
16
LP(LiquefiedPetroleumGas) ....................................................................................
16
GeneralGrillCleaning.........................................................................................
16,17
CleaningTheFrontControlBurnerAssembly.....................................................18,19
CleaningTheSideControtBumerAssembly..........................................................
20,21
CleaningTheHeatWaveRotisserie
Burner ..........................................................
22,23
SeasoningAndUsingCastIronCookingGrates.....................................................24
RepaintingYourGrill..................................................................................................
24
CareOfWood ............................................................................................................
24
HeatWaveRotisserie
BurnerUse ............................:,............................................25
................................................................................................

CookingChartForHeatWaveRotisserieBurner......................................................
25
CookingTips ...........................................................................................................
25
CookingChart........................................................................................................
26, 27
FoodSafety..............................................................................................................
27
HowToTeUIf MeatIs GrilledThoroughly................................................................
27
TroubleshooUng
-General......................................................................................
28, 29
Troubleshooting-ElectronicIgnitionSystem...........................................................
30, 31
StoringYourGrill ........................................................................................................
3!
4

Wa rra nty's
Char-Broilwarrants 1othe original consumer-purchaserthat [his product shelf be flee from
defecls ill workmanship and materials under normal and reasonable use and correct assembIy
(if assembled byconsumer-purchaser), asfollows.
(1) The aDrninum lop and bottom castingsfor lhe lifeoforiginal purchase,excluding the
paintfinisll;
(2) The burnerlventuri assembly for a period of three (3) years from the date of purchase;
and
(3) All olher paris for a period done (I) year from the date of purchase
Char-Broil will, al its option, refinish or replace any product or part found to be defective
during the warranly period Char-Broilwilt require you to return the parti s) claimed to be
defective,for its inspection,freight or postage prepaid
If you wish toobtain 3erformanceof anyobligation under this limited warranty, you should
wrileto:
CHAR.BROIL
Consumer Warranty / P,,O Box 1240
Columbus, GA 3t902-1240
Char-Broil may require reasonable proofof purchase and we suggest you keep your
receipt In theslate of Oaliforniaonly, ifrefinishing or replacementofthe producfis not
commerciallypraclicable, tile retaiier sellingtllis product or Char..Broilwill refundtile purci_ase
price paid for tile product, less lhe amountdirectly attributable touse by theoriginal consumeF
purchaser prior to discovery of thenonconformity Inaddition_in the stateof Californiaonly. you
may take the product to tt_eretailestablishment from which it was purchased or to ally retail
establishmentselling this productin order to oblain performanceunder thiswarranty
This warranly does nol inchlde the cost on any inconvenience or properly damage due !o
faifureof the product and does notcover damage due to misuse, abuse, accident, damage
arisingoul of transportationof theproduct, or damageincurred througll commercia! useof the
product,This express warranty is the solewarranty given by ihe manufacturer and is in lieu of
all otherwarranties, expressor implied,inc}udingimpliedwarranty of merchanlability orillness
fora particular purpose Neither Char-BroiIdealers nor De retail establishmen_sellinglhis
product has any authority to make anywarranties or to promise remedies in addition 1oor
incensistentwilh those statedabove Char-Broil'smaxirnumliability,in any event,shallnol
exceed thepurchase priceofthe produc[paid bythe originalconsumeFpurchaser Some stales
do not altow theexclusion orlimitation ofincidental or consequenlial damages Sotheabove
limitations or exclusions may not apply to you This warranty gives you specific legal righls and
may also have other rights which vary from state 1ostate

Electronic

Ignition

System

!0 Year Limited

Warranty

Char-Broilguaranlees this ElectronicIgnition System(battery excluded)in both
malerials and workmanship for a ten (10) year period from date of purchase to the original
purchaser ifused for home use, lithe productfails tooperate due to a manufacturingdefect, the
defective part will be repaired or reptaced atCHAR-BROIL'Soption. The producl, along with
proof of purchase,must be returned poslageprepaid
If youwish toobtain performance of any obligationunder this limited warranty, you should
write to CHAR-BROIL. Consumer Warranty. P,O, Box 1240. Columbus, GA 319021240

Connecting
The Regulator
To The LP Tank
1 LP tank must be properly secured onto grill
2 Turn all control knobs including sidebumer (if featured) to the OFF position
3 Turn LP tank OFF by turning handwheel clockwise to a ful! stop,
OI_ Clockwise

Safety Relief Valve

OPD Hand Wheel

4-,_-----

Type I outlet with thread on outside

/
/

I
../
Strap and Cap

i-"

Remove the protective cap from the LP tank valve. Always use cap and strap
supplied with valve Use of the POL transport

plug (B) (plastic part with

external threads) will defeat safety feature of valve.

Do not use this POL transport plug
(plastic part with external threads)

Hold regulator, insert nipple (C) into LP tank valve, Hand tighten coupling
nut, holding regulator in a straight line (D) with LP tank valve so as not to
cross thread the connection.

i,
%

Nipple has to be centered into
the LP tank valve

..._..._.

Hold coupling nut and regulator as shown for proper
connection to LP tank valve

?.
E

Regulator
J. -

CouplingNut

Turn the coupling nut clockwise to tighten to a ful! solid stop The regulator wilt
seat on the back check feature in LP tank valve, resulting in some resistance An
additional one-half to three quarters turn is required to complete
connectiom Tighten by hand only - do not use tools,
NOTE: tf you cannot complete connection, disconnect regulator and repeat steps 5
and 6 If you are still unable to complete the connection,do not use this
regulator!
7

Follow "Leak Test" instructions on page 8,

Do not insert any foreign objects into the valve outtet. You may damage
the valve and cause a leak. Leaking propane may result in explosion,
fire, severe personal injury, or death,
Never attempt to attach this grill to the self-contained LP gas system of
a camper trailer or motor )lome.
7

• Do not use grill until leak checked.
• If leak is detected at any time, STOP and correct before using grill
fu rth er.
,

Leak

If you cannot stop a gas leak, immediately close LP tank valve and call
LP gas supplier or your fire department!

Test

For your safety
o Leak test must be repeated each time LP tank is connected or reconnected
. Do not smoke during leak test
. Do not use an open flame to check for gas leaks
o Grill must be leak checked outdoors in well-ventilated area, away from ignition
sources such as gas fired or electrical appliances During leak test, keep grill away
from open flames or sparks
o Never remove opening at end of valve (A)
To leak test your grill: Use a clean paint brush and 50/50 soap and water solution
Use mild soap and water, A Do not use household cleaning agents, Damage
to gas train components can result
1. Turn all grill control knob(s) to OFF,
2. Be sure regulator is tightly connected to LP tank
3. Completely open LP tank valve by turning hand wheel counter clockwise If you hear
a rushing sound, turn gas off immediately There is a major leak at the connection
Correct before proceeding
4. Brush soapy solution onto following connections
o LP tank valve (1) including th_eadedportion into LP tank
,
Regulator fitting, face at crimps and vent hole (2).
.
Hose (3) and all connections
,
All LP tank welds (4) (LP tank collar, middle and bottom)
•
Valve (5) behind console or under side control panel
•
Valve on Sidebumer Assembly (If featured) (6)
•
HeatWave valve (if featured) (7) and all connections
5. "If growing" bubbles appear, there is a leak Close LP tank valve immediately
Retighten connections and repeat leak test procedures If leaks cannot be stopped
replace parts. Order new parts by giving the serial, model number and name of
items needed to the Grill Service Center at _ 1-800-241-7548
6, Always close LP tank valve after performing leak test by turning hand wheel
clockwise

i.
/
Sideburner Valve
(if featured)

HeatW_ve Hose
(if featured)

Sidebumer Hose

/
J

i "¸¸. ,

J
J

LPTank

For Safe
•
•
,
,
o
,

Use Of Your

Grill:

Do not let children operate or play near grill
Keep grill area clear and free from materials that burn.
Do not block holes in bottom or back of grill
Cheek burner flames regularly.
Use grill only in well-ventilated space NEVER use in enclosed space such as
carport, garage, porch, covered patio, or under a surface that can catch fire.
Use grill at least 3 ft. from any wall or surface. Maintain I0 ft clearance to
objects that can catch fire or sources of ignition such as pilot lights on water
t_eaters, live electrical appliances, etc
Do not use charcoal in a gas grill

NEVER attempt to light burner with lid closed. A buildup of non-ignited
gas inside of closed grill is hazardous,
o Never operate grill with LP tank out of correct position specified in
Assembly Instructions.
o Always close LP tank valve and remove coupling nut before moving LP
tank from specified operating position.
10

Safety

Tips

Before opening LP tank valve, check the coupling nut for tightness
When grill is not in use, turn off all control knobs and LP tank valve.
Never move grill while in operation or still hot.
Use long-handled barbecue utensils to avoid bums and spralters
Maximum load for sidebumer,side shelf and front shelf is 10 lb.
A soup can must be attached to grease clip and emptied after each use. Do not
remove soup can until grill has completely cooled
,& If you notice grease or other hot matedal dripping from grill onto valve, hose or
regulator turn off gas supply at once Determine the cause, correct, and clean
valve, hose and regulator before continuing Performa leak test
,& The regulator may make a humming or whistling noise during operation This will
not affect safety or use of grill
A If you have a grill problem see the TroubleshootingSectbn
,&
A
A
,&.
,&

A CAUTION
ml, ,rlnl i

i, ilU ,,,

i i

'_'

_;,

i,n,lUll ii

Putting out grease fires by closing the lid is not possible. Grills are well
ventilated for safety reasons.
• Do not use water on a grease fire. Personal injury may result. If a grease
fire develops turn knobs and L.Ptank off.
• Do not leave grill unattended while preheating or burning off on high. If
grill has not been regularly cleaned a grease fire can occur that may
damage the product,

Before

Your

First

Cookout

• Light burners, check to make sure they are lit, close the lid and warm up gill on
HIGH for 15 minutes Curing of paint and parts will producean odor only on first
lighting
Ignitor Lighting For Front Control
A
Do not lean over grill while lighting,
1 Open lid. Turn on gas at LP tank
2 Turn one knob to _ IGNITE
3

&
_:/_._i_
__....
z

--<_

:::_
....

Push IGNITORButton ,._r:
_. or Switch C_'i:#rapidly to light Be sure burner lights
and stays lit,
,

Grills

Turn other knob (if featured)to _ IGNITEto light other side
If IGNITOR does not work, follow match lighting instructions.

After Lighting: Turn knob(s)to HIGH for warm-up.

Match Lighting
A Do not lean over gr[ti while lighting,
1 Open lid, Turn on gas at LP tank
2 Piace fit match into match lighting hole from
outside grill bottom (as shown)
3 Push in and turn Single or RIGHT knob to
,

IGNITE.. Be sure burner lights and stays lit.
",: ,q!
Light left burner (if featured) by pushing LEFT knob ', "1= /
in and turning to _ 1GN1TE

holeMatChis
tlghtingin
bottom or side

After Lighting: Turn Knob(s) to HIGH for warm-up
Ignitor

Lighting

For Side

Control

Grills

•

A
Do not lean over grill while lighting.
1. Open lid, Turn on gas at LP tank
2 Push in and turn FRONT control knob to HIGH
3

_• _;
_

. ,,
;:_

::"

Press Button :
or ignitor switch; :_i}_ ( up to 4 seconds)
_.
or turn ignitor Knob ,,;:'
;":,..,,(up to 5 tin:_es)to light grill Be
sure front burner lights and stays tit.
Push in and turn BACK knob to tight back burner
tf iGNiTOR does not work, fotlow match lighting instructions below
Match LighthTg
A 13onot lean over grill while lighting,
1 Open lid Turn on gas at LP tank
HeatWave grifls only Push in and turn Burner
Selector Knob to ON MAIN BURNERS
2 Place lit match into match lighting hole from
outside grill bottom.
3, Push in and turn BACK knob to HIGH Be sure

hole
Burner
holes

Match lighting
hole on right
side of grill

back burner lights and stays tit.
4 Light front burner by pushing FRONT knob in and turning to HIGH

Ignitor Lighting
Burners

For HeatWave

Rotisserie

Grills-_rlain

A
1
2

Do not lean over grill while lighting,
Open lid, Turn on gas at LP tank
Push in and turn Burner Selector Knob to ON MAIN BURNER

3
4

Push in and turn FRONT burner knob on panel to HIGH.
Press Ignitor Switch ..c:C_,.,._,
, hold up to 4 seconds Or turn Ignitor Knob _:!_iii_

rapidly (up to 5 times) to light grill. Be sure front burner light and stays lit.
Push in and turn BACK knob to light back burner,,

if IGNITOR does not work, follow match lighting instructions above.

Ignitor

Lighting

For HeatWave

Rotisserie

Burner

Turn all knobs to OFF

2
3

Open lid during lighting, Turn gas on at LP tank.
Push in and turn Burner Selector Knob to ON ROTISSERIE BURNER

Press Ignitor Switch, hotd up to 4 seconds Or turn Ignitor Knob rapidly (up to 5
times) Be sure burner lights and stays lit.
If IGNITOR does not work, follow match lighting instructions

Match Lighting
1. Open lid Turn on gas at LP tank
2. Place lit match near porthole of burner.
3.. Push in and turn Burner Selector Knob to
ON ROTISSERIE BURNER Be sure burner lights and stays lit
Note: It is not possible to use the HeatWave
To match light use first
rotisserie burner and main burner at same time
opening on burner
Ignitor
Lighting
The Sideburner
I
Turn gas on at LP tank
2 Push in and turn knob to HIGH
3

Turn or push
lights and stays fit

_:_,_:..,(up to 5 times to light burner) Be sure burner

Match Lighting
1 Turn gas on at LP tank
2 To light use any hole on sideburner. Push in and turn knob to
HIGH Be sure burner lights and stays lit

Burner
,

Flame

Check

Light burner, rotate knobs from HIGH to LOW
You should see a smalier flame in LOW
position than seen on HIGH. Always check
flame prior to each use. Perform flame check
for sideburner (if equipped) tf only low flame is
seen refer to "Sudden drop or low flame" in
the Troubleshooting Section

....

.....

HIGH
LOW

Turning
Grill Off
• Turn all knobs to OFF position Turn LP tank OFF by turning handwheel clockwise
to a full stop,
13

Ignitor
Check
, Turn gas off at LP tank. Press ignitor button or turn ignitor knob rapidly "Click"
should be heard and spark seen each time between collector box or burner and
electrode See Troubleshooting if no click or spark.
Valve

Check

o important', Make sure gas is OFF at LP tank before checking valves. Knobs
lock in OFF position To check valves, first push in knobs and release, knobs
should spring back If knobs do not spring back, replace valve assembly before
using grill Turn knobs to LOW position then turn back to OFF position Valves
should turn smoothly.
Hose
°

Check

Before each use, check to see if hoses are cut or worn Replace damaged hoses
before using grill Use only valveihosefregulator specified by manufacturer

LP Tank Filling
o Use only licensedand experienceddealers
,

LP tank must be purged before filling

° Dealer should NEVER fill LP tank more than 80% of LP tank volume, Volume of
propane in tank wilt vary by temperature.
• A frosty regulator indicates gas overfill Immediately close LP tank valve and call
local LP gas dealer for assistance.
• Do not release liquid propane (LP) gas into the atmosphere. This is a hazardous
practice.
• To remove gas from LP tank, contact an LP dealer or call a local fire department
for assistance. Oheck the telephone directory under "Gas companies" for nearest
certified LP dealers_
LP tank Exchange:You may choose to replace your empty LP tank through an
exchange service. Use only those reputable exchange companies that inspect,
precision fill, test and certify their cylinders. Exchange for OPD safety feature
equipped tank as described in LP Tank
• Always keep LP tank in upright position during use, transit or storage_

° NEVER store a spare LP tank under or near grill or in enclosed areas°
° An oveffifled spare LP tank is hazardous due to possible gas released
from the safety relief valve. The safety relief valve on a LP tank could
activate releasing gas and causing a fire.
, If you see, smell or hear escaping gas, immediately get away from the
LP tank/grill and call your fire department.
, All spare LP tanks must have safety caps installed on the LP tank
outlet.

LP Tank Removal,
Transport
And Storage
o Turn OFF all control knobs and LP tank valve Turn coupling nut counte_ clockwise
by hand only - do not use tools to disconnect Lift LP tank wire upward off of LP tank
collar, lift LP tank up and off of support bracket Install safety cap onto LP tank valve.
Always use cap and strap supplied with valve Failure to use safety cap as
directed may result in serious personal injury andlor property damage.

"z--L,.J' " _

, I

<
LP Tank
Valve

_" ..... @J
Retainer

Safety
Cap

Strap
A disconnected LP tank in storage or being transported must have a safety cap
installed (as shown) Do not store an LP tank in enclosed spaces such as a carport,
garage, porch, covered patio or other building Never leave a LP tank inside a
vehicle which may become overheated by the sun
Do not store LP tank in an area where children play

LP Tank
, The LP tank used with your grill must meet the following requirements.
o Purchase LP tanks only with these required measurements: 12" (30.5cm)
(diameter) x 18" (45 7 cm) ([all) with 20 lb (9 kg ) capacity maximum
• Be constructed and marked in accordance with specifications for LP tank of the
U S Department of Transportation (DOT) or for Canada, Transport Canada (TC)
See LP tank collar for marking
LP tank valve must have
• Type 1 outlet compatible with regulator or grill
• Safety reliefvalve
• UL listed Overfill Protection Device (OPD) This
OPD safety feature is identified by a unique
triangular hand wheel Use only tanks
equipped with this type of valve,

OPD Hand Wheel

• Supply system must be arranged for vapor withdrawal and include collar to protect
LP tank valve
LP (Liquefied
Petroleum
Gas)
• ts nontoxic, odorless and colorless when produced. For Your Safety, LP gas has
been given an odor (similar to rotten cabbage) so that it can be smelled
o LP gas is very explosive when mixed with correct amounts of air
General Grill Cleaning
• Do not mistake brown or black accumulation of grease and smoke for paint
Interiorsof gas grills are not painted at the factory (and should never be painted)
Apply a strong solution of detergent and water or use a grill cleaner with scrub
brush to insides of grill lid and bottom Rinse and allow to completely air dry Do
not apply a caustic grilltoven cleaner to painted surfaces,
• Plated wire grate(s): wash grate(s) and drip vapofiser bar with concentrated grill
cleaner or use soap and water solution Dry thoroughly and store indoors between
cookouts
Plastic parts: wash with warm soapy water and wipe dry A Do not use citrisol,
abrasive cleaners, degreasers or a concentrated grill cleaner on plastic parts
Damage to and failure of parts can result
Porcelain grate(s): because of glass-like composition, most residue can be
wiped away with baking soda/water solution or specially formulated cleaner, Use
nonabrasive scouring powder for stubborn stains,
I6

StainlessSteel:Washwithmilddetergentor nonabrasive
cleanerandwarm
soapywater,wipedrywitha softnonabrasive
cloth
ExteriorStainlessSteelParts:Usenonabrasive
stainlessor glasscleanersor a
spraylubricantWipedrywitha softnonabrasive
cloth Note:Spraylubricantis
excellentfor removingfingerprints
BriquetandFire grates:will eventuallydecompose
andweakenwithuse
Removegratefromgrillandtapto loosenanyscalingBlushgratevigorously
witha
wirebrushto removeanyadditionalscaling,rustor residue

CAUT ©H
....................

......... --

• Clean burner prior to use after storing, at the beginning of grilling season or a
period of one month not being used Spiders and insects like to build nests in
burner tubes (especially during colder months) These nests can cause fires in
burner tubes or under grill

Typical spider webs inside burner

r 7_-i"J"

_,j..<"

/
f

-,iT

•

See following pages for specific instructions.

Cleaning

The Front Control Burner Assembly

Follow these instructionsto clean and/orreplace parts of bumer assemblyor if you have
trouble
ignilJng
grill
t, "rum gas off at control knobs and LP tank.
2, Removecooking grate and drip vaporiserbar.
3, Discard briquets before removingburner and briquetgrate.
4. Removecan from grease clip.
5. Beneathconsole disconnectshort ignitor wire from ignitor(A).
6, Removescrew holding collectorbox (B). Note whichhole on collector box used for
attachingto bumer. Remove coflectorbox, clean ceramicportion of electrode wiIfi
rubbingalcohol and cloth.
7. Under console disengagebumer spring from burnertube (C). Do not remove
spring from valve.
8. Removebriquetgrateand burner tagether,slidebackwards,lift upand outof grill(D),
Separate burner and briquetgrate.Removescalefrom briquetgrate,replace if
necessary.
9. Clean outsideof burner withsoap and water. Layburnerupside
down on flat surface,
insert gardenhose to force waterthrough tubes.
Makesure watercomes out of all
burner holes. Open cloggedholes with a thin wire. Shake out excess waterand
examine holes, Due to normal wear and corrosionsome holes may become
enlarged. If any large cracks or holes are found replace bumero
10. If grill isto be stored,coat burner lighUywith cooking oi!.Wrap inprotectivecover to
keep insectsout. If not storinggrill, hold briquetgrate and bumer together,angle into
grill bottom (D).
11. Nter cleaning,insert wire and electrode into hole in grill bottom(A). Reattachcollector
box to bumer with screw (B). Be sureto use correct hole.
12. Place end of springinto hole on undersideof burnertube as before(C) to secure
burner°
VERY IMPORTANT:Burner tube(s) must engagevalve opening(s)as shown (E).
13. Reattachround connectorof ignitorwire to ignitor.
14. Do not use morethan 16 newbriquetson briquetgrate aroundburner.Do not let
briquetscover burner holes.
!5. Repesitiondrip vaporiserbar and cooking grate(s).Reattachclean can to grease clip.
16. Beforecooking again on grilt,follow BurnerFlame Check.

Single Valve

Burner

attact

to Valve /r, x

Grate
......

Spring

• i

"_"

" '_

Round
end to

ignitor

Spring

Cleaning

The

Side

Control

Burner

Assembly

Followthese instructionsto clean and!or replace partsof burner assemblyor if you have
Iroubleigniting gdll
I Turn gas off at control knobs and LP tank.
2 Removecooking grate(s) and otd briquets.
3 RemoveDripVapoRtSER Bar from tube burner by carefullybendingfour tabs down
and awayfrom tube burner (A)
4 Undergrill remove soup can from grease clip.
5 Beneathside controlpanel disconnect short ignitor wire from ignitor Discop_nect
battery(if featured)and then ignitorwire from electrode
6 To removetube burner, removehitch pin from hinge pin at burner support bracket (B);
lift curvedend of tube burner upward,slide tubes awayfrom valve Removespider
guards (C), slide tube burner and ignitorwire out d grill bottom
7 Removescrew holdingignitor shield and wire mesh to tube burner (D). Electrodeand
wire (if featured)remain attachedto shield. Be carefulnot to lose screw or wire mesh
Wipe ceramic portion of electrodewith rubbing alcohol and cloth Clean wire mesh
with soap and water
8 Clean burner exlefior with soap and water. Lay burner on flat surface, insert garden
hose (preferablywith nozzle),into burnertubes forcing waterthrough tubes Make sure
water comes out of every porthole. Open clogged portholeswith a thin wire Shake
out excess water and examine portholes Due to normal wear and corrosionsome
portholesmay become enlarged, if so replace burner If any horizontalcracks appear
from portholeto per[holeor' large holes (other than portholes)are found replace
burner
9

tf grill is to be stored,coat tube burner lightlywittl cookingoil Wrap in protectivecover
to keep insectsout If not storingusefollowing steps
t0.. After cleaning burner place portholesfacing upward, reattach ignitor shield, electrode,
and wire mesh with small screw(D). Use same porthole Do not overtighten screw
11 Angletube burner as shown, insert ignitorwire (ffattad_ed to electrode)and burner
tubes back into holes in grill bottom Fit wire (if batu_ed)and electrodeinto small hole
towardsfrontof grill bottom Reattachspider guards (C) Valve openingsmust fit inside
burner tubes..

VERY IMPORTANT: Burner tubes must engage valve openings as shown (E),
12. Reattachtube burner to burner support bracketwith hitch pin and hinge pin (B)
13 Attachflat or round connector of ignitorwire to electrodeor ignitor Replace battery (if
featured)
14 Place DripVapoRtSER Bar onto bumer and carefullybend tabs back aroundtube
humor(A)
15 On briquet plate arrangenew briquetsaround tube burner Do not let briquetscover
burner portholes.Do not use mere than 20 briquets
t6 Repositioncooking grate(s). Reattachsoup can to grease clip under grill bottom
17. Before cooking again on grill, foltowBurner Flame Check
20

Drip VapoRISER

Bar

Tab

P
Burner

Support

Bracket

Burner

/
't

" '

\
_J

Hitch Pin

Hinge Pin

\
\

Match-

_Wire
Ignitor..i_l_..... Mesh -_.
Shield.....
. :....
ube Burner

aurner_
Screw

- _
_
/
\
//
Electrode ___..:Z_..

Control

0% '_'_

,anel

fighting hole

Non-Electronic Ignition Grills:
End of Ignitor Wire with round
connection goes to Ignitor
under Side Control Panel

Cleaning The HeatWave Rotisserie Burner
Follow these instnJctionsto clean andtor replace parts or if you have trouble igniting
the HeatWave burner
1 Turn gas off at control knobs and LP tank,
2 Disconnectignitor wire from electrode(A)
3. Removescrew from shield (B), removeshield and clean any accumulationof grease
with soap and water
4. Using screwdnver,pry clamp (C) off d grill bottom,pry the other clampoff Remove
HeatVVaveburner from grill
5 Using gardenhose (preferablywith nozzle),force water through burner tube. Make
sure watercomes out of every burner porthole Open clogged portholeswith thin wire
6_ Examine HeatWavehousingand burner closely (D). If any cracks or largeholes (other
than portholes)are found replace HeatWave burner.
7 Wipe ceramic portion of electrode (A) with rubbing alcohol and cloth.
8 if grill is to be stored,coat burner lightly with cooking oil Wrap with protectivecover to
keep insects out.
9 After burner has beencleaned, it may be necessaryto reshapeclamps by squeezing
themwith pliers, (just enoughto promote snug fit)
10 Angle burnertube over gastube (E).Gas tube must fit insideburnertube. With
electrodeon outside of grill bottom,lightly tap clamps onto grill with hammer
VERY IMPORTANT: Do NOT hit ceramic electrode while tapping clamp onto
grill bottom. A cracked electrode will not operate!
VERY IMPORTANT: Burner tube must engage gas tube as shown (F).
1t

Attachflat end of ignitorwire (A) to electrode.Make sure wire runs undemeathcasting
seat
12. Positionshieldover burner tube (B) and attachwith screw.

Gas Tube

Housing
"?.

_l_:t"

Burner Portholes _

Gas Tube

\ i
i

, /

]

i.>

Burner Tube

=u=er
To_e

i
i ..................

i
!

..........................................................................
i:....

Seasoning
And Using Cast Iron Cooking
Grates
Before using cast iron grates wash with dish washing liquid to remove a waxed
coating used for protection in shipping. Rinse with hot water and dry complete!y
Never allow to drain dry, or wash in a dishwasher. Tt}is can cause rust and cause
food io have a metallic taste or discolor foods After drying grates, coat entire surfaces
with a thin coat of solid vegetable shortening, Do not use salted fat such as margarine
or butter
Place grates into grill, light grill and turn to tow for one (1) hour Turn off all control
knobs Leave grates in grin to cool Your cast iron grates are ready to use Repeat if
necessary
You may also season cast iron grates in the oven Follow instructions above to
wash, dry and coat entire surface with solid vegetable shortening Put grates on top
rack of a clean oven Place alum!nun1foil on lower oven rack to catch any drippings,
Bake in a 300 degree oven for I hour. Turn oven off, teave grate(s) in oven to cool to
room temperature If oven is to be used immedialely after seasoning use hea! resistant
barbecue mitts or pads to remove grates horn oven while HOT Place grates on a heat
resistant surface and aflow to cool to room temperature
Always clean grates immediately after each use Rinse and dry thoroughly If there
is a lot of food sticking to the grates clean with a steel wool scouring pad Rinse well
with hot water and re-season in grill or oven per instructions
Prior to storing, grease very lightly with a solid vegetable shortening or a vegetable
cooking spray, wipe dry with a paper towel Store in a dry place.
Cast iron grates will turn black with use The pores of the iron will be sealed,
providing a durable coating that helps to prevent foods from sticking and reduces
corrosion. Grates will further season with use Regular' applications of a thin coat of
solid vegetaNe shortening or vegetable cooking spray will improve its resistance to
rust

Cast iron holds heat wel!, you will not need to use extremely high cooking
temperatures when grilling A Do not drop cast iron gtates, they will break
Repainting
Your Grill
. After extended use and exposure to weather, paint on grill may deteriorate or
become spotted Although this detracts from grill's appearance, it will not impair its
performance
To refinish your grill brush outside of grill lid and bottom with wire brush and lightly
sand with fine grit sandpaper Sanding allows new paint to adhere more easily
Wash grill lid and bottom with soap and water to remove dust and grease. Do not
use a grill cleaner on outside of grill Wipe with vinegar Refinish outside with heatresistant paint, Do not paint inside of grill.
Care
.

Of Wood

Wood items can be sanded lightly with fine grit sandpaper Refinish with stain, paint
or water sealant

HeatWave

Rotisserie

Burner

Use

The HeatWave rotisserie burner is an 11,000 BTU radiant heat burner that transforms your grill into a multilevel cooking center It is attached to the back of the bottom
casting, above the main grid To install, just follow the instructions in this manual.
You can use the burner as a broiler to cook foods on the cooking grates or bonusgrid If you do, then you cannot use tile bottom burner
Or, you can remove the cooking grates or bonus grid, install a rotisserie and use the
burner to perfectly roast foods on the spit This is the most common use for the burner
You cannot use the bottom burner with this process either
By not using the lower burner, the grease and food drippings won't burn and cause
flare-ups It's healthier, it's fuel-efficient, and it creates a delicious slow-cooked roast
beef, chicken, or veggie kabob on the rotisserie
or a beautiful broiled salmon,
lobster, or vegetable medley on the grid.
Cooking

Chart

For HeatWave

Rotisserie

Burner
}

Item

Weight

Time

ips
........

ChickenlFryer

351bs

65minutes

Interna!lemperalure 180C'F

Turkey Breast!

2 5 tbs

1 hr: 30 rain

Inlemal temperature170_F

I hL 10min

Inlernaltemperature 180'_F

2 hr: 15rain

InternalIemperature t 80"F

_2!t,_r--

:':, ]
!2 ;:,

Bone-in

CornishHens

20oz
!

Duck

4 5 Ibs

PorkShoulder "3'25ibs 2 hr:30rain

Placepan of waler in botlom of grill Internal
temperaturet 70_F

PorkBostonBult 33Ibs,

2hr:45min

Roasl

Placepan of water in bot!omof grill Internal
temperature 170_F

Pork Tenderloin

251bs

i Pork Spareribs/ 2 751bs

Med,40min

Inlerna!temperature: Med:i60"F

We_l:50 min

Well.170_F

1 hr: 30 rain

Placepan of water in bottomof grill

iB
-_ '
, ee_uacKRibs
BeefBottom

3 3 Ibs

RoundRoast
....

Cooking
,

•

Med rare: 1 hr 50 rain Internat lemperature:Med rare.I40;F
Med: 150_F
IMed. 2 hrs
Wetl:160_F
[!Veil, 2hrs ,Omin

Tips

If you set a foil pan in the bottom casting, right on the burner and briquets, it will
catch any food drippings created by cooking with the Rotisserie Burner You'll
have no grease in the grill to clean
tf you group different vegetaNes by the length of time it takes to cook, then
everything will be done at the same time Check the enclosed food chart for
cooking times
25

Cooking
Chart
Cooking times and temperatures rnay vary according to specific recipes, cooking
conditions or barbecue equipment used, Take these factors into consideration to
insure best results If you use tile indirect cooking method (indirect cooking is lighting
only one burner and placing food on opposite side of cooking grate), allow more
grilling time
Temperatures: High = 650 F_I Medium = 450 F° 1 Low = 300 F°
Food

Setting

Cooking Time

Beef
Hamburger 1f2" _hick

Medium

Med: 7-i 0 min!Welt done. 10-t5 rain

Steak II2"

Medium-Hoi

Rare: b6 rninlMed: G9 minlWeil done: 9-12 rnin

Roast

Low

Rare. t8-22 rain per IbiMed: 22-28 rain per tb
Well done: 28-32 rainper fb

Pork
Chops 112"

Medium

Well done: 15-20rain

Ribs 5-6 Ibs

Low-Medium

Well done: 45-90rain

Roast3-5 Ibs

Low-Medium

Well done: 18-23 rain per Ib

Ham Steak 1t2"

Medium-Hot

t 2-15 nTin

Ham5 Ib fullycooked

Low-Medium

20 rain per Ib

Lamb
Chops I12"

Medium

G12min

Chicken 2 !12-3 ti2 fbs

LOW

1 hr I5 rain to 1hr 30 rain

Chicken-halvedor quartered

Low

40-60 rain

Turkey

Low-Nled

t8-20 rain per Ib

Seafood
Steaks1"thick

Medium-Hot

Well done. 10-15min

FFlets6-8 oz

Mediumdqot

8-I2 rain

Shrimplarge orjumbo

Low-Medium

8d2min

Venison
Steak 1"lhick

Medium

Rare: 8-10 minfl_l_d: t0-12 rain

Burgers 112"

Medium

Rare: IGI2 minlMed: 12-15rain

Roast 3-4 Ibs

Low-Medium

Rare: 20-22 rain per IblMed. 22-25 rain per Ib

Food

Setting

Cooking Time

Bakingpolato, whole

Low

55-60 rain

Onions,whole

Low

45 rain

Tomaloes,half

Medium

3040 rain

Corn, whole

Low

35-45 rain

_Vfigetables
Wrap vegetablesin foil

Medium

Mushrooms
i

t5-20 min

Food Safety
•
Food safety is a very important part of enjoying the outdoor cooking experience.
To keep food safe from harmful bacteria, follow these four basic steps:
Clean:
Wash hands, utensils, and surfaces with hot soapy water before and after
handling raw meat and poultry.
Separate: Separate raw meats and poultry from ready-to-eatfoods to avoid cross
contamination. Use a clean platter and utensils when removing cooked
foods.
Cook:
Chill:

Cook meat and poultry thoroughly to kil! bacteria. Use a thermometer to
ensure proper internal food temperatures,
Refrigerate preparedfoods and leftovers promptly.

For more information call: USDA Meat and Poultry Hotline at
1-800-535-4555 In Washington, DO (202) 720-3333, 10:00 am-4:00 pm EST
How To Tell If Meat Is Grilled
Thoroughly
.
Meat and poultry cooked on a grill often browns very fast on the outside Use a
meat thermometer to be sure food has reached a safe internal temperature, and
cut into food to check for visual signs of doneness.
.

Whole poultry should reach 180:' F; breasts, 170_ F Juices should run clear and
flesh s!_ouldnot be pink,,

Hamburgersmade of any ground meat or poultry should reach 160_ F, and be
brown in the middle with no pink juices. Beef, veal and lamb steaks, roasts and
chops can be cooked to 1450F All cuts of pork should reach 160o F

NEVER partially grill meat or poultry and finish cooking later. Cook food
completely to destroy harmful bacteria

•

When reheating takeout foods or fully cooked meats like hot dogs, grill to 165_ F,
or until steaming hot,
27

Troubleshooting

- General

Problem

Possible Cause

PreventiontCure

Burner will not light
using ignitor.

Wire(s) and/or electrode
covered with cooking residue

Cleanwire(s) and/or electrode with
rubbing alcohol and dean swab.

Electrode(s) and burner are
wet

Wipe drywith clofl_

Electrode(s) crackedor broken
"sparks atcrack"

Replaceelectrode(s)

Wire(s) isloose or
disconnected

Reconnect wires or replace
eleclrodelwire assembly

Wireis shorting (sparking)
between ignitor andelectrode

Replace ignitorwire/electrode
assembly,

Bad ignitor

Replaceignitor

No gas flow

Check tosee if LP tank isempty. If
LP tank is nol empty, refer to
"Suddendrop in gas flow"

Coupling nutand
regulatornotfully connected

Turn the coupiing nut aboutonehalfto threequarters additional
turn until solidstop Tighten by I_and
only-do notuse toois

Obsiructionof gasflow

Clear burner tubes

Disengagemen!ofburner to
valve

Reengage burner and valve
Reatlachspringclip (iffealured)

Isgril! assembledcorrectly?

Checkstepsin assembfy
inslructions

Outofgas.

Check for gas in LP tank

Excess flow vaive lripped

Turn off knobs,wait 30 seconds

Burner(s) will not
match light°

Sudden drop in gas
flow or low flame,

and lighi grill
Ifflames are stilltowturn offknobs
and LPtankvalve Disconnecl
regulator Reconnectregulator and
leak check Turn on LP tank valve,
wait 30 seconds and thenlight grill
28

Problem

Possible

Flames blow out

Highor gusting winds

Turn front of gril! to face wind or
increaseflameheight

Low on LP gas

RefillLP tank

Excessflow valve tripped

Refer to "Suddendrop in gas flow"
above

Greasebuildup

Cleangrill

Excessivefafin meat

Trimfat from meatbeforegrilling

Excessivecooking
tempera[ure

Adjust (lower)temperature
according}y

Persistent grease
fire (can damage
the appearance of

Grease trapped byfood
buildup around burner
system

steel panels and
aluminum castings
on the grill),

Turn knobs 1oOFF Turn gas offat
LP lank Leavelid in position and let
fire burnout Aflergnl! cools,
lemove and de an all parts

Greasesoakedinto briquets

Replacebriquets Ifcookingwith fatly
meals removebriquels.

Flashback -

Burner and/or burner tubes

Clean burner and/or burner tubes

(fire in burner Iube(s)

are blocked

Unable to fill LP
tank

Somedealers haveolder fifl
nozzleswithworn threads

Flare-up

Cause

PreventienlCure

The worn t]ozzles don't have
enough "bile" toengage the valve
Try a second LP dealer

Troubleshooting

- Electronic

Ignition

System
Solution

Problem

Possible Cause

Check
Procedure

No sparks

Batterynotinsta!led

appear at any
electrodes when

completely

Doesbattery stideout Installbattery (makesure
hat"+" and %"connectors
of modulewith little
effort?

are oriented correctly);
battery should snap when
completelyinstalled

Dead battery or
incompleteswilch
connections

Has battery been
used previously?
Are ignitorswitch
wires securely
relained in spark
module?

Replace battery with new 9-

FaultyswiIch

With a new battery
installed,insertthe
endsdan unfolded

Replaceignitionswitch

ignition switch
is pushed; no
noise can be
heard from spark
module_

volt alkaline battery Push
ignitorswitch wiresinto
sparkmodule

paper clip into each
ofthe openingson the
switchreceptacle If
sparksare generated
atlhe electrodes,
switchis faulty.Note:
Remove paper dip
aflerlest
Faulty spark module

If no sparks are
generatedin check
forfadty switch,

Replace spark module
assembly

moduleisfaully.
No sparks
appear at any
electrodes when
ignition switch
is pushed; noise
can be heard
from spark
module.

Outpuflead
connectionsnot

Are output
conneclionson and

complete

tight?

lncompleteground
connection,

is ground ring
terminal loose on
mountingscrew?
(If'featured)

Remove and reconnect all
outputconnectionsatmodule
and electrodes

Tighten mountingscrew with
ground ring securely to leg
assembly

Problem

Possible Cause 1Cileck

Solution

I Procedure
Sparks are
3resent but not

Outputfead
connectionsnot

Are output
cormecfionson and

at all electrodes
andlor not at full

complete

[igii?

strength.

Incompleteground
conneciion

Is ground ring
terminal Iooseon
mountingscrew?

Remove and reconnectall
outputconneclionsatmodule
and electrodes
Tighten mounling screwwith
ground ring securely Io leg
assembly

(Iffealured)
Arcing to grill away
from burner(s)

If possible,observe
gri/till darklocation
Operateignition
system and Iookfor
arcingbekveenoutpul
wires and grill frame

If sparks are observed olher
lhan from burner(s), wire
insulationmay be damaged
Replacewires

Weak baltery

Ail sparks presentbut Replace batlery with a new
weak or a( slow
9-voll all
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Char Broil 4639071 User Manual GAS GRILL Manuals And Guides L0803637

CHAR-BROIL Grill, Gas Manual L0803637 CHAR-BROIL Grill, Gas Owner's Manual, CHAR-BROIL Grill, Gas installation guides

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