Product guide

ManualsBrandsChar-Broil ManualsGrill415.16112010

PRODUCT GUIDE

Sears item No, 161 t2

Sears Mode| No. 415.16112010

IMPORTANT: Fill out the product record information below.

Serial Number

Date Purchased

Seeratinglabelongrillfor serialnumber.

Forsupportandto registeryour

grill, pleasevisit usat

www.charbroil.com

Ifyou 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;Commercial 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 ofthe 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;D406,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;D438A27; [:)439,11O; 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;DOt0,422;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 Model463723310 10/23/09• G305-001-210801

Summary of content (32 pages)

PAGE 1
PRODUCT Sears item Sears Mode| GUIDE No, 161 t2 No. 415.16112010 IMPORTANT: Fill out the product record information below. Serial Number See ratinglabel on grill for serialnumber. Date Purchased 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.
PAGE 2
For Your Safety .................................... 2-3 Grilling Guide ...................................... 4-7 Use and Care .................................... 8-13 If you smell gas: 1. Shut off gas to the appliance. Limited Warranty .................................... 14 2. Extinguish any open flame. Parts List .......................................... 15 3. Open lid. Parts Diagram ...................................... 16 Assembly .......................................
PAGE 3
CAUTION CALIFORNIA PROPOSITION 65 1.Combustionby-productsproducedwhenusing this productcontainchemicalsknownto the Stateof Californiato causecancer,birth defects,andother reproductiveharm. 2.This productcontainschemicals,including lead and lead compounds, known to the State of California to cause cancer, birth defects or other reproductive harm. Wash your hands after handling this product.
PAGE 4
Temperature First Time Use Read your Assembly Manual and ensure the grill is put together properly. Remove all Point-of-Purchase advertising material from all grill surfaces before first use. We recommend operating your grill on its highest setting for 15-20 minutes prior to your first use. This aids in removing the oils used during manufacturing.
PAGE 5
Outdoor grillingisreallyquitesimple.You'llsucceed with burgers, dogs,orsteaks usually onyourveryfirsttry.With experience, youwilllearnhowtoworkwithyourgrill,creating moreimaginative meals allthetime.Thisknowledge makes up theartofgrilling.Before youstartgrilling, organize yourfood according tocooking technique andrequired cooking time,and optimize theuseofyourgrillingarea. Rotisserie Cooking Rotisserie cooking isbestfor'round' meat,suchaslargeroasts, wholepoultry, andpork.
PAGE 6
Cooking onyournewgrillisahands-on experience, anditis recommended toremain outside withyourgrillwhilecooking. Grilling canbeaffected bymanyexternal conditions. Incold weather, youwillneedmoreheattoreachanidealcooking temperature, andgrillingmaytakelonger.Themeat'sinternal temperature andthickness canalsoaffectcooking times.Cold andthickermeats willtakelongertocook. Wood Chips For extra smoke flavor when grilling, try adding wood chips.
PAGE 7
WhyClean? We'veallheardthesaying, 'anounceofprevention iswortha pound ofcure.'Thisisgreatadvice whenitcomes tokeeping yourgrillclean. RoutineCare Periodic cleaning ofthisgrillisnecessary, asgrillfirescanoccurwhengrease and fooddebriscollect inthebottom ofthegrill. Aftereachuse,remove anyremaining foodparticles fromthecooking grateand insideofthegrillusinga grillbrush.Do thisafterthegrillhascooled down,yetis stillwarm.
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 the appliance or in an enclosed area. •LP cylinders must be constructed and marked in accordance with specifications for LP cylinders of the U.S.
PAGE 9
LP Cylinder Exchange Connecting Regulator to the LP Cylinder •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" section of this manual. 1.LP cylinder must be properly secured onto grill. (Refer to assembly section.
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. There is a major leak at the connection. Correct before proceeding. Hold coupling nut and regulator as shown for properconnection to LP cylinder valve. 4.Brush soapy solution onto areas circled below, or other similar fittings on your grill.
PAGE 11
Safety Tips A Before opening LP cylinder valve, check the coupling nut for tightness. For Safe Use Of Your Grill And To Avoid Serious injury: • 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. • Check burner flames regularly. • Use grill only in well-ventilated space. NEVER use in enclosed space such as carport, garage, porch, covered patio, or under an overhead structure of any kind.
PAGE 12
Ignitor Lighting A Do not lean over grill while Eghting. 1. Turn OFF gas burner control valves. 2 Turn ON gas at LP cylinder. 3. Open lid during lighting.. 4. To ignite, turn the IGNITION BURNER knob to the Sideburner Match Lighting 1. Turn OFF all burner control valves. 2. Open sideburner lid (if equipped). Turn ON gas at LP cylinder. 3. Place lit match near burner. 4. Turn sidebumer knob to the HI position. Be sure burner lights and stays lit. HI position. 5. Push and hold ELECTRONIC IGNITOR button.
PAGE 13
* Plated wire grates: Wash grates with concentrated grill cleaner or use soap and water solution. Dry thoroughly and store indoors between cookouts. o 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 grates: Because of glass-like composition, most residue can be wiped away with baking soda/water solution or specially formulated cleaner.
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*. The manuPacturer reserves the right to require that defective parts be returned, postage and or freight pre-paid by the consumer for review and examination.
PAGE 15
il! i IIIIIIIIIIllliii A 1 LEFT FRONTLEG, CURVED HH 2 MOUNTING BRACKET, F/SHELF, (LF/RB) B 1 LEFT BACK LEG, STRAIGHT II 2 MOUNTING BRACKET, F/SHELF, (RF/LB) C 1 SIDE BRACE JJ 1 LEFT SIDE SHELF F/SB D 1 MATCH HOLDER KK 1 DRIP PAN F/SB E 2 UPPER LEG LL 1 SIDEBURNER F 2 SUPPORT BRACKET MM 1 ELECTRODE W/ WIRE, F/SB G 1 RIGHT FRONT LEG, CURVED NN 1 RETAINER CLIP H 1 RIGHTBACK LEG, STRAIGHT OO 1 LID F/SB I 2 LEG EXTENDER PP 1 SIDEBURNERGRATE J 1 UPPER FRONT
PAGE 16
UU xx TT i / vv V QQ _w GG\ R_-_ W ,/ Q i!
PAGE 17
g Left Leg one upper leg as shown. NOTE: Left front and left back legs do not have leg extenders. In front, attach upper leg, side i Place 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" machine screw and #10-24 flange nut. Do not tighten. i Attach support bracket in the third hole from bottom of leg with hinge pins and hitch pins (A). j Upper Leg Hitch Pin Qty.
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" machine screws and #10-24 flange nuts through the 2 lowest holes on the legs. } Attach top brace with #10-24x2" machine screws and #10-24 flange nuts through the 2 bottom holes of the upper leg.
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" Sheet Metal Screw #8-32X3/8" Sheet Metal Screw Qty. 2 T Loosen screws to adjust upper and front panels to line up Tank Exclusion Wire Back Brace Wheels Turn assembly upside down. Insert axle rod through wheel, legs and other wheel. Attach with a wheel bushing and hitch pin. See insert below for the correct holes to use.
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. } In back, attach upper firebox support with #10-24x2" machine screws and #10-24 flange nuts.
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" Machine Screw Qty.2 #10-24 Flange Nut 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). iiiiiiiAttach condiment basket to upper front panel as shown ( B ). A #10-24 Flange Nut Qty.
PAGE 22
Burner, Firebox and Control Knobs Place burner assembly into firebox. Fasten the burner assembly to the firebox using 5x15 fiber washers and #1024x1/2" 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). Place firebox on cart. Make sure burner tubes are correctly engaged with valves. Attach ignitor wire to ignition module (B).
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. Attach Right Side Shelf and Side Burner Support Shelf to front of leg with 1/4"-20x1/2" machine screws.
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). A 1' 5x9 Fiber Washer Qty.1 #8-32 Wing Nut Qty.1 #8-32x3/8" Machine Screw Qty.2 5x9 Fiber Washer ....
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 Fiber Washer ... ...... #10-24xl/2" Machine Screw #10-24xl/2" Machine Screw Qty.4 Center flat portion of hinge on bottom #10-24 nge Nut 5x15 Fiber Washer Qty.8 #10-24 Flange Nut Qty. 4 Lid Handle and Upper Hinges Attach handle to lid with 7x15 fiber washers and 1/4"-20 wing nuts (A).
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. Cooking Grate Heat Tent Swing Away 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.
PAGE 27
Grease Cup and Grease Cup Clip Hang grease cup clip from bottom of firebox and place grease cup into grease cup clip. 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. Grease Cup Clip Grease Cup LP Tank Tank collar opening must face to front of grill. Loosen wing nut from tank retainer bracket. Set bottom of tank into notches of tank support bracket. Place tank retainer bracket onto tank collar and tighten wing nut.
PAGE 28
EIVlERGENCIIES= if a gas leak cannot be stopped, or a fire occurs due to gas leakage, call the fire department. Gasleakingfrom cracked/cut/burned hose. , Damagedhose. , Turnoff gas at LP cylinderor at sourceon naturalgassystems.If anythingbut burned,replacevalve/hose/regulator. If burned, discontinueuseof productuntila plumberhas investigatedcause and correctionsare made. Gasleakingfrom LP cylinder. , Mechanicalfailuredue to rustingor mishandling. , ReplaceLP cylinder.
PAGE 29
Troubleshooting (continued) Burner(s)will not light usingignitor. (See ElectronicIgnition Troubleshooting also) Burner(s)will not matchlight. ELECTRONICIGNITION: • Nospark,no ignitionnoise. • SeeSectionI of ElectronicIgnitionSystem. • Nospark,someignitionnoise. • SeeSectionII of ElectronicIgnitionSystem. , Sparks,but notat electrodeor at full strength. • SeeSectionIII of ElectronicIgnitionSystem. • See"GAS ISSUES:"on previouspage. • Matchwill not reach. , Uselong-stemmatch(fireplacematch).
PAGE 30
Troubleshooting - Electronic Ignition SECTIONI Nosparksappearat • Batterynot installed anyelectrodeswhen properly. ElectronicIgnitionButton is pressed;no noise can be heardfromspark , Deadbattery. module. , Checkbatteryorientation. • Installbattery(makesurethat "+"and "-" connectorsare orientedcorrectly,with "+"end up and "-" enddown.) , Has batterybeen used previously? • Replacebatterywith newAA-sizealkalinebattery. , Buttonassemblynot installedproperly. Checkto insurethreadsare properlyengaged.
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 DEVUELVALADENTRODE LOS 10 DIAS DE LACOMPRA. SI NO LADEVUELVE,PUEDEVERSEAFECTADA SU COBERTURA DE GARANTIA.
PAGE 32
• Register your Char-Broil • Get information about • Our replacement parts • Reliable customer • Delicious recipes • Char-Broil ®on-line • Sizzle On The Grill • And much ® product our products support store E-newsletter TM more! Please visit us at www.charbroil.com Buy Online link to find maintenance items, Char-Broil covers, tools and accessories, grill parts, as well as ®grills and cookers.