PRODUCT GUIDE MODEL 463225112 Kmart Item No. 640-04005540-2 C-69G4S 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.
TABLE OF CONTENTS DANGER For Your Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Grilling Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Use and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 Limited Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Parts Diagram. . . .
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. Wash your hands after handling this product.
GRILLING GUIDE – Getting Started 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.
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. Before you start grilling, organize your food according to cooking technique and required cooking time, and optimize the use of your grilling area.
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. The meat's internal temperature and thickness can also affect cooking times. Cold and thicker meats will take longer to cook.
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. After each use, remove any remaining food particles from the cooking grate and inside of the grill using a grill brush.
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. This could cause an intense fire with risk of property damage, serious injury or death. • If you see, smell or hear gas escaping, immediately get away from the LP cylinder/appliance and call your fire department.
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.
Leak Testing Valves, Hose and Regulator 1.Turn all grill control knobs to OFF. 2.Be sure regulator is tightly connected to LP cylinder. Str aig ht Hold coupling nut and regulator as shown for proper connection to LP cylinder valve. 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. 4.
WARNING 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 sides 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. • Do not use charcoal or ceramic briquets in a gas grill.
SEAR Burner Ignitor Lighting Ignitor Lighting s Do not lean over grill while lighting. 1. Turn OFF gas burner control valves. 2. Turn ON gas at LP cylinder. 3. Open lid during lighting. 4. To ignite, push and turn IGNITION BURNER knob to HI. . ush and hold ELECTRONIC IGNITION button until the burner 5. P lights. 6. If ignition does NOT occur in 5 seconds, turn the burner controls OFF, wait 5 minutes and repeat the lighting procedure. 7.
Burner Flame Check General Grill Cleaning • Remove cooking grates and flame tamers. Light burners, rotate knobs from HI to LOW. You should see a smaller flame in LOW position than seen on HI. Perform burner flame check on sideburner, also. Always check flame prior to each use. If only low flame is seen refer to "Sudden drop or low flame" in the Troubleshooting Section. • Do not mistake brown or black accumulation of grease and smoke for paint.
3. Remove carryover tubes and burners. 4. Detach electrode from burner. CAUTION SPIDER ALERT! SPIDER AND WEBS INSIDE BURNER TUBE If you notice that your grill is getting hard to light or that the flame isn’t as strong as it should be, take the time to check and clean the venturi’s. VALVE CONTROL PANEL SPIDER WEBS INSIDE VENTURI BURNER In some areas of the country, spiders or small insects have been known to create “flashback” problems.
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*.
PARTS LIST Key A B C D E F G H I J K L M N O P Q R S T U V W X Y Z AA BB CC DD EE FF GG HH II JJ Qty 1 5 1 1 1 4 1 1 1 1 1 7 7 1 1 1 1 2 2 1 1 5 4 1 1 1 1 1 1 1 1 1 1 1 1 1 Description FIREBOX MAIN BURNER-TUBE BURNER MAIN BURNER-BAR BURNER ELECTRODE, F/ TUBE BURNER ELECTRODE, F/ BAR BURNER CARRY OVER TUBE CONTROL PANEL, MAIN ELECTRONIC IGNITION MODULE BUTTON, F/ IGNITION MODULE SHIELD, F/ ELECTRONIC IGNITION MODULE HOSE VALVE REGULATOR ASSEMBLY BEZEL F/ CONTROL KNOB CONTROL KNOB TOP LID LOGO PLATE F/ LID
PARTS DIAGRAM N X V V V V V W W W W B B B Q P C B B E O EEE U D F F F F R DD A S T H I BB J AAA FF EE G CC AA Z HH K L L L L L M L M M M M M II SS Y MM JJ GG ZZ QQ DDD DDD PP M L XX XX PP TT KK RR OO NN CCC LL UU BBB WW YY UU VV BBB ZZ 17
ASSEMBLY 1 • Attach bottom shelf to left and right leg assemblies with 1/4-20x2-3/8” machine screws and 1/4-20 flange nuts. The cut out hole for the LP cylinder should be on the left side. For Front Door Brace Assembly Right Side Panel Left Side Panel 1/4-20x2-3/8" Machine Screw Qty: 6 Front 1/4-20 Flange Nut Qty: 6 Rear Bottom Shelf 2 • Place lower back panel between side panels as shown. Attach to left and right side panels with (4) #8x3/8” sheet metal screws.
3 • Hang tank exclusion wire onto lower back panel, attach other end to bottom shelf with #8x3/8” sheet metal screw. Lower Back Panel #8x3/8" Sheet Metal Screws Qty. 1 4 • Place front door brace as shown. Attach to left and right leg assemblies with 1/4-20x2-3/8" machine screws and 1/4-20 flange nuts.
5 • 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 bottom • • shelf 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 (B). After all 4 casters are secure remove the Caster Pin and save for future maintenance. Stand cart upright.
6 • 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.
• Hook side wall of shelf over support brackets on side of firebox. At back of firebox, insert (1) 7mm fiber washer and (1) 7 1/4-20x1/2” screw as shown(A). • Inside firebox, insert (3) 7mm fiber washers and (3) 1/4-20x1/2” screws as shown (B). • Attach shelf with (4) 1/4-20 flange nuts on each side (C). A Right Side Shelf Support Bracket 1/4-20x1/2" Screw Qty. 4 1/4-20 Flange Nut Qty: 4 7mm Fiber Washer 1/4-20x1/2" Screw 7mm Fiber Washer Qty.
9 • Hook side wall of side burner shelf over support brackets on side of firebox. At back of firebox, insert (1) 7mm fiber washer and (1) 1/4-20x1/2” screw as shown (A). • Inside firebox, insert (3) 7mm fiber washers and (3) 1/4-20x1/2” screws as shown (B). • Attach side burner shelf with (4) 1/4-20 flange nuts on each side (C). A Left Side Shelf 1/4-20x1/2" Screw B 7mm Fiber Washer 7mm Fiber Washer Back of Firebox 1/4-20x1/2" Screw Support Bracket C 1/4-20x1/2" Machine Screw Qty.
11 • Attach side burner bezel and valve with #8x3/8” SS screws. (A). • Place side burner into shelf. Make sure valve is inside side burner tube. Attach side burner with #8 wing nut (B). Hook venturi clip to side burner tube and around manifold. Attach side burner ignitor wire to ignitor as shown (C). • Press side burner control knob onto valve stem (D). • Place grate onto side burner shelf (E).
12 • Attach handle to door with #10-24x1/2” machine screws, 5mm flat washers and 5mm lock washers (A). • 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.
13 • Place heat tents over tube burners and the heat tent for sear burner over sear burner by inserting tabs into slots in front of firebox. Opposite ends of heat tents rest on pins in back of firebox. box f Fire o Back Heat Tent, F/Sear Burner (Stainless Steel) Hea Pin t Te nt Heat Tent (Black) Sear Burner t of Fron box Fire He at Te n t 14 • Place cooking grates onto grate rests. • Insert ends of Warming Rack pivot wire into holes in sides of gril lid.
• Attach the 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). 15 Heat Shield A #8x3/8" Sheet Metal Screws Qty. 4 B Grease Tray 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. Grease Tray Grease Pan 16 • LP tank is sold separately. Use only with an OPD (over-fill protection device) equipped LP tank.
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 cracked/cut/burned hose. • Damaged hose. • Turn off gas at LP cylinder or at source on natural gas systems. If anything but burned, replace valve/hose/regulator. If burned, discontinue use of product until a plumber has investigated cause and corrections are made. Gas leaking from LP cylinder.
Troubleshooting (continued) Problem Possible Cause Prevention/Solution Burner(s) will not light using ignitor. (See Electronic Ignition Troubleshooting also) ELECTRONIC IGNITION: • No spark, no ignition noise. • See Section I of Electronic Ignition System. • No spark, some ignition noise. • See Section II of Electronic Ignition System. • Sparks, but not at electrode or at full strength. • See Section III of Electronic Ignition System. Burner(s) will not match light.
Troubleshooting - Electronic Ignition Problem (Ignition) Check Procedure Prevention/Solution • Check battery orientation. • Install battery (make sure that “+” and “–” connectors are oriented correctly, with “+” end up and “–” end down.) • Has battery been used previously? • Replace battery with new alkaline battery. • Button assembly not installed properly. • Check to insure threads are properly engaged. Button should travel up and down without binding.
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