Char-Broil 415.161209 Product Manual Download Page 1

PRODUCT GUIDE

Printed in China 

Serial Number

Date Purchased

IMPORTANT: Fill out the product record information below.

See rating label on grill for serial number.

For support and to register your 
grill, please visit us at 

www.charbroil.com

Estimated assembly time: 35-40 minutes 

If you have questions or need 
assistance during assembly, 
please call 

1-800-241-7548

.

10/22/09 • G211-001-090801

Sears Item No. 16120

Sears Model No. 415.16120901

KSN No. 640-174093112

Assembly instructions © 2009

      

© 2009 Char-Broil, LLC    Columbus, GA  31902

Model 463611810 463612010

 • 

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:

®

®

Protected under one or more of the following U.S. Patents: 5,421,319; 5,458,309; 5,579,755; 5,996,573; 6,135,104; 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; 6,792,935; 6,951,213; 7,047,590; 
7,516,693; 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; D423,274; 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:D97,504;D99,355; D102,037; D104,200;D108,377; 2,315,567; 
France:D010,231;D010,422;D010,590;D010,849; 1,089,646; South Korea: 384,565; United Kingdom: 2,099,402. Other Patents Pending.  © 2009 W.C. Bradley Company

The following are trademarks of W.C. Bradley Co.: Advantage Series™; Auto-Clean™;Chef Tested™; Commercial Series™; Designer Series™;; Diamond Flame™; 
Double Chef™; Fireball™; Firenzy™; FlavorMaster™;Front Avenue™; Grill 2 Go® Advantage™; Hog and Yard Bird™; H20 Smoker™; Infrared. Grilling’s Juicy Little 
Secret™;  Incredible  Taste.  Infallible  Results™;  Infrared  Inside™;  Insure™;  Let’s  Grill  Something  Together™;  Lev-Alert™;  Longhorn™;  Magneto™;  Precision 
Flame™;  Quick2Burn™;  QuickSet™;  Ready  When You Are™;  Season,  Set, And  Savor™;  Sizzle  On The  Grill™;  Signature  Series™;  SureFire™; The  Minute 
Grill™;Torchfork™; Universal Grill Parts™; You Bring the Party™      TEC™ is a trademark of Tec Infrared Grills.

®

Summary of Contents for 415.161209

Page 1: ...72 637 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 274 D423 876 D428 303 D430 772 D435 396 D436...

Page 2: ...lly hazardous situation or unsafe practice which if not avoided may result in minor or moderate injury Safety Symbols The symbols and boxes shown below explain what each heading means Read and follow...

Page 3: ...elf Installation Safety Precautions Use grill as purchased only with LP propane gas and the regulator valve assembly supplied If your grill is Dual Fuel ready a conversion kit must be purchased for us...

Page 4: ...ertently activate this safety feature without having a gas leak This typically occurs when you turn on the gas using the grill control knob before you turn on the LP tank valve If the gas regulator sa...

Page 5: ...ath the meat to catch grease and food drippings and helps minimize clean up Rotisserie Cooking Rotisserie cooking is best for round meat such as large roasts whole poultry and pork It generally requir...

Page 6: ...ades and Rubs To enhance the flavor of grilled foods a liquid marinade or dry rub can be used prior to cooking Meat can be either soaked or injected with liquid marinade up to 24 hours prior to grilli...

Page 7: ...inless steel can rust under certain conditions This can be caused by environmental conditions such as chlorine or salt water or improper cleaning tools such as wire or steel wool It can also discolor...

Page 8: ...unexpectedly when mixed with air LP Cylinder Filling Use only licensed and experienced dealers LP dealer must purge new cylinder before filling Dealer should NEVER fill LP cylinder more than 80 of LP...

Page 9: ...s described in the LP Cylinder section of this manual Always keep new and exchanged LP cylinders in upright position during use transit or storage Leak test new and exchanged LP cylinders BEFORE conne...

Page 10: ...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 Brush soapy solution...

Page 11: ...appliance s Never move grill while in operation or still hot s Use long handled barbecue utensils and oven mitts to avoid burns and splatters s Maximum load for side shelves is 10 lbs s The grease cup...

Page 12: ...ank off by turning OPD hand wheel clockwise to a full stop Ignitor Check Turn gas off at LP tank Press and hold ignitor button Click should be heard and spark seen each time between collector box or b...

Page 13: ...e in dry location When LP cylinder is connected to grill store outdoors in a well ventilated space and out of reach of children Cover grill if stored outdoors Choose from a variety of grill covers off...

Page 14: ...y or for failure or damage resulting from acts of God improper care and maintenance grease fire accident alteration replacement of parts by anyone other than Manufacturer misuse transportation commerc...

Page 15: ...REGULATOR ASSEMBLY M 2 KNOB N 1 IGNITOR O 1 BURNER P 1 ELECTRODE COLLECTOR Q 2 VENTURI CLIP R 1 HEAT SHIELD F FIREBOX S 1 TANK EXCLUSION GRID T 4 SHELF ARM U 2 SIDE SHELF V 2 LOWER HINGE W 1 LID X 1...

Page 16: ...16 PARTS DIAGRAM Y X U BB CC T C I A S E K M O P J R W AA Z U V L T C B DD H N A G F Q D...

Page 17: ...lts and four 1 4 20 tee knobs Do not fully tighten all tee knobs until step6 Tank support bracket and Wheels Turn assembly upside down Insert axle bolts into wheels Facing the back position tank suppo...

Page 18: ...24x1 1 4 machine screws from outside the firebox then fasten with 10 24 flange nuts and 5x15 fiber washers from the inside A Insert one end of burner clip into hole in venturi tube and hook other end...

Page 19: ...ebox to cart using four 10 24x1 1 4 machine screws 5x15 fiber washersand 10 24wingnuts Tank Exclusion Grid Attach tank exclusion grid to lower cart legs with four 8 32x3 8 sheet metal screws Fully tig...

Page 20: ...ngfour1 4 20x2 carriageboltsandfour1 4 20teeknobspershelf SideShelf Arm Slideshelfarmsintolegassembliesandsecurewithonepushfastenerperarm Tank Retainer Push Fastener Qty 4 Shelf Arm 1 4 20 Tee Knob 1...

Page 21: ...iber Washer 10 24x1 2 Machine Screw 5x15 Fiber Washer HandleandUpperHinges Attachhandleandtwoinsulationwasherstofrontoflid Securewithtwo5x15fiberwashersand 10 24wingnuts A Attachupperlidhingestobackof...

Page 22: ...nside hinges on firebox Secure using two hinge pins and two hitch pins 11 12 CookingGrateandHeatTent Placeheattentintofirebox Aligntheslotsonheattenttoheattentsupportscrews Placecookinggrateintofirebo...

Page 23: ...toleftsidesupportbraceusingone1 4 20x1 1 4 carriageboltandone1 4 20teeknob Donot fullytightenuntilLPcylinderisinstalled 14 Failure to install grease cup clip and cup will cause hot grease to drip from...

Page 24: ...front of grill See Use Care section of this manual to perform the Burner Flame Check and for important safety instructions before using 15 Always keep LP cylinders in upright position during use trans...

Page 25: ...cylinder Turn off LP cylinder valve Return LP cylinder to gas supplier Turn off LP cylinder valve Remove regulator from cylinder and visually inspect rubber seal for damage See LP Cylinder Leak Test a...

Page 26: ...e knob Inspect wire insulation and proper connection Replace wires if insulation is broken Use long stem match fireplace match See Match Lighting section of Use and Care Check for gas in LP cylinder T...

Page 27: ...27 Warranty Registration Department P O Box 1240 Columbus GA 31902 1240...

Page 28: ......

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