Char-Broil 415.161209 Product Manual Download Page 25

25

EMERGENCIES:

 If a gas leak cannot be stopped, or a fire occurs due to gas leakage, call the fire department.

Emergencies

Problem

Gas leaking from 
cracked/cut/burned 
hose.

Gas leaking from LP 
cylinder.

Gas leaking from LP 
cylinder valve.

Gas leaking between 
LP cylinder and 
regulator connection.

Fire coming through 
control panel.

Grease fire or 
continuous excessive 
flames above cooking 
surface.

Burner(s) will not  light 
using ignitor.

Continued on next 
page.

Possible Cause

Possible Cause

•Damaged hose.

•Mechanical failure due to rusting or 

mishandling.

• Failure of cylinder valve from 

mishandling or mechanical failure.

•Improper installation, connection not 

tight, failure of rubber seal.

• Fire in burner tube section of burner due 

to blockage.

• Too much grease buildup in burner area.

GAS ISSUES:

• Trying to light wrong burner.

• Burner not engaged with control valve.

• Obstruction in burner.

• No gas flow.

• Vapor lock at coupling nut to LP cylinder.

• Coupling nut and LP cylinder valve not 

fully connected.

ELECTRICAL ISSUES:

•Electrode cracked or broken; “sparks at 

crack.”

•Electrode tip not in proper position.

•Wire and/or electrode covered with 

cooking residue.

•Wires are loose or disconnected.

•Wires are shorting (sparking) between 

ignitor and electrode.

Prevention/Solution

Prevention/Solution

•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.

•Replace LP 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 
and Connecting Regulator to the LP Cylinder.

•Turn off control knobs and LP cylinder valve. Leave lid open to 

allow flames to die down. After fire is out and grill is cold, remove 
burner and inspect for spider nests or rust. See Natural Hazard 
and Cleaning the Burner Assembly pages.

• Turn off control knobs and LP cylinder valve. Leave lid open to 

allow flames to die down. After cooling, clean food particles and 
excess grease from inside firebox area, grease cup, and other 
surfaces.

• See instructions on control panel and in Use and Care section.

• Make sure valves are positioned inside of burner tubes.

• Ensure burner tubes are not obstructed with spider webs or other 

matter. See cleaning section of Use and Care.

• Make sure LP cylinder is not empty. If LP cylinder is not empty, 

refer to “Sudden drop in gas flow.”

• Turn off knobs and disconnect coupling nut from LP cylinder. 

Reconnect and retry.

• Turn the coupling nut approximately one-half to three-quarters 

additional turn until solid stop. Tighten by hand only - do not use 
tools.

• Replace electrode(s).

Main Burners:
• Tip of electrode should be pointing toward gas port opening on 

burner. The distance should be 1/8” to 1/4”. Adjust if necessary.

Sideburner (if featured):
• Tip of electrode should be pointing toward gas port opening on 

burner. the distance should be 1/8” to 3/16”. Adjust if necessary.

•Clean wire and/or electrode with rubbing alcohol and clean swab.

•Reconnect wires or replace electrode/wire assembly.

•Replace ignitor wire/electrode assembly.

Troubleshooting

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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