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Char-Broil The Big Easy 4638234 - User Manual

Char-Broil The Big Easy 4638234
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Natural Gas Grill
4638234
ASSEMBLY, USE AND
CARE MANUAL
WARNING
Combustion by-products produced when using this product contain chemicals
known to the State of California to cause cancer, birth defects, or other
reproductive harm.
4638234 / 0–4165057 (01-24-02)
THIS GRILL IS FOR
OUTDOOR USE ONLY
Failure to follow all manufacturer’s
instructions could result in serious
personal injury and/or property
damage.
WARNING
!
CAUTION
!
Some parts may contain sharp edges
– especially as noted in the manual!
Wear protective gloves if necessary.
CAUTION:
INSTALLER/ASSEMBLER:
CONSUMER:
Read and follow all safety
statements, assembly instructions,
and use and care directions before
attempting to assemble and cook.
Leave
these instructions with consumer.
Keep this manual for
future reference.
If you have any questions or need
assistance during assembly, please
call 1-800-241-7548.
Visit us on the web at:
www.charbroil.com

Table of Contents

Questions and Answers

  • A
    Amanda Matthews DDSJul 31, 2025
    How to fix Char-Broil The Big Easy 4638234 Grill burner that will not light using ignitor?
    • K
      Kevin EllisJul 31, 2025
      If the burner on your Char-Broil Grill won't light with the ignitor, it could be due to several reasons: the wire is covered with cooking residue, the electrode and burner are wet, the electrode is cracked or broken, the wire is loose or disconnected, the wire is shorting, or the ignitor is bad. Try cleaning the wires with rubbing alcohol and a clean swab, then wipe them dry with a cloth. You may need to replace the burner or reconnect/replace the ignitor wire. In some cases, replacing the burner might be necessary.
  • J
    jamienicholsAug 4, 2025
    What to do if my Char-Broil Grill burner(s) will not match light?
    • M
      Mrs. Victoria BurnettAug 5, 2025
      If the burner(s) on your Char-Broil Grill won't match light, it could be due to no gas flow, an obstruction of gas flow, disengagement of burner to valve, or incorrect grill assembly. First, ensure that the gas is turned on at the source. Then, clean the burner tubes to clear any obstructions. Reengage the burner to the valve. Finally, check the assembly steps in the manual to ensure the grill is correctly put together.
  • A
    Anthony CaseyAug 10, 2025
    Why does my Char-Broil The Big Easy 4638234 flare-up?
    • Y
      yangvirginiaAug 10, 2025
      Flare-ups on your Char-Broil Grill can happen due to grease buildup, excessive fat in the meat you're grilling, or cooking at too high a temperature. To resolve this, clean your grill thoroughly. Trim excess fat from meat before grilling. Adjust the cooking temperature to a lower setting.
  • N
    nicole73Aug 15, 2025
    What to do if there is a persistent grease fire in my Char-Broil The Big Easy 4638234?
    • R
      Ryan PageAug 15, 2025
      If you experience a persistent grease fire in your Char-Broil Grill, immediately turn all control knobs to the OFF position. Then, turn off the gas supply at its source. Leave the grill lid closed and allow the fire to burn itself out completely. Once the grill has cooled down, remove and thoroughly clean all of its parts to prevent future occurrences. This issue is usually caused by grease trapped by food buildup around the burner system.
  • A
    Ann CruzAug 20, 2025
    Why do the flames blow out on my Char-Broil The Big Easy 4638234?
    • R
      Ronald MartinezAug 20, 2025
      If the flames on your Char-Broil Grill are blowing out, it is likely due to high or gusting winds. To address this, turn the front of the grill to face the wind or increase the flame height.
  • M
    mariarobertsAug 25, 2025
    How to fix Flashback (fire in burner tube(s)) in Char-Broil The Big Easy 4638234 Grill?
    • L
      Lori YoungAug 26, 2025
      If you're experiencing flashback (fire in burner tubes) in your Char-Broil Grill, it's likely because the burner tubes are blocked. Clean the burner tubes to resolve this issue.

Summary

Installation Safety Precautions

Safety Symbols and Warnings

DANGER

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

Be alert to the possibility of serious bodily injury if the instructions are not followed. Be sure to read and carefully follow all of the messages.

CAUTION

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

Warranty Information and Claims

Warranty Coverage and Limitations

Details warranty periods for specific parts, exclusions, and manufacturer's liability. Includes contact for claims.

Parts List

Grill Assembly Steps

Step 1: Attaching Wheels and Tank Bracket

Instructions for attaching wheels and tank bracket, including parts needed and diagram.

Step 2: Connecting Upper and Lower Panels

Explains how to insert the lower panel into the upper panel and attach the console.

Grill Assembly Steps Continued

Step 3: Assembling the Stand Cart

Guides attaching left and right shelves using carriage bolts, wing nuts, and screws.

Step 4: Installing Condiment Wire and Tray

Details the attachment of the condiment wire and tray to the grill assembly.

Grill Assembly Steps Continued

Step 5: Attaching Grates, Burner Tents, and Shield

Instructions for placing grates, griddle, burner tents, and shield onto the grill body.

Step 6: Mounting the Grill Lid and Logo Plate

Guides the installation of the grill lid, hinge pins, hitch pins, logo plate, and handle.

Grill Assembly Steps Continued

Step 7: Installing Chefs Delite and Grid Bolts

Details attaching the Chef's Delite, swing grid bolts, and wing nuts to the grill assembly.

Step 8: Connecting Chains and Match-Holder

Instructions for connecting the chains with coupling and attaching the match-holder.

Grill Assembly Steps Continued

Step 9: Attaching the Grease Clip

Guides the attachment of the grease clip to the grill bottom and includes a critical caution.

Step 10: Connecting the Natural Gas Hose

Instructions for attaching the 12' natural gas hose, tightening the connection, and leak testing.

Connecting Your Grill to the Natural Gas Source

Gas Connection Safety and Warnings

Details safe connection procedures, required hose types, and warnings about piping and pressure testing.

Leak Testing and Safety Tips

Performing a Leak Test

Step-by-step instructions for checking gas connections for leaks using a soapy solution.

General Safety Precautions

Provides essential safety advice for grill operation, maintenance, and placement to prevent accidents.

Ignitor, Valve, and Hose Checks

Ignitor and Match Lighting Procedures

Guides on how to safely light the grill using the ignitor or a match, including troubleshooting.

Valve and Hose Inspection

Instructions for checking valve operation and hose condition before and after use.

Burner Assembly Cleaning and Maintenance

Cleaning the Burner Assembly

Detailed instructions for cleaning burner tubes, electrodes, and related components for optimal performance.

Cooking Chart and Food Safety

Grill Cooking Guidelines

Provides cooking times and temperatures for various foods, along with essential food safety practices.

Storing Your Grill

Offers advice on proper storage procedures for the grill, both indoors and outdoors.

Troubleshooting Guide

Common Grill Problems and Solutions

Addresses issues like burner ignition failure, flame blowouts, flare-ups, and grease fires with prevention tips.

Char-Broil The Big Easy 4638234 Specifications

General IconGeneral
BrandChar-Broil
ModelThe Big Easy 4638234
CategoryGrill
LanguageEnglish

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