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Thermos HEATWAVE 461262409 - User Manual

Thermos HEATWAVE 461262409
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Assembly instructions © 2008
PRODUCT GUIDE
MODEL 461262409
© 2008 Char-Broil, LLC Columbus, GA 31902
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: 30-45 minutes
If you have questions or need
assistance during assembly,
Please call
.
1-888-430-7870
10/31/08 80018823
This product is manufactured by Char-Broil, LLC, a division of the W. C. Bradley Company under the terms of a license agreement granted by Char-Broil Thermos
Holdings, LLC. In the United States, in the category of gas grills and grill accessories, Thermos is a registered trademark of Char-broil Thermos Holdings, LLC. In the
United States in all other categories and worldwide in all categories, Thermos is a registered trademark of Thermos L.L.C. or one of its affiliates. All rights reserved.
The following are trademarks registered by W.C. Bradley Co. in the U.S. Patent and Trademark Office: Char-Broil®; America's Legendary Barbeque Company®;
American Gourmet®; Bandera®; BrushHawg®; CB940®; Char-Diamonds®; Char-Broil Charcoal/Gas®; DiamondFlame®; Everybody Grills®; Everybody Outside®;
FastStart®; Fireball®; Firenzy®; FlavorMaster®; Grill2Go®; Grill2Go® Express®; Grill Lovers®; H20 Smoker®; Keepers of the Flame®; New Braunfels Smoker
Company®; Oklahoma Joe's®; Patio Bistro®; Patio Caddie®; Patio Kitchen®; Precision Flame®; Quantum®; Santa Fe®; Sear and Grill®; Sierra®; Signature
Series®; The Big Easy®; The Minute Grill®; Trentino®; Wild West Tradition®; and the following marks:
® ®
Protected under one or more of the following U.S. Patents: 4,989,579; 5,421,319; 5,458,309; 5,579,755; 5,996,573; 6,114,666; 6,135,104; 6,209,533; 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;
6,863,100; 6,935,327; 6,951,213; 6792,935; 7,047,590; 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; D423,876;
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: 87,743; 87,744; 97,504; 99,355;
102,037; 104,200; 2,315,567; 2,336,036; France: 010,231; 010,422; 010,590; 010,849; 1,089,646; Germany: 1,089,646; South Korea: 384,565; China: 99,127,066.5; United Kingdom: 2,099,402; 1,089,646. Other Patents Pending.
© 2008 W.C. Bradley Company
The following are trademarks of W.C. Bradley Co.: Commercial Series™; Designer Series™; Grill2Go® Advantage™; Longhorn™; Double Chef™; QuickSet™;
Ready When You Are™; Hog and Yard Bird™; You Bring the Party™; SureFire™; Universal Grill Parts™
TEC™ is a trademark of Tec Infrared Grills.
TM REVISION 00

Questions and Answers

  • A
    Alyssa MurphyAug 15, 2025
    What to do if my Thermos Grill has a flare-up?
    • Y
      yfrenchAug 15, 2025
      If your Thermos Grill experiences a flare-up, it could be due to grease buildup. Clean the burners and the inside of the grill/firebox. Another cause might be excessive fat in the meat; trim the fat before grilling. Finally, check for excessive cooking temperature and adjust accordingly by lowering the temperature.
  • M
    Mary SanchezAug 18, 2025
    Why is there a sudden drop in gas flow in my Thermos HEATWAVE 461262409?
    • D
      Dillon FrostAug 18, 2025
      A sudden drop in gas flow or low flame in your Thermos Grill can be caused by several factors. First, check if your LP cylinder is out of gas. Second, the excess flow valve may have tripped; to resolve this, turn off the knobs, wait 30 seconds, and light the grill. If flames are still low, turn off the knobs and LP cylinder valve, disconnect the regulator, reconnect it, perform a leak test, turn on the LP cylinder valve, wait 30 seconds, and then light the grill. Lastly, a vapor lock may have occurred at the coupling nut/LP cylinder connection; turn off the knobs and LP cylinder valve, disconnect the coupling nut from the cylinder, reconnect it, and try again.
  • M
    Matthew NewmanAug 21, 2025
    What to do if flames blow out on my Thermos Grill?
    • W
      Wendy BaileyAug 22, 2025
      If the flames on your Thermos Grill blow out, it could be due to high or gusting winds; turn the front of the grill to face the wind or increase the flame height. It could also be because you're low on LP gas; refill the LP cylinder. Another possible cause is that the excess flow valve has tripped; refer to the instructions for a 'Sudden drop in gas flow' to resolve this.
  • L
    Lindsay MeyerAug 25, 2025
    What to do if my Thermos HEATWAVE 461262409 Grill has a persistent grease fire?
    • C
      Colton SerranoAug 26, 2025
      If your Thermos Grill has a persistent grease fire, it's likely due to grease trapped by food buildup around the burner system. Turn the knobs to the OFF position and turn off the gas at the LP cylinder. Leave the lid in position and let the fire burn out. After the grill cools, remove and clean all parts.
  • A
    Amanda FoxAug 28, 2025
    What to do if my Thermos HEATWAVE 461262409 has a flashback (fire in burner tube(s))?
    • A
      anthonyperezAug 28, 2025
      If you experience a flashback (fire in burner tube(s)) in your Thermos Grill, it indicates that the burner and/or burner tubes are blocked. Turn the knobs to the OFF position and clean the burner and/or burner tubes. Consult the burner cleaning section of the Use and Care guide for detailed instructions.
  • R
    Reginald KennedyAug 31, 2025
    What to do if one burner does not light from other burners on my Thermos HEATWAVE 461262409 Grill?
    • A
      Angel CisnerosSep 1, 2025
      If one burner on your Thermos Grill does not light from the other burners, it's likely due to grease buildup or food particles in the end(s) of the carryover tube(s). Clean the carry-over tube(s) with a wire brush.
  • S
    Steven RochaSep 4, 2025
    What to do if there are no sparks at any electrodes when the control knob is turned and no noise can be heard from the spark module on my Thermos Grill (SECTION I)?
    • J
      Jessica RogersSep 4, 2025
      If there are no sparks at any electrodes and no noise from the spark module on your Thermos Grill, first check the battery orientation. If that's not the issue, replace the battery with a new AA-size alkaline battery. Also, ensure the button assembly is installed properly by unscrewing and reinstalling it, making sure the threads are aligned and fully engaged. If none of these steps work, the spark module may be faulty and needs replacement.
  • Y
    youngsuzanneSep 7, 2025
    What to do if there are no sparks at any electrodes when the control knob is turned, but noise can be heard from the spark module on my Thermos HEATWAVE 461262409 Grill (SECTION II)?
    • J
      Jared WilliamsSep 7, 2025
      If there are no sparks at any electrodes but you can hear noise from the spark module on your Thermos Grill, the output lead connections may not be connected. Remove and reconnect all output connections at the module and electrodes.
  • M
    Monique ShawSep 10, 2025
    What to do if sparks are present but not at all electrodes and/or not at full strength on my Thermos HEATWAVE 461262409 Grill (SECTION III)?
    • W
      William MccarthySep 10, 2025
      If sparks are present but not at all electrodes or not at full strength on your Thermos Grill, first, remove and reconnect all output connections at the module and electrodes. If possible, observe the grill in a dark location to check for arcing between output wires and the grill frame. Replace the battery with a new AA-size alkaline battery if it's weak. Use a paper towel to remove moisture if the electrodes are wet. Finally, replace any cracked or broken electrodes.

Summary

Use and Care Guide

LP Cylinder Specifications and Handling

Details LP cylinder requirements, specifications, and properties of LP gas for safe handling.

LP Cylinder Filling and Exchange

Provides guidance on safe LP cylinder filling and the exchange process.

Leak Testing and Regulator Connection

Step-by-step guide for leak testing and connecting the regulator to the LP cylinder.

System Leak Testing

Instructions for leak testing the grill's valves, hose, and regulator connections.

Safe Grill Operation and Safety Tips

Essential safety guidelines and tips for operating the grill safely.

Burner Lighting Procedures

Detailed instructions for safely lighting the main burners using the ignitor.

Alternative Lighting and Burner Checks

Covers match lighting, sideburner ignition, and burner flame checks.

Grill Shutdown and Maintenance Checks

Procedures for safely shutting down the grill and performing maintenance checks.

General Cleaning and Storage

Guidelines for comprehensive cleaning and proper storage of the grill.

Burner Assembly Cleaning

Detailed instructions for cleaning or replacing burner assemblies to ensure proper function.

Limited Warranty Information

Parts List

Parts Diagram

Assembly Instructions

Base Assembly and Side Panels

Attaches casters to the bottom shelf and secures side panels to the base.

Lower Back Panel and Grill Head Placement

Installs the lower back panel and positions the main grill head onto the cart.

Front Brace and Upper Back Panel Installation

Secures the front brace and attaches the upper back panel to the grill structure.

Side Shelf and Fascia Attachment

Attaches the right side shelf, fascia, and related hardware.

Left Side Shelf and Fascia Attachment

Attaches the left side shelf, fascia, and related hardware.

Sideburner Valve and Bezel Installation

Installs the sideburner valve bracket, bezel, and control knob.

Sideburner and Grate Installation

Installs the sideburner, drip pan, ignitor wire, and cooking grate.

Electronic Ignition and Heat Shields

Connects the electronic ignition module and installs heat shields.

Doors and Trough Installation

Attaches the grill doors and places the trough into the firebox.

Final Grates and LP Tank Setup

Places cooking grates, warming rack, and prepares for LP tank connection.

Emergencies

Troubleshooting Guide

Burner Ignition Issues

Diagnoses and resolves issues with ignitors failing to light burners.

Match Lighting and Flame Issues

Troubleshoots match lighting, low flames, flame blowouts, and flare-ups.

Fire, Flashback, and Gas Leaks

Addresses issues related to grease fires, flashbacks, and gas leaks.

LP Cylinder and Fueling Problems

Resolves problems with filling LP cylinders and ensuring proper fuel supply.

Electronic Ignition System Faults

Detailed guide for diagnosing and fixing electronic ignition system faults.

Notes

Thermos HEATWAVE 461262409 Specifications

General IconGeneral
Fuel TypePropane
Number of Burners3
Primary Cooking Area360 square inches
Secondary Cooking Area120 square inches
BTU36000
Total Cooking Area480 square inches

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