1. Introduction
This instruction manual provides essential information for the safe and effective installation, operation, and maintenance of your Char-Broil G208-5200-W2 Burner Replacement Part. Please read this manual thoroughly before attempting any installation or use to ensure proper function and to prevent potential hazards.
2. Important Safety Information
WARNING: Improper installation, adjustment, alteration, service, or maintenance can cause injury or property damage. Read the installation, operating, and maintenance instructions thoroughly before installing or servicing this equipment.
Always ensure the grill is completely cool and disconnected from its fuel source (gas tank or natural gas line) before attempting any maintenance or replacement of parts. Wear appropriate safety gear, such as gloves and eye protection, during installation.
Image: A red stop sign with text emphasizing the importance of checking your grill's model number before purchasing or installing replacement parts to ensure compatibility.
Verify Compatibility:
- Before beginning installation, confirm that the Char-Broil G208-5200-W2 burner is the correct replacement part for your specific grill model. Refer to your grill's original manual or manufacturer's specifications.
- The OEM Part Number for this replacement burner is G208-5200-W2.
- This is an authorized aftermarket product designed to meet the specifications of the original equipment manufacturer.
3. Package Contents
Upon opening the package, verify that all components are present and undamaged. The Char-Broil G208-5200-W2 Burner Replacement Part typically includes:
- One (1) H-Type Burner Assembly (Part Number 463620415)
- Flexible Venturi Tubes (2)
- Mounting Hardware (screws, nuts, clips, washers)
Image: The complete Char-Broil G208-5200-W2 H-type burner replacement kit, laid out to show the main H-shaped burner, two flexible venturi tubes, and all accompanying screws, clips, and washers for installation.
4. Setup and Installation
Follow these steps carefully to install the replacement burner. Refer to your grill's specific manual for detailed disassembly instructions if needed.
- Preparation: Ensure the grill is cool and disconnected from the gas supply. Remove cooking grates, heat tents, and any lava rocks or briquettes to access the old burner.
- Remove Old Burner: Carefully detach the old burner from the grill. This may involve unscrewing mounting brackets and gently pulling the venturi tubes off the gas valves.
- Assemble New Burner (if necessary): Some replacement burners may require minor assembly of the venturi tubes to the burner body using the provided screws and washers. Ensure a secure fit.
- Install New Burner: Position the new H-type burner in the grill. Align the venturi tubes with the gas valve orifices. Gently push the venturi tubes onto the gas valves. Secure the burner to the grill base using the provided mounting clips and screws.
- Reassemble Grill: Replace lava rocks/briquettes (if applicable), heat tents, and cooking grates.
- Leak Test: Reconnect the gas supply. Before lighting, perform a leak test by applying a soapy water solution to all gas connections. Bubbles indicate a leak. Tighten connections or replace parts as necessary. Do not use the grill if a leak is detected.
Video: This video demonstrates the assembly and installation process for an H-Type Dual Control Bar Burner, similar to the Char-Broil G208-5200-W2, showing how to attach the venturi tubes and secure the burner within a grill.
Video: This video illustrates the installation steps for universal H-type dual control bar burner replacement parts, detailing how to secure the components and place them into a grill.
5. Operating Instructions
Once the burner is correctly installed and a leak test has been performed, operate your grill according to its original manufacturer's instructions. The replacement burner is designed to function identically to the original part.
- Ensure all gas connections are tight and there are no leaks.
- Open the gas supply valve slowly.
- Turn the control knob(s) to the 'LIGHT' or 'HIGH' position and press the igniter button (if applicable) or use a long-stemmed lighter to ignite the burner.
- Adjust flame intensity as desired.
6. Maintenance
Regular maintenance helps prolong the life of your burner and ensures safe operation.
- Cleaning: Periodically clean the burner ports to remove any food debris or grease buildup that may obstruct gas flow. Use a wire brush or a stiff bristle brush.
- Inspection: Annually inspect the burner for signs of corrosion, cracks, or excessive wear. Check the venturi tubes for blockages (e.g., spider webs, insect nests) which can cause flashback fires.
- Gas Connections: Re-check gas connections for leaks periodically, especially after moving the grill or replacing parts.
7. Troubleshooting
If you encounter issues after replacing the burner, consider the following common problems and solutions:
| Problem | Possible Cause | Solution |
|---|---|---|
| Burner does not light | No gas flow, blocked venturi tube, faulty igniter | Check gas tank/line, clear venturi tubes, inspect igniter electrode. |
| Uneven flame | Blocked burner ports | Clean burner ports with a wire brush. |
| Low flame | Low gas pressure, blocked venturi tube, regulator issue | Check gas tank level, clear venturi tubes, reset or replace regulator. |
| Gas smell | Gas leak | Immediately turn off gas supply. Perform a leak test. Do not operate until leak is resolved. |
8. Specifications
- Product Dimensions: 1 x 1 x 1 inches (Note: These are general dimensions; actual burner size may vary slightly for specific grill models)
- Item Weight: 1 pound
- Manufacturer: Char-Broil
- Item Model Number: G208-5200-W2
- Part Number: 463620415
9. Warranty and Support
For warranty information or technical support regarding your Char-Broil G208-5200-W2 Burner Replacement Part, please refer to the documentation provided with your original grill or contact Char-Broil customer service directly. Keep your purchase receipt for warranty claims.
