Char-Broil 4539937 User Manual

NATURAL GAS

CONVERSION KIT

Model # 4539937

FOR OUTDOOR USE ONLY

This Natural Gas Conversion Kit can be used ONLY with

Dual Fuel™ grills.

If you have questions or need assistance during assembly, please call 1-800-241-7548

WARNING

• Read and follow all Safety Assembly,,
and Use and Care Instructions in this
Guide before assembling and cooking
with this grill.

• Failure to follow all instructions in this
Use and Care Guide may lead to fire or
explosion which could result in property,
damage personal injury or death,.

Estimated assembly time: 45-60 minutes

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®; GrillLovers®; H20 Smoker®; Keepersof the Flame®;New Braunfels Smoker Company®;Oklahoma Joe's®; Patio Bistro®;Patio Caddie®; PatioKitchen®; Precision Flame®; Quantum®;Santa
Fe®; Sear andGrill®; Sierra®; Signature Series®; The Big Easy®;The MinuteGrill®; Trentino®;Wild West Tradition®;and the following marks:

® ®

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™; YouBring the Party™; SureFire™; Universal GrillParts™

TEC™ is atrademark ofTec Infrared Grills.

Protected underone ormore of thefollowing 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; SouthKorea: 384,565; China:
99,127,066.5; UnitedKingdom: 2,099,402;1,089,646. Other PatentsPending.
© 2008W.C. BradleyCompany

© 2008 Char-Broil, LLC Printed in USA• Columbus, GA 31902 • • Assembly Instructions © 2008

Natural Gas Conversion Kit 4539937 • •11/04/083499893

TM REVISION 00

TABLE OF CONTENTS

USE AND CARE

For Your Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Safety Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Installation Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Food Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Use and Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Parts List/ Parts Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Main Burner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-17

Natural Gas Hose Conversion. . . . . . . . . . . . . . . . . . . . . . .17-18

Sideburner Conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-21

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Call Grill Service Center for Help and Parts

• To order non-warranty replacement parts or accessories
please visit us on the web at or call

1-800-241-7548 and one of our friendly and knowledgeable
agents will be glad to assist you.

Safety Symbols

The symbols and boxes shown below explain what each heading
means. Read and follow all of the messages found throughout
the manual.

www.charbroil.com

Natural Gas Connections and Service Regulators
Above 1/2 psi.

Prior to 1998, all residual gas service regulators were
set with an outlet pressure of 7 inches water column.

In the 1998 edition of NFPA 54, the National Fuel Gas
Code, a change was made allowing service regulators
of 2 and 5 psi.

With this change it was also required that an in line
regulator be connected between the service regulator
and the appliance regulator if the 2 or 5 psi system is
used. This additional regulator is not supplied with the
product.

It is possible for a consumer, making the connection
themselves, or a plumber, not checking, to tap into a 2
or 5 psi line. If a pressure of 2 psi or greater is supplied
to the appliance regulator on certain grills it will shut
down and not deliver any gas to the grill. Other
concerns are the quick disconnect socket and hose
which are only rated to 1/2 psi.

If the quick disconnect socket, hose, and grill are
properly connected and still not getting gas, delivery
pressure needs to be verified. If pressure is greater
than 1/2 psi, make sure that an in line regulator is
present.

Once the grill has been over-pressured, the regulator
may or may not have been damaged. The best practice
is to replace the regulator.

WARNING

WARNING: Indicates an potentially hazardous situation
which, if not avoided, could result in death or serious injury.

CAUTION

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

DANGER

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

2

CAUTION:

Read and follow all safety statements, assembly
instructions, and use and care directions before attempting
to assemble and cook.

INSTALLER/ASSEMBLER:

Leave this manual with consumer.

CONSUMER:

Keep this manual for future reference.

WARNING:

Failure to follow all manufacturer’s instructions could result
in serious personal injury and/or property damage.

CAUTION:

Some parts may contain sharp edges – especially as noted
in the manual! Wear protective gloves if necessary.

WARNING

WARNING

CALIFORNIA PROPOSITION 65

1. Combustion by-products produced when using
this product contain chemicals known to the State of
California to cause cancer, birth defects, and other
reproductive harm.

2. This product contains chemicals, including lead
and lead compounds, known to the State of
California to cause cancer, birth defects or other
reproductive harm.

Wash your hands after handling this product.

Installation Safety Precautions

••Use grill, as purchased, only with LP (propane) gas and the

regulator/valve assembly supplied. A conversion kit must be
purchased for use with natural gas.
Grill installation must conform with local codes, or in their
absence of local codes, with either the

Code, ANSI Z223.1/ 4, Natural Gas and Propane
Installation Code, CSA B149.1, or Propane Storage and
Handling Code, B149.2, or the Standard for Recreational
Vehicles, ANSI A 119.2/NFPA 1192, and CSA Z240 RV Series,
Recreational Vehicle Code, as applicable.

• All electrical accessories (such as rotisserie) must be
electrically grounded in accordance with local codes, or

National Electrical Code, ANSI / NFPA 70 or Canadian
Electrical Code, CSA C22.1.

fuel supply hoses away from any hot surfaces.

• This grill is safety certified for use in the United States and/or
Canada only. Do not modify for use in any other location.
Modification will result in a safety hazard.

NFPA 5

Keep any electrical cords and/or

National Fuel Gas

Do not attempt to repair or alter the
hose/valve/regulator for any “assumed” defect. Any
modification to this assembly will void your warranty
and create the risk of a gas leak and fire. Use only
authorized replacement parts supplied by
manufacturer.

Food Safety

Food safety is a very important part of enjoying the outdoor
cooking experience. To keep food safe from harmful bacteria,
follow these four basic steps:

Wash hands, utensils, and surfaces with hot soapy water

Clean:

before and after handling raw meat and poultry.

Separate:

foods to avoid cross contamination. Use a clean platter and
utensils when removing cooked foods.

Cook:

thermometer to ensure proper internal food temperatures.

Chill:

Seperate raw meats and poultry from ready-to-eat

Cook meat and poultry thoroughly to kill bacteria. Use a

Refrigerate prepared foods and leftovers promptly.

For more information call: USDA Meat and Poultry Hotline

at 1-800-535-4555 in Washington, DC [phone],
10:00 am-4:00 pm .

How To Tell If Meat Is Grilled Thoroughly

Meat and poultry cooked on a grill often browns very fast on the
outside. Use a meat thermometer to be sure food has reached a
safe internal temperature, and cut into food to check for visual
signs of doneness.

DANGER

If you smell gas:

1. Shut off gas to the appliance.

2. Extinguish any open flame.

3. Open lid.

4. If odor continues, keep away from the
appliance and immediately call your gas
supplier or your fire department.

CAUTION

For residential use only. Do not use for commercial
cooking.

Whole poultry should reach 165 F. Juices should run clear and
flesh should not be pink.

o

Hamburgers made of any ground meat or poultry should reach
160 F, and be brown in the middle with no pink juices. Beef,
veal and lamb steaks, roast and chops can be cooked to 145 F.
All cuts of pork should reach 160 F.

NEVER partially grill meat or poultry and finish cooking later.
Cook food completely to destroy harmful bacteria.
When reheating takeout foods or fully cooked meats like hot
dogs, grill to 165 F, or until steaming hot.

WARNING:

to the minimum internal temperatures listed in the table on next
page.

o

To ensure that it is safe to eat, food must be cooked

o

o

o

3

USDA Safe Minimum Internal Temperatures*

Fish
Pork
Egg Dishes
Steaks and Roasts of Beef,

Veal or Lamb
Ground Beef, Veal or Lamb
Whole Poultry (Turkey,

Chicken, Duck, etc.)
Ground or Pieces Poultry

(Chicken Breast, etc.)

*United States Department of Agriculture

CAUTION

Using pots larger than 6 quarts in capacity could
exceed weight limit of the
side burner shelf,
resulting in failure
of grill cart
components.

145 F°
160 F°
160 F°

145 F°
160 F°

165 F°
165 F°

USE AND CARE

DANGER

NEVER store a spare cylinder under or near the applience
or in an enclosed area.

Never fill a cylinder beyond 80% full.

WARNING

1. Do not store or use gasoline or other
flammable liquids or vapors in the vicinity of
this or any other appliance.

2. An LP cylinder not connected for use shall not
be stored in the vicinity of this or any other
appliance.

An over filled or improperly stored cylinder is a hazard due
to possible gas release from the safety relief valve.

f you see, smell or hear gas escaping, immediately get
away from the LP cylinder/appliance and call your fire
department.

This could cause an intense fire with risk of property
damage, seriouse injury or death.

LP Cylinder Removal, Transport and Storage

1.

Turn OFF all control knobs and LP cylinder valve. Turn coupling
nut counterclockwise by hand only - do not use tools to disconnect.
Loosen cylinder screw beneath bottom shelf, then lift LP cylinder
up and out of cart. Install safety cap onto LP cylinder valve.
Always use cap and strap supplied with valve.

safety cap as directed may result in serious personal injury
and/or property damage.

2.

A disconnected LP cylinder in
storage or being
transported must have a safety cap
installed (as shown). Do not store an LP
cylinder in enclosed spaces such as a
carport, garage, porch, covered patio or
other building. Never leave an LP cylinder
inside a vehicle which may become overheated
by the sun.

Failure to use

Do not store an LP cylinder in an area where children play.

3.

4

LP Cylinder

The LP cylinder used with your grill must meet the following
requirements:

1. Use LP cylinders only with these required measurements: 12”
(30.5cm) (diameter) x 18” (45.7cm) (tall) with 20 lb. (9kg) capacity
maximum.

2. LP cylinders must be constructed and marked in accordance with
specifications for LP cylinders of thr U.S. Department of
Transportation (DOT) or for Canada, CAN/CSA-B339, cylinders,
spheres and tubes for transportation of dangerous goods.
Transport Canada (TC). See cylinder collar for marking.

3.

LP cylinder valve must have:

-Type 1 outlet compatable with

regulator or grill.

-Safety relief valve.

-UL listed Overfill Protection

Device (OPD). This OPD safety
feature is identified by a unique triangular hand wheel. Use only
LP cylinders equipped with this type of valve.

4. LP cylinder must be arranged for vapor withdrawal and include
collar to protect LP cylinder valve. Always keep LP cylinder in
upright position during use, transit or storage.

OPD Hand Wheel

LP Cylinder Exchange

Many retailers that sell grills offer you the option of replacing
your empty LP cylinder through an exchange service. Use only
those reputable exchange companies that inspect, precision fill,
test and certify their cylinders.

for an OPD safety feature-equipped cylinder as 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
connecting to grill.

Exchange your cylinder only

LP Cylinder Leak Test

For your safety

Leak test must be repeated each time LP cylinder is exchanged
or refilled.

Do not smoke during leak test.

Do not use an open flame to check for gas leaks.

Grill must be leak tested outdoors in a well-ventilated area, away
from ignition sources such as gas fired or electrical appliances.
During leak test, keep grill away from open flames or sparks.

Use a clean paintbrush and a 50/50 mild soap and water
solution. Brush soapy solution onto areas indicated by arrows in
figure below.

LP cylinder in upright position for vapor withdrawal

LP (liquefied Petroleum Gas)

LP gas is nontoxic, odorless and colorless when produced.

Your Safety

cabbage) so that it can be smelled.
LP gas is highly flammable and may ignite unexpectedly when

mixed with air.

, LP gas has been given an odor (similar to rotten

LP Cylinder Filling

Use only licensed and experienced dealers.
LP dealer before filling.
Dealer should NEVER fill LP cylinder more than 80% of LP

cylinder volume. Volume of propane in cylinder will vary by
temperature.

A frosty regulator indicates gas overfill. Immediately close LP
cylinder valve and call local LP gas dealer for assistance.

Do not release liquid propane (LP) gas into the atmosphere.
This is a hazardous practice.

To remove gas from LP cylinder, contact an LP dealer or call a
local fire department for assistance. Check the telephone
directory under “Gas Companies” for nearest certified LP
dealers.

must purge new cylinder

For

Do not use household cleaning agents.

components can result.

Damage to gas train

WARNING

If “growing” bubbles appear do not use or move the
LP cylinder. Contact an LP gas supplier or your fire
department!

5

Connecting Regulator to the LP Cylinder

1. LP cylinder must be properly secured onto grill. (Refer to
assembly section of your grill manual).

2. Turn all control knobs to the OFF position.

3. Turn LP cylinder OFF by turning hand wheel clockwise to a

Full Stop.

4. Remove the protective cap from LP cylinder valve. Always use
cap and strap supplied with valve.

c

k

w

o

i

l

C

f

f

O

s

e

Straight

Hold coupling nut and regulator
as shown for proper connection
to LP cylinder valve.

Safety Relief Valve

Strap and Cap

Do not use a POL transport
plug (plastic part with external
threads)! It will defeat the
safety feature of the valve.

5. Hold regulator and insert nipple into LP
cylinder valve. Hand-tighten the
coupling nut, holding regulator in a
straight line with LP cylinder valve so
as not to cross-thread the connection.

Nipple has to be centered
into the LP cylinder valve.

OPD Hand Wheel

Type 1 outlet with
thread on outside

Connecting Regulator to the LP Cylinder (Con’t.)

6. Turn the coupling nut clockwise and tighten to a .
The regulator will seal on the back-check feature in the LP
cylinder valve, resulting in some resistance.

one-half to three-quarters turn is required to complete the
connection. Tighten by hand only - do not use tools.

NOTE:

If you cannot complete the connection, disconnect regulator and
repeat steps 5 and 6. If you are still unable to complete the
connection,

do not use this regulator!

Full Stop

An additional

DANGER

Do not insert any tool or foreign object into the valve outlet

or safety relief valve. You may damage the valve and
cause a leak. Leaking propane may result in explosion,
fire, severe personal injury, or death.

WARNING

Outdoor gas appliance is not intended to be installed in
or on a boat.
Outdoor gas appliance is not intended to be installed in
or on an RV.
Never attempt to attach this grill to the self-contained LP
gas system of a camper trailer or motor home.
Do not use grill until leak-tested.
If a leak is detected at any time, and call the fire
department.
If you cannot stop a gas leak close LP
cylinder valve and call LP gas supplier or your fire
department!

STOP

IMMEDIATELY

6

Leak Testing Valves, Hoses and Regulator

1.

Turn all control knobs to the OFF position.

2. Be sure regulator is tightly connected to LP cylinder.

3. Completely open LP cylinder valve by turning hand wheel
counterclockwise. If you hear a , turn gas off
immediately. There is a major leak at the connection.

before proceeding.

4. Brush soapy solution onto areas circled below.

Never remove threaded orifice
at end of valve during leak
testing of valves.

rushing sound

Correct

WARNING

For Safe Use of Your Grill and to Avoid Serious
Injury:

-Do not let children operate or play near grill.

-Keep grill area clear and free from materials that burn.

-Do not block holes in sides or back of grill.

-Check burner flames regularly.

-Use grill only in well-ventilated space. use in
enclosed space such as carport, garage, porch, covered
patio, or under an overhead structure of ant kind.

-Do not use charcoal or ceramic briquets in a gas grill.
(Unless briquets are supplied with your grill)

-Use grill at least 3 ft. from any wall or surface.

Maintain 10ft. clearance to objects that can catch fir or
sources of ignition such as pilot lights on water heaters,
live electrical appliances, etc.

NEVER

5. If “growing” bubbles appear there is a leak. Close LP cylinder
valve immediately and retighten connections. If leaks cannot
be stopped do not try to repair. Call for replacement parts.
Order new parts by giving the serial, model number and name
and part number of items needed (see parts list) to the Grill
Service Center at 1-888-430-7870.

6. Always close LP cylinder valve after performing leak test by
turning hand wheel clockwise.

Apartment Dwellers:

Check with apartment management to learn the
requirements and fire codes for using an LP gas grill in
your apartment complex. If allowed, use outside on the
ground floor with a three (3) foot clearance from walls or
rails. Do not use on or under balconies.

NEVER attempt to light burner with lid closed. A
buildup of non-ignited gas inside a closed grill is
hazardous.

Never operate grill with LP cylinder out of correct
position specified in assembly instructions.

Always close LP cylinder valve and remove coupling
nut before moving LP cylinder from specified
operation position.

7

Safety Tips

- Before opening LP cylinder valve, check the coupling nut for
tightness.

- When grill is not in use, turn off all control knobs and LP cylinder
valve.

Never move grill while in operation or still hot.

-

- Use long-handled barbecue utensils and oven mitts to avoid

burns and splatters.

- Maximum load for sideburner and side shelf is 10 lbs.

- The grease tray be inserted into grill and emptied after
each use. Do not remove grease tray until grill has completely
cooled.

- Clean grill often, preferably after each cookout. If a bristle brush
is used to clean any of the grill cooking surfaces, ensure no
loose bristles remain on cooking surfaces prior to grilling. It is
not recommended to clean surfaces while grill is hot.

- If you notice grease or other hot material dripping from grill onto
valve, hose or regulator, turn off gas supply at once. Determine
the cause, correct it, then clean and inspect valve, hose and
regulator before continuing. Perform a leak test.

- Keep ventilation openings in cylinder enclosure (grill Cart) free
and clean of debris.

- Do not store objects or materials inside the grill cart enclosure
that could block the flow of combustion air to the underside of
either the control panel or the firebox bowl.

- The regulator may make a humming or whistling noise during
operation. This will not affect safety or use of grill.

- If you have a grill problem see the of
your grill manual.

- If the regulator frosts, turn off grill and LP cylinder valve
immediately. This indicates a problem with the cylinder and it
should not be used on any product. Return to supplier!

must

“Troubleshooting Section”

CAUTION

Ignitor Lighting
Do not lean over grill while lighting.
Light burners one at a time.

1. Turn all Gas Burner Control Valves.

2. Turn gas source or tank.

3. Open lid during lighting.

4. To ignite turn burner control valve to .

5. Push and hold button until the burner

6. If ignition does not occur in 5 seconds, turn the burner controls

7. Ignite remaining burners by repeating steps 4 through 6 for each

If ignition still does not occur, follow match-lighting instructions.

lights.

OFF

burner.

OFF
ON

ELECTRONIC IGNITOR

, wait 5 minutes, and repeat the lighting procedure.

Main Burner Match-Lighting
Do not lean over grill while lighting.

1. Turn all Gas Burner Control Valves.

2. Open lid during lighting. Turn gas source or tank.

3. Place match into match holder (hanging from side of cart). Light

4. Push in and turn control knob to high position for the desired

5. If ignition does not occur in 5 seconds, turn the burner controls

6. Ignite remaining burners by repeating steps 3 through 5 for each

OFF

ON

match, place into lighting hole for desired burner to light. The
lighting holes are located at the front of the cooking grates
between the emitter plate mounting brackets.

burner to light. Be sure burner lights and stays lit.

OFF

burner.

, wait 5 minutes, and repeat the lighting procedure.

Putting out grease fires by closing the lid is not possible.
Grills are well ventilated for safety reasons.

Do not use water on a grease fire. Personal injury may
result. If grease fire develops, turn knobs and LP cylinder
off.

Do not leave grill unattended while preheating or burning
off food residue on Hi. If grill has not been regularly
cleaned, a grease fire can occur that may damage the
product.

WARNING

Turn controls and gas source or tank OFF when not
in use.

CAUTION

If ignition does NOT occur in 5 seconds, turn the burner
controls OFF, wait 5 minutes and repeat the lighting
procedure. If the burner does not ignite with the valve
open, gas will continue to flow out of the burner and could
accidently ignite with risk of injury.

8

Emitter Plate Brackets

Side Burner Match-Lighting
Do not lean over grill while lighting.

1. Open lid during lighting. Turn
gas source or tank.

2. Place lit match near burner.

3. Turn sideburner knob to high
position.

Be sure burner lights and stays lit.

4. If ignition does not occur in 5 seconds,

turn the burner controls ,
wait 5 minutes, and repeat the lighting
procedure.

ON

OFF

Burner Flame Check

Remove cooking grates and troughs. Light burners, rotate knobs
from to . You should see a smaller flame in
position than seen on . Perform burner flame check on side
burner, also. Always check flame prior to each use. If only low
flame is seen refer to “Sudden drop or low flame” in the

Troubleshooting Section

of your grill manual.

Turning Grill Off

Turn all knobs to position. Turn LP cylinder off by
turning hand-wheel clockwise to a full stop.

OFF

Ignitor Check

Turn Gas OFF at LP cylinder. Press and hold electronic ignitor
button. “Click” should be heard and spark seen each time
between collector box or burner and electrode. See

“Troubleshooting” .

in your grill manual if no click or spark

Valve Check

IMPORTANT: Make sure gas is OFF at LP cylinder before
checking valves. OFF

Knobs lock in position. To check valves,
first push in knobs and release, knobs should spring back. If
knobs do not spring back, replace valve assembly before using
grill. Turn knobs to position then turn back to position.

LOW OFF

Valves should turn smoothly.

Hose Check

Before each use, check to see if hoses are cut or worn. Replace
damaged hoses before using grill. Use only valve/hose/regulator
specified by manufacturer.

5. If “growing”

source immediately and tighten connection.

be stopped do not try to repair.

bubbles appear, there is a leak. Close gas

If leaks cannot

Call for replacement parts.
Order new parts by giving the serial, model number and name
of items needed to the Grill Service Center at .

6.

Always close gas source after performing leak test.

1-888-430-7870

CAUTION

SPIDER ALERT!

SPIDER AND WEBS

INSIDE BURNER TUBE

If you notice that your grill is getting hard to light or that the
flame isn’t as strong as it should be, take the time to check and
clean the venturi’s.

CONTROL PANEL

VALVE

Normal
Hose

Kinked
Hose

Leak Testing

1. Turn all grill control knobs to OFF.

2.

Be sure gas hose is tightly connected to gas source.

3.

Completely open gas source. If you hear a , turn

rushing sound

gas off immediately. There is a major leak at the connection.

Correct before proceeding

4.

Brush soapy solution onto area circled below.

.

SPIDER WEBS

INSIDE VENTURI

In some areas of the country, spiders or small insects have been
known to create “flashback” problems. The spiders spin webs, build
nests and lay eggs in the grill’s venturi tubes(s) obstructing the flow of
gas to the burner. The backed-up gas can ignite in the venturi behind
the control panel. This is known as a flashback and it can damage
your grill and even cause injury.

To prevent flashbacks and ensure good performance the burner and
venturi assembly should be removed from the grill and cleaned before
use whenever the grill has been idle for an extended period.

General Grill Cleaning

Do not mistake brown or black accumulation of grease and
smoke for paint. Interiors of gas grills are not painted at the

(and should never be painted)

factory . Apply a strong solution
of detergent and water or use a grill cleaner with scrub brush on
insides of grill lid and bottom. Rinse and allow to completely air
dry.

Do not apply a caustic grill/oven cleaner to painted

surfaces.

9

General Grill Cleaning(con’t.)

Plastic parts:

not use citrisol, abrasive cleaners, degreasers or a concentrated
grill cleaner on plastic parts. Damage to and failure of parts can
result.

Porcelain surfaces:

residue can be wiped away with baking soda/water solution or
specially formulated cleaner. Use non-abrasive scouring powder
of stubborn stains.

Painted surfaces:

cleaner and warm soapy water. Wipe dry with a soft non­abrasive cloth.

Stainless steel surfaces:

appearance, wash with mild detergent and warm soapy water
and wipe dry with a soft cloth after each use. Baker-on grease
deposits may require the use of an abrasive plastic cleaning pad.
Use only in direction of brushed finish to avoid damage. Do not
use abrasive pad on areas with graphics.

Cooking surfaces:

grill cooking surfaces, ensure no loose bristles remain on
cooking surfaces prior to grilling. It is not recommended to clean
cooking surfaces while grill is hot.

Wash with warm soapy water and wipe dry. Do

Because of glass-like composition, most

Wash with mild detergent or non-abrasive

To maintain your grill’s high quality

If a bristle brush is used to clean any of the

Cleaning the Burner Assembly

Follow these instructions to clean and/or replace parts of burner

assembly or if you have trouble igniting grill.

Turn gas OFF at control knobs and LP cylinder.

1.

2. Remove grease tray from back of grill.

3. Open doors, remove tank heat shield and grease pan from
underneath the firebox.

4. Remove screws that hold orifice holder with the burner tube.

Figure A.

5. Remove cooking grates and radiator plates.

6. Remove hitch pin from front of the burner to disengage it.

Figure B.

7. Carefully lift up the burner enough to expose the electrode wire.

Detach wire from electrode underneath the burner.

8. Carefully take out the burner to clean.

Figure C.

9. While cleaning, make sure that the ignitor wire is not bent or

broken.

A

We suggest three ways to clean the burner tubes. Use the one

easiest for you.

A. Bend a stiff wire (a light weight coat hanger works well)

into a small hook. Run the hook through each burner tube
several times.

B. Use a narrow bottle brush with a flexible handle (do not

use a brass wire brush), run the brush through each
burner tube several times.

Wear eye protection:

C. Use an air hose to force air into the

burner tube and out the burner ports. Check each port to
make sure air comes out each hole.

10. Wire brush entire outer surface of burner to remove food
residue and dirt.

11. Clean any blocked ports with a stiff wire such as an open paper
clip.

12. Check burner for damage, due to normal wear and corrosion
some holes may become enlarged. If any large cracks or holes
are found replace burner.

VERY IMPORTANT: Burner tubes
must be properly connected to
orifice holders.
See illustration at right.

Correct

engagement

Orifice
Holder

NOTE:

Reinstall

Screws

13. After cleaning put the burner back into the firebox and attach the
electrode wire onto the electrode connector under the burner.

14. Place burner into position and reinstall the hitch pin.

15. Under the firebox, attach the orifice holder with the burner tube
with the screws previously removed.

16. Replace the grease pan, tank heat shield, grease tray, radiator

plate and cooking grates.

Burner Tube

Storing Your Grill

-Clean cooking grates.

C

View from under firebox

-Store in a dry location.

-When LP cylinder is connected to grill, store outdoors in a

well-ventilated space and out of reach of children.

B

Front

of

Grill

-Cover grill if stored outdoors. Choose from a variety of grill

covers offered by manufacturer.

-Store grill indoors ONLY if LP cylinder is turned off and

disconnected, removed from grill and stored outdoors.

-When removing grill from storage, follow

Burner Assembly”

10

Pull hitch pin from front of burner

instructions before starting grill.

“Cleaning the

This unit should be hard plumbed using components that

meet National Fuel Gas Code.

WARNING

Do not use flexible gas hose supplied for Drop-in Models.

Connecting Your Grill to the Natural Gas Source.

1.

A professionally-installed shut-off valve between the supply piping
and the socket is recommended, but not required, by the National
Fuel Gas Code. Socket connection must be made outdoors.

2.

Coat the gas supply pipe nipple with gas resistant pipe dope or
approved teflon tape. Screw socket onto gas supply pipe (house gas
source) as shown in below, and wrench-tighten.

Figure A

4.

When the quick disconnect socket and the gas hose are connected,
a valve in the socket opens automatically to permit full gas flow.
When the gas hose is disconnected, the valve in the socket instantly
and positively shuts off the flow of gas. Because the valve in the
socket positively shuts off the flow of gas, the grill can be
disconnected from the gas source by disconnecting the gas hose
from the quick disconnect socket. The socket should be left attached
to the gas source (house piping). , below, shows properly
connected hose and socket.

Figure C

CAUTION

The quick disconnect socket should never be connected
to the grill. Direction of gas flow is indicated on the
socket.

Quick disconnect socket

3.

Pull back the sleeve on the quick disconnect socket and insert the
unattached end of the gas hose into the socket. Release the sleeve
and continue pushing the hose into the socket until the sleeve snaps
into the locked position. See .

Figure B

House piping

Figure A

Figure C

With proper assembly, the gas hose cannot be removed without
pushing the quick disconnect sleeve back.

sleeve back and pull plug out of sleeve (this automatically shuts off
gas).

Please Note: Hose and assembly are C.S.A. listed for natural gas,
manufactured gas, mixed gas and for liquefied petroleum and for
LP Gas-Air mixtures on basis of 0.64 specific gravity for 1000
BTU’s per cubic foot of gas at 0.3 in. water column pressure drop.
Only ANSI Z21.54 approved hoses should be used with this grill.

The appliance and its individual shut off valve must be
disconnected from the gas supply piping system during any
pressure testing on that system at test pressures in excess of 1/2
psig (3.5kPa).

The appliance must be isolated from the gas supply piping system
by closing its individual manual shutoff valve during any pressure
testing of the gas supply piping system at test pressures equal to
or less than 1/2 psi (3.5kPa).

To disconnect, push

Gas hose

Sleeve

Figure B

WARNING

Do not use hard metal piping of any kind to connect this
type of grill to natural gas source. Use only hose
specified by manufacturer. Using hard metal piping or
convoluted metal tubing is an unsafe practice. Movement
of the grill can cause breakage of metal pipe.

11

PARTS LIST/DIAGRAM

Key Qty. Description Part No.

A . . . . . 3 . . . . . Main Burner Natural Gas Bezel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80004350

B . . . . . 1 . . . . . Sideburner Natural Gas Bezel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80004350

C . . . . . 1 . . . . .

D . . . . . 1 . . . . . 10 ft., 3/8” Natural Gas Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3496263

E . . . . . 3 . . . . .

Orifice Driving Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80004378

Main Burner NG Orifice (Yellow Dot- #55). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80018401

Note: Illustrations are not to scale.

A

D

B

#55
Yellow Dot

E

Tools required for assembly:

Orifice Driving Tool - Provided

Adjustable Wrench - Not provided

C

Standard #2 Phillips Screwdriver - Not provided

NOTE: Magnetic tip screwdrivers are recommended, but not required.

Estimated assembly time: 45-60 minutes

12

Main Burner Conversion

1

-

First, make sure all control knobs are in the OFF position, LP tank valve is closed, and tank is disconnected from regulator and
removed from grill.

- Next, from rear of grill, remove grease pan..

Grease Pan

2

Remove LP tank Heat Shield

- Open the cabinet doors. Remove any stored items from the cabinet.

- Using a #2 Phillips screwdriver, remove the two #8x3/8” screws that attach the LP Tank Heat Shield to the door brace.

LP Tank Heat Shield is held in place with tabs and slots.

- Holding the front of the LP Tank Heat Shield, rotate it down and pull it forward to disengage the rear tabs from the back panel.

- Place the LP Tank Heat Shield on the bottom shelf for storage.

LP Tank
Heat Shield

Remove 2 #8x3/8”
screws from LP Tank
Heat Shield.

Door
Brace

Note: The rear of the

LP Tank
Heat Shield
In Stored
Position

NOTE: Cabinet doors are shown
removed to enhance clarity
DO NOT remove cabinet doors

13

Main Burner Conversion (Cont.)

3

Remove Grill Bottom Pan

- Using a #2 Phillips screwdriver, remove the six #8x3/8” screws that attach the Grill Bottom Pan to the underside of grill

- Holding the front of the Grill Bottom Pan, rotate it down and pull it forward to remove it.

- Place the Grill Bottom Pan on the bottom shelf for storage.

Grill
Bottom
Pan

Remove 6 #8x3/8”
screws from Grill
Bottom Pan.

NOTE: Cabinet doors are shown
removed to enhance clarity
DO NOT remove cabinet doors

.

Grill
Bottom Pan
In Stored
Position

4

Remove LP Orifices

- Using a #2 Phillips screwdriver, remove the two #8x3/8” screws that attach the Orifice Holder to the burner flange. Repeat for each Orifice
Holder.

Burner
Flange

Remove 2 #8x3/8”
screws from
Burner Flange.

Orifice
Holder

14

Main Burner Conversion (Cont.)

5

Remove LP Orifices

-

Pull the Orifice Holder and the gas tubing away from the Burner Flange. The gas tubing is flexible and will allow sufficient clearance to

complete this conversion.

Using an adjustable wrench, not provided, place the wrench securely on the Orifice Holder in the area shown below.

-

- While holding the adjustable wrench firmly, use the Orifice Driving Tool to loosen and remove the Orifice by turning it counter-clockwise.

- Save the removed orifice for converting back to LP gas.

Orifice Driving
Tool

DO NOT twist or crimp the Gas Tubing. To do so may result in Gas Leakage.

Place Adjustable Wrench
Here While Removing
Orifice

Orifice
Holder

6

I

nstall Natural Gas (NG) Orifices

-

Using your fingers, thread the Main Burner NG Orifice(#55 Yellow Dot Orifice) into each orifice holder 2-3 turns, clockwise.

Using an adjustable wrench, not provided, place the wrench securely on the Orifice Holder in the area shown below.-

- While holding the adjustable wrench firmly, use the Orifice Driving Tool to tighten each Orifice by turning it clockwise.

orifice sufficiently to prevent gas leakage. DO NO over-tighten. DO NOT use any tool other than the Orifice Driving Tool!

Orifice

NOTE: Tighten the

Orifice Driving
Tool

Place Adjustable Wrench
Here While Removing
Orifice

Orifice
Holder

#55 Yellow Dot Orifice

15

Main Burner Conversion (Cont.)

7

- Using a #2 Phillips screwdriver, reinstall the two #8x3/8” screws that attach the Orifice Holder to the burner flange. Repeat for each Orifice

Holder. DO NOT over-tighten the Orifice Holder screws.

Burner
Flange

Re-install 2 #8x3/8”
screws into
Burner Flange.

Orifice
Holder

8

Replace Main Burner Bezels and Control Knobs

NOTE: REPLACE ONE BEZEL AT A TIME. DO NOT REMOVE ALL THE BEZELS AT THE SAME TIME.

- Pull the Burner Control Knobs off of Valve Stems.

- Remove screws and washers that secure each Bezel to the Control Panel. Remove Bezels. Save removed Bezels for converting back to LP
Tank Gas.

- Install new Natural Gas Bezels provided with Kit (see illustration below) in place of old Bezels onto Control Panel, and secure using previously
removed screws and washers. Assure proper alignment with control knob before fully tightening.

for the control knob to properly control ignition and flames for your grill.

- Press Control Knobs back onto Valve Stems. Make adjustments needed to Bezels for free movement of Control Knobs.

Valve
Stem

Note: New bezels will change the rotation

Screw

Main Burner
Control Knob

Natural Gas Bezel

80004350

NOTE: Replace only one

16

bezel at a time!

Screw

Bezel

Main Burner Conversion (Cont.)

9

Reinstall Grill Bottom Pan

- Holding the front of the Grill Bottom Pan, rotate it up and push it backwards to reposition the Grill Bottom Pan.

- Using a #2 Phillips screwdriver, reinstall the six #8x3/8” screws that attach the Grill Bottom Pan to the underside of grill. DO NOT over-

tighten the screws.

Grill
Bottom Pan
In Stored
Position

NOTE: Cabinet doors are shown
removed to enhance clarity
DO NOT remove cabinet doors

Grill
Bottom
Pan

Reinstall 6 #8x3/8”
screws into Grill
Bottom Pan.

Before reinstalling Tank Heat Shield proceed to “Natural Gas Hose Conversion” below.

Natural Gas Hose Conversion

10

- Manifold connection is located on the right hand side and toward the front and inside of the cart.

- Using a wrench, not provided, remove LP Regulator Hose Assembly from Manifold Connection. Save removed LP Manifold Connection for
converting back to LP Tank Gas.

Manifold
Connection

6

Cabinet doors shown removed
for clarity. DO NOT remove
cabinet doors.

LP Regulator
Hose Assembly

17

Natural Gas Hose Conversion (Con’t.)

11

- Secure the Natural Gas Hose Assembly using an adjustable wrench, not provided, to Manifold Connection.

Manifold
Connection

Natural Gas
Hose Assembly

Main Burner Conversion (Cont.)

12

Reinstall LP tank Heat Shield

- Insert tabs without screw holes(at rear of heat shield) into back panel slots.

- Align the tabs with screw holes at the front of the heat shield to the door brace.

- Carefully insert the #8x3/8” screws through the tabs and into the door brace..

- Using a # 2 Phillips screwdriver, not provided, tighten both screws. DO NOT over-tighten the screws.

LP Tank
Heat Shield

LP Tank
Heat Shield
In Stored
Position

Reinstall 2 #8x3/8”
screws into LP Tank
Heat Shield.

Door
Brace

NOTE: Cabinet doors are shown
removed to enhance clarity

18

DO NOT remove cabinet doors

Main Burner Conversion (Cont.)

13

Reinstall Grease Pan

- Reinstall Grease Pan into the rear of the grill.

Grease Pan

Sideburner Conversion

14

- Open the sideburner cover. Remove the cooking grate.

- Pull the sideburner control knob off the valve stem. Remove the existing bezel by removing the two screws and two lock washers securing bezel
to shelf fascia. Save the bezel for converting back to LP gas. Save screws and lock washers for reuse.

- Removing these screws will cause the gas valve to disengage from the back of the shelf fascia. This is normal.

Sideburner Grate

Sideburner
Shelf Fascia

Valve Stem

Control Knob Bezel

NOTE: Use upper and lower
holes on fascia to attach bezel

4mm
Lock Washer

6

#8-32x3/8” Screw

Control Knob

19

Sideburner Conversion (Con’t.)

15

- Remove the wingnut from the burner as Shown in illustration A.

- Remove the Ignitor wire from the electrode as

- Remove the burner from the sideburner pan as

A

Wingnut

Wing Nut

Shown in illustration B.

Shown in illustration C.

Sideburner Drip Pan

C

B

Wing Nut

Electrode

Sideburner

Ignitor Wire

C

Sideburner

Sideburner Drip Pan

16

- Locate the Sideburner Valve underneath the sideburner shelf. The Sideburner Valve will be attached to the Sideburner Fascia.

- Using the supplied , remove the orifice from the sideburner valve as shown belowOrifice Driving Tool .

- This style

Sideburner is designed to work with Natural Gas once Orifice is removed. Do not replace any Orifices when using Natural Gas.

B

B

Orifice

Orifice Driving
Tool

Sideburner Valve

Sideburner Fascia

Sideburner Fascia

6

6

20

Sideburner Conversion (Con’t.)

17

- Reinstall the burner as Shown in illustration A.

- Make sure the burner tube is properly aligned with the sideburner valve as

Shown in illustration B.

6

- Reinstall the wingnut to the burner stud. Attach the ignitor wire to the electrode as

A

Sideburner

Sideburner
Drip Pan

B

Burner tube

Proper Alignment

Shown in illustration C.

Valve

C

Wing Nut

Electrode

Sideburner
Ignitor Wire

18

- Place sideburner cooking grate onto sideburner shelf, aligning grate legs with holes in shelf as shown below.

Sideburner Grate

6

6

21

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

Emergencies

Gas leaking from
cracked/cut/burned
hose.

Troubleshooting

Problem

Burner(s) will not light
using ignitor.

Burner(s) will not
match light.

Flames blow out.

Possible Cause

• Damaged hose.

Possible Cause

GAS ISSUES:

• No gas flow.

• See .

“GAS ISSUES:”

• Match will not reach.

• Improper method of match-lighting.

• Natural gas valve not fully open.

• Inadequate gas pressure.

Prevention/Solution

• Turn off gas at at source. If anything but burned, replace parts. If
burned, discontinue use of product until a plumber has investigated
cause and corrections are made.

Prevention/Solution

• Make sure gas hose is properly connected to grill. If hose is
properly connected, make sure gas source is turned on.

• Use long-stem match (fireplace match).

• See “Match-Lighting” section of Grill Use and Care.

• Open Natural Gas Valve to full open position.

• Call gas company.

22

Notes:

23

Char-Broil, LLC ®

 Columbus, GA 31902  Assembly Instructions © 2008 