Char-Broil 4984619 User Manual
NATURAL GAS
CONVERSION KIT
Model # 4984619
For use with Commercial Series Dual Fuel™ Grills only.
FOR OUTDOOR USE ONLY
This Natural Gas Conversion Kit can be used ONLY with
Dual Fuel™ grills.
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, or 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.
WARNING CAUTION
1. Failure to follow all manufacturer’s instructions could
result in serious personal injury and/or property
damage.
2. Grill installation must conform with local codes,
regulations or in their absence with National Fuel
Gas Code, NFPA 54/ANSI Z223.1 (In Canada must
conform to CSA B 149.1).
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.
1. Read and follow all safety statements, assembly
instructions, and use and care directions before
attempting to assemble and cook.
2. Some parts may contain sharp edges-especially as
noted in the manual! Wear protective gloves if
necessary.
CONSUMER:
Keep this manual for future reference.
INSTALLER/ASSEMBLER:
Leave this manual with consumer.
If you have questions or need assistance during assembly, please call
To insure your satisfaction and for follow-up service, register your grill online at www.grillregistration.com
1-800-241-7548 (USA) or 1-800-387-6057 (Canada)
Natural Gas Conversion Kit • • 09/29/073496258
TABLE OF CONTENTS
For Your Safety ......................................1
Grill Service Center...................................2
Installation Safety Precautions ..........................2
Safety Symbols......................................2
Use and Care .....................................2-4
Parts List...........................................4
Installation Safety Precautions
•
This kit converts your grill for natural gas use at 7 inch water
column supply pressure. Verify supply pressure with your local
gas company. If supply pressure is different than 7 inch water
column pressure, contact a certified plumber for assistance.
Not for use with LP gas.
• Does
If grill is certified for use in Canada, this conversion kit
Not
nullify that certification.
USE AND CARE
Tube Burner Conversion .............................5-7
Natural Gas Hose Conversion ..........................8
Sideburner Conversion............................. 9-11
Sideburner Conversion(Outdoor Stove & Griddle).... ...12-14
Rotisserie Burner Conversion........................15-16
Troubleshooting ....................................17
Call Grill Service Center for Help and Parts
• If you need assistance with your product or warranty parts call
1-800-241-7548 (USA) 1-800-387-6057 (Canada) Hours of
Service Center Operation are 8:00 A.M. To 6:00 P.M. EST
Monday - Friday.
• To order non-warranty replacement parts or accessories
please visit us on the web at or call
1-800-241-7548 (USA) or 1-800-387-6057 (Canada) 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.
or
www.charbroil.com
DANGER
DANGER: Indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
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 a 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.
2 • Natural Gas Conversion Kit
WARNING
Do not attempt to repair or alter this conversion kit 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.
DANGER
Incorrect connection can result in a gas leak with possibility of
fire.
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.
Natural Gas Conversion Kit • 3
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
gas off immediately. There is a major leak at the connection.
Correct before proceeding
4.
Brush soapy solution onto area circled below.
5. If “growing”
source immediately and tighten connection.
be stopped do not try to repair.
Order new parts by giving the serial, model number and name
of items needed to the Grill Service Center at
(USA) or 1-800-387-6057 (Canada)
bubbles appear, there is a leak. Close gas
.
Call for replacement parts.
.
rushing sound
If leaks cannot
1-800-241-7548
CAUTION
CAUTION: Sideburner lid must be open when sideburner
is in operation, if so equipped.
Burner Flame Check
• Remove cooking grates and flame tamers. Light burners,
rotate knobs from to . You should see a smaller
flame in low position than seen on HIGH. Perform burner flame
check on sideburner also. Always check flame prior to each
use. If only low flame is seen refer to "Sudden drop or low
flame" in the .
Hose Check
• Before each use, check to see if hoses are cut, worn or kinked.
Replace damaged hoses before using grill. Use only
valve/hose/regulator specified by manufacturer.
HIGH LOW
Troubleshooting Section
HIGH
LOW
6.
Always close gas source after performing leak test.
Safety Tips
s When grill is not in use, turn off all control knobs and gas
source.
PARTS LIST/DIAGRAM
Note: Illustrations are not to scale.
Normal
Hose
Key Qty. Description Part No.
A.....5.....Main Burner and Sideburner Natural Gas Bezel ...............................80004350
B.....1.....Stove and Griddle Natural Gas Bezel .......................................80004352
C.....1.....Orifice Removal Tool ....................................................80004378
D.....1.....
E.....1.....
10 ft., 3/8” Natural Gas Hose
...................................
Rotisserie Burner Orifice (Light Blue Dot-1.15mm)
.......................
3496263
80006910
Kinked
Hose
A
4 • Natural Gas Conversion Kit
B
C
D
Tools required for assembly:
Orifice Removal Tool - Provided Adjustable Wrench - Not provided
Estimated assembly time: 30-45minutes
E
Tube 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, open Lid and remove Warming Rack, Cooking Grates, and Flame Tamers.
Your Grill may differ from illustrations shown. This manual covers a variety of grills styles, use pictures
as reference only. Not all steps will apply to your grill conversion.
Lid
2
- Remove Self-tap screws and remove Carryover tubes.
- Remove screws and washers at back of burners to detach Tube Burners from Burner Brackets.
Warming Rack
Cooking Grates
(2 or 3 depending on Unit purchased)
Flame Tamers
Carryover
Tube
Tube Burner
Carryover
Self-tap
Screws
Tube Burner
Burner
Machine
Screws
Lock Washer
Tube Burner
Burner
Brackets
Tube Burner
Tube Burner
Natural Gas Conversion Kit • 5
3
- Remove two screws that secure each Electrode to Tube Burner (Electrode remains in Firebox).
- Lift back end of burner while sliding Tube Burner out of Firebox, disengaging burners from Valves.
Screws
Tube
Burner
Electrode
Front of Grill Firebox
Valve
Tube Burner
Tube Burner
4
- Insert Orifice Removal Tool provided with Kit into Firebox Burner openings and unscrew Orifices from ends of Valves. Save removed Orifices
for converting back to LP Tank Gas. These grill valves are designed to work with Natural Gas once Orifices are removed. Do not replace any
Orifices when using Natural Gas. Note: This gas conversion kit comes with replacement Orifices for the Rotisserie Burner ONLY, if
applicable, do not use on Tube Burner valves. See later steps for Rotisserie conversion.
Valve
Front of Grill Firebox
Burner
Opening
Orifice
6 • Natural Gas Conversion Kit
Orifice Removal Tool
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