Char-Broil 7116572 User Manual
Use & Care Guide
Model: 7116572
Char-Broil®
FOP
Natural Gas Conversion Kit
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 (USA) or 1-800-387-6057 (Canada)
To insure your satisfaction and for follow-up service, register your grill online at www.grillregistration.com
DANGER
WARNING
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.
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 Tank not connected for use shall not
be stored in the vicinity of this or any other
appliance.
Call the Grill Information Center for Help and Parts
Missing Parts? Assembly Questions?
Before returning grill to store, call 1-800-241-7548
Operation Problems?
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.
Safety Symbols
The symbols and boxes shown below explain what each heading
means. Read and follow all of the messages found throughout
the manual.
DANGER
DANGER: Indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
WARNING
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.
To Installer/Assembler: Leave these instructions with
consumer.
To Consumer: Keep this manual for future reference.
CAUTION
Some parts may contain sharp edges, especially
as noted in these instructions.
Wear protective gloves if necessary.
CAUTION
For residential use only. Do not use for commercial
cooking.
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
CAUTION: Indicates a potentially hazardous situation which,
if not avoided, may result in minor or moderate injury.
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,.
© 2012 Sears Brands Management Corporation
2
Printed in USA
7116572 • 3499694 • 07-20-11
TABLE OF CONTENTS
Warning & Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Table Of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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.
Use and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Parts List/ Parts Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Grill Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
SectionA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Section B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Section C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-12
Section D . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-15
Section E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-18
Section F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-20
Section G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-22
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
USE & CARE
Natural Gas Connections and Service Regulators
Above 1/2 psi.
Prior to 1998, all residential gas service regulators were set with
an outlet pressure of 7 inches water column.
In the 1998 edition of NFPA54, 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.
The included quick disconnect socket and hose should not be
used at pressures above 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
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.
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 Figure A below, and wrenchtighten.
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.
Gas hose
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). shows properly connected hose and socket.
Figure C
Sleeve
House piping
Figure A
Figure B
3
USE AND CARE CON’T.
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.
To disconnect, push
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).
PARTS LIST
Key Qty. Description Part No.
A 6 Main & Sideburner Natural Gas Bezel (Large Bezel) 3499856
B 1 Rotisserie Burner Natural Gas Bezel (Small Bezel) 3498841
C 1 Orifice Driving Tool 80004378
D 1 10 ft., 3/8” Natural Gas Hose 3496263
E 1 Rotisserie Burner Natural Gas Orifice (Red Dot-1.45MM) 80007768
F 3 Main Burner Natural Gas Orifice (Blue Dot-#57) 3498451
G 1 Searing Burner Natural Gas Orifice (Green Dot-1.65MM) 3498837
H 2 Sideburner & Rotisserie Burner Natural Gas Orifice (Yellow Dot-#53) 3499765
Note: Illustrations are not to scale.
OFF
OFF
1.45mm
Hi
Med
Low
Hi
Med
Low
Red Dot
E
#57
Blue Dot
F
A
Tools required for assembly:
Orifice Driving Tool - Provided
Adjustable Wrench - Not Provided
Standard #2 Phillips Screwdriver - Not Provided
NOTE: Magnetic tip screwdrivers are recommended, but not required.
4
B
CD
1.65mm
Green Dot
G
#53
Yellow Dot
H
Model 415.16135110 Model 415.16649011
For Conversion Use Sections:
A, B, F
Parts Required:
5- Large Bezels
1 -10’ Hose
1-Orifice Driving Tool
Model 415.16138110
415.16167210
415.16164210
For Conversion Use Sections:
A, B, D, E
Parts Required:
6 -Large Bezels
1 -Small Bezel
1 - 10’ Hose
1 -Orifice Driving Tool
1 -Orifice (1.45MM Red Dot)
Model 415.16139110
415.16139111
For Conversion Use Sections:
A, B, F
Parts Required:
5 -Large Bezels
1 - 10’ Hose
1 -Orifice Driving Tool
For Conversion Use Sections:
A, C, D, G
Parts Required:
5 -Large Bezels
1 -Small Bezel
1 - 10’ Hose
1 -Orifice Driving Tool
3 - #57 Orifice (Blue Dot)
2 - #53 Orifice (Yellow Dot)
1 -1.65MM (Green Dot)
5
Section A
A1
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 Heat Diffusers.
Your Grill may differ from illustrations shown. This manual covers a variety of grills styles, use pictures as reference only.
Lid
A2
Using a wrench (not provided) remove LP Regulator Hose Assembly from Manifold Connection. Save removed LP Regulator Hose
assembly for converting back to LP Tank Gas. Your LP Regulator hose will be located under the Sideburner Shelf.
Warming Rack
Cooking Grates
(2 or 3 depending on Unit purchased)
Heat Diffusers
6
Manifold
Connection
LP Regulator
Hose Assembly
6
A3
Position Natural Gas Hose Assembly behind cart up to Manifold Connection.
Secure the Natural Gas Hose Assembly, to Manifold Connection, using a wrench (not provided).
Manifold
Connection
Natural Gas
Hose Assembly
A4
Leak Testing Natural Gas Hose
Turn all grill knobs to OFF.
Brush soapy solution onto areas where bubbles are shown in picture.
If “growing” bubbles appear, there is a leak. Retighten connections. If leak cannot be stopped do not try to repair. Call Sears for
replacement parts.
Manifold
Connection
Natural Gas
Hose Assembly
Leak test this
connection
7
Section B
B1
Remove Hitch Pins and remove Carryover Tubes.
Remove Hitch Pins at back of Burners to detach Burners from Burner Brackets.
Lift back of Burner while sliding Burner out of Firebox, disengaging burners from Valves.
Burner
Carryover Tube
Hitch Pin
Front of
Firebox
Hitch Pin
Burner
B2
Insert Orifice Driving Tool 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
unless otherwise noted.
Firebox Burner Opening
Orifice
Orifice
Valve
Front of
Firebox
Orifice Driving Tool
Orifice Driving Tool
8
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