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Natural Gas Conversion Kit 4539937 •

•11/04/08

3499893

NATURAL GAS

CONVERSION KIT

FOR OUTDOOR USE ONLY

This Natural Gas Conversion Kit can be used ONLY with

Dual Fuel™ grills.

Model # 4539937

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

© 2008 Char-Broil, LLC

Printed in USA

• Columbus, GA 31902 •

• Assembly Instructions © 2008

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

Estimated assembly time: 45-60

minutes

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

,

.

WARNING

Summary of Contents for 4539937

Page 1: ... 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...

Page 2: ...ervice 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 www charbroil com USE AND CARE 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 inc...

Page 3: ... 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 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 b...

Page 4: ...ceed weight limit of the side burner shelf resulting in failure of grill cart components NEVER store a spare cylinder under or near the applience or in an enclosed area Never fill a cylinder beyond 80 full 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 a...

Page 5: ...led LP gas is highly flammable and may ignite unexpectedly when mixed with air 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 no...

Page 6: ...valve resulting in some resistance NOTE If you cannot complete the connection disconnect regulator and repeat steps 5 and 6 If you are still unable to complete the connection Full Stop An additional one half to three quarters turn is required to complete the connection Tighten by hand only do not use tools do not use this regulator Safety Relief Valve OPD Hand Wheel ckw o l is C e f f O Strap and ...

Page 7: ...er heaters live electrical appliances etc 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 WARNING Never remove threaded orifice at end of valve during leak testing of valves Leak Testing Valves Hos...

Page 8: ...heating or burning off food residue on Hi If grill has not been regularly cleaned a grease fire can occur that may damage the product 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 Maximum load for sideburner and side shelf is 10 lbs The grea...

Page 9: ...uri assembly should be removed from the grill and cleaned before use whenever the grill has been idle for an extended period Normal Hose Kinked Hose Leak Testing 1 Turn all grill control knobs to OFF 2 3 Correct before proceeding 4 Be sure gas hose is tightly connected to gas source Completely open gas source If you hear a turn gas off immediately There is a major leak at the connection Brush soap...

Page 10: ...r Assembly B A Burner Tube View from under firebox Front C Pull hitch pin from front of burner of Grill General Grill Cleaning con t Wash with warm soapy water and wipe dry Do not use citrisol abrasive cleaners degreasers or a concentrated grill cleaner on plastic parts Damage to and failure of parts can result Because of glass like composition most residue can be wiped away with baking soda water...

Page 11: ...UTION The quick disconnect socket should never be connected to the grill Direction of gas flow is indicated on the socket Figure C With proper assembly the gas hose cannot be removed without pushing the quick disconnect sleeve back 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 speci...

Page 12: ...Burner NG Orifice Yellow Dot 55 80018401 E 3 A B D Note Illustrations are not to scale E C 1 Orifice Driving Tool 80004378 C 55 Yellow Dot Tools required for assembly Estimated assembly time 45 60 minutes Orifice Driving Tool Provided Adjustable Wrench Not provided Standard 2 Phillips Screwdriver Not provided NOTE Magnetic tip screwdrivers are recommended but not required 12 ...

Page 13: ...move the two 8x3 8 screws that attach the LP Tank Heat Shield to the door brace 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 Note The rear of the LP Tank Heat Shield is held in place with tabs and slots Remove 2 8x3 8 screws from LP Tank Heat Shield LP Tan...

Page 14: ...bottom shelf for storage Main Burner Conversion Cont Grill Bottom Pan In Stored Position 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 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 Rem...

Page 15: ... Main Burner Conversion Cont Orifice Orifice Driving Tool Orifice Holder Place Adjustable Wrench Here While Removing Orifice I NOTE Tighten the orifice sufficiently to prevent gas leakage DO NO over tighten DO NOT use any tool other than the Orifice Driving Tool nstall Natural Gas NG Orifices While holding the adjustable wrench firmly use the Orifice Driving Tool to tighten each Orifice by turning...

Page 16: ...atural 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 Press Control Knobs back onto Valve Stems Make adjustments needed to Bezels for free movement of Control Knobs Replace Main Burner Bezels and Control Knobs NOTE REPLACE ONE BEZEL...

Page 17: ...tom Pan Grill Bottom Pan NOTE Cabinet doors are shown removed to enhance clarity DO NOT remove cabinet doors 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 Conn...

Page 18: ...ewdriver not provided tighten both screws DO NOT over tighten the screws Reinstall 2 8x3 8 screws into LP Tank Heat Shield LP Tank Heat Shield Door Brace LP Tank Heat Shield In Stored Position NOTE Cabinet doors are shown removed to enhance clarity DO NOT remove cabinet doors 11 Secure the Natural Gas Hose Assembly using an adjustable wrench not provided to Manifold Connection Manifold Connection ...

Page 19: ...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 14 6 Sideburner Conversion Sideburner Grate Control Knob Bezel 8 32x3 8 Screw 4mm Lock Washer Valve Stem Sideburner Shelf Fascia Control Knob 19...

Page 20: ...C 6 Sideburner Valve B Orifice 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 below Orifice 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 6 16 Sidebur...

Page 21: ... wingnut to the burner stud Attach the ignitor wire to the electrode as Shown in illustration B Shown in illustration C 6 A Electrode Sideburner Ignitor Wire Wing Nut C Sideburner Conversion Con t 6 Place sideburner cooking grate onto sideburner shelf aligning grate legs with holes in shelf as shown below 6 18 Burner tube V a l v e B Proper Alignment Sideburner Grate 21 ...

Page 22: ...re made Prevention Solution Make sure gas hose is properly connected to grill If hose is properly connected make sure gas source is turned on Troubleshooting Possible Cause No gas flow Problem Burner s will not light using ignitor GAS ISSUES Burner s will not match light Flames blow out See Match will not reach Improper method of match lighting Natural gas valve not fully open Inadequate gas press...

Page 23: ...23 Notes ...

Page 24: ... Columbus GA 31902 Assembly Instructions 2008 Char Broil LLC ...

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