Char-Broil 4539937 User manual

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

2
For Your Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Parts List/ Parts Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Main Burner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-17
Natural Gas Hose Conversion. . . . . . . . . . . . . . . . . . . . . . .17-18
Sideburner Conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-21
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Use and Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Installation Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Food Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
TABLE OF CONTENTS
DANGER
DANGER: Indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
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.
Safety Symbols
The symbols and boxes shown below explain what each heading
means. Read and follow all of the messages found throughout
the manual.
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.
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.
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 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.

3
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
• All electrical accessories (such as rotisserie) must be
electrically grounded in accordance with local codes, or
Keep any electrical cords and/or
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.
National Fuel Gas
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.
National Electrical Code, ANSI / NFPA 70 or Canadian
Electrical Code, CSA C22.1.
NFPA 5
WARNING
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.
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.
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
before and after handling raw meat and poultry.
Seperate raw meats and poultry from ready-to-eat
foods to avoid cross contamination. Use a clean platter and
utensils when removing cooked foods.
Cook meat and poultry thoroughly to kill bacteria. Use a
thermometer to ensure proper internal food temperatures.
Refrigerate prepared foods and leftovers promptly.
Clean:
Separate:
Cook:
Chill:
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.
Whole poultry should reach 165 F. Juices should run clear and
flesh should not be pink.
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.
To ensure that it is safe to eat, food must be cooked
to the minimum internal temperatures listed in the table on next
page.
WARNING:
o
o
o
o
o

4
LP Cylinder Removal, Transport and Storage
1.
Failure to use
safety cap as directed may result in serious personal injury
and/or property damage.
2.
3.
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.
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.
Do not store an LP cylinder in an area where children play.
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.
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/appliance and call your fire
department.
This could cause an intense fire with risk of property
damage, seriouse injury or death.
DANGER
USE AND CARE
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.
WARNING
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.)
145 F°
160 F°
160 F°
145 F°
160 F°
165 F°
165 F°
*United States Department of Agriculture

5
If “growing” bubbles appear do not use or move the
LP cylinder. Contact an LP gas supplier or your fire
department!
WARNING
LP Cylinder Exchange
LP Cylinder Leak Test
Exchange your cylinder only
for an OPD safety feature-equipped cylinder as described in
the “LP Cylinder” section of this manual.
Leak test new and exchanged LP cylinders BEFORE
connecting to grill.
For your safety
Do not use household cleaning agents.
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.
Always keep new and exchanged LP cylinders in upright position
during use, transit or storage.
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.
Damage to gas train
components can result.
LP (liquefied Petroleum Gas)
LP Cylinder Filling
For
Your Safety
must purge new cylinder
LP gas is nontoxic, odorless and colorless when produced.
, LP gas has been given an odor (similar to rotten
cabbage) so that it can be smelled.
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 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.
OPD Hand Wheel
LP cylinder in upright position for vapor withdrawal
LP Cylinder
The LP cylinder used with your grill must meet the following
requirements:
3.
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.
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.