Char-Broil 4989940 User manual

Bar Kit 4989940 • 80003010 • 12-16-04
MODEL 4989940
PRODUCT GUIDE
.

2 • 4989940
Call Service Center For Help And Parts
• If you need help or warranty parts call 1-800-241-7548 U.S. or
1-800-387-6057 CANADA.
Business hours: Open 24 hours – Seven days a week.
• To order non-warranty replacement parts or accessories call
1-800-993-2677 or send a FAX to 1-706-565-2121.
Model Number
Date Purchased
IMPORTANT: Fill out the product record information below.
TABLE OF CONTENTS
Service Center ......................................2
Product Record Information ............................2
Limited Warranty.....................................3
Parts List and Diagram ................................4
Assembly .........................................5-8
Use and Care ....................................9-10
Registration Card ...................................11
To insure your satisfaction
and for follow-up service,
register your accessories
online at:
www.grillregistration.com

LIMITED WARRANTY
Manufacturer warrants to the original consumer-purchaser only that this product shall be free from defects in workmanship and materials
after correct assembly and under normal and reasonable home use for a period of one (1) year beginning with the date of purchase.
This limited warranty is for replacement of defective parts only. Manufacturer will not be responsible for failure or damage resulting from
use, accident, alteration, misuse, transportation, commercial use, abuse, hostile environments, improper installation or installation not in
accordance with local codes.
This limited warranty does not cover scratches, dents, corrosion or discoloring by heat, abrasive and chemical cleaners or any tools used
in the assembly or installation of the appliance.
This limited warranty does not include the cost of any inconvenience, personal injury or property damage due to failure of the product.
THIS EXPRESS WARRANTY IS THE SOLE WARRANTY GIVEN BY THE MANUFACTURER AND IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE OR USE.
Neither dealers nor the retail establishment selling this product has any authority to make any additional warranties or to promise
remedies in addition to or inconsistent with those stated above. Manufacturer’s maximum liability, in any event, shall not exceed the purchase
price of the product paid by the original consumer-purchaser.
NOTE: Some states do not allow an exclusion or limitation of incidental or consequential damages, so the above limitations or
exclusions may not apply to you. This limited warranty gives you specific legal rights as set for herein. You may also have other rights which
vary from state to state. In the state of California only, if refinishing or replacement of the product is not commercially practicable, the retailer
selling this product or the Manufacturer will refund the purchase price paid for the product, less the amount directly attributable to use by the
original consumer-purchaser prior to discovery of the nonconformity. In addition, in the state of California only, you may take the product to the
retail establishment selling this product in order to obtain performance under this limited warranty.
If you wish to obtain performance of any obligation under this limited warranty, you should write to:
Manufacturer will, at its option, refinish or replace any product or part found to be defective during its respective warranty period.
Manufacturer will require return of the part(s) claimed to be defective, for its inspection, freight or postage prepaid. Manufacturer may require
reasonable proof of purchase and suggests that receipts be retained.
This limited warranty does not cover surface rust, or the discoloration of stainless steel
surfaces.
Consumer Warranty / P.O. Box 1240
Columbus, GA 31902-1240
4989940 • 3

PARTS LIST AND DIAGRAM – Model No. 4989940
Certified Grill Parts And Accessories®, Char-Broil and Design®, Char-Broil (Gas Grill Briquettes)®, Char-Diamonds®, Cooking Zone and Design®, Diamond Flame®, Executive Chef®, Faststart®, Flare
Fighter®, FlavorMaster®, Gas Grill Silouette and Design®, H2O Smoker®, Lava Flame®, MasterFlame®, MasterFlame Precision Cooking System®, PowerSpark®, Quantum®, VIP®, PrecisionFlame and
Design®, Sierra®, and TruFlame® are registered Trademarks of the W.C. Bradley Company. Thermos® is a registered trademark of the Thermos Company and its affiliates.
Artisan Collection by Char-Broil ™, C3 and Design™, Char-Broil and Design™, Flame Design™, FlavorTents™, Grill 2 Go™, Grillin’ Stick™, Keeper of the Flame™, Keepers of the Flame™, Natural Grip™,
Outdoor Cooking Collection and Design™, Patio Bistro™, PrecisionFlame™, Pro-Check™, QuickSet Grills and Design™, SmokerTents™, The Big Easy™, The Minute Grill™, The Edge™, The Tuscan
Collection™, and The Urban Grill™ are Trademarks of the W.C. Bradley Company. Universal Grill Parts and Design™ is a trademark of the Thermos Company and its affiliates.
Protected under one or more of the following U.S. Patents: 4,598,692; 4,624,240; 4,747,391; 4,747,391; 4,817,583; 4,924,846; 4,989,579; 5,003,960; 5,076,256; 5,076,257; 5,090,398; 5,109,834; 5,224,676;
5,277,106; 5,421,319; 5,441,226; 5,452,707; 5,458,309; 5,566,606; 5,566,606; 5,579,755; 5,582,094; 5,613,486; 5,649,475; 5,706,797; 5,711,663; 5,765,543; 5,931,149; 5,996,573; 6,095,132; 6,135,104;
6,173,644B1; 6,279,566; 6,397,731; 6,418,923; 6,439,222; 6,523,461; D282,619; D339,714; D341,292; D343,337; D358,059; D361,466; D364,535; D372,637; D373,701; D377,735; D383,035; D397,910;
D405,643; D405,643; D406,005; D406,009; D413,043; D413,229; D413,229; D414,982; D415,388; D416,164; D416,441; D416,441; D417,587; D422,516; D423,274; D423,876; D428,303; D435,396; D436,004;
D438,059; D438,060; D438,427; D439,110; D442,505; D443,179; D443,354; D447,384; D447,385; D447,909; D448,610; D448,614; D448,615; D448,616; D448,975; D449,492; D451,759; D456,202S; D460,313
and D461,359. Canada: 87743; 87744; 92607; 92608 and 1,316,424. Other Patents Pending.
4 • 4989940
Tools required for assembly: Phillips Screwdriver • Adjustable Wrench
Estimated assembly time: 15 minutes
(not provided) (not provided)
Key Qty Description Part #
A 1 Prep Box Assembly ...............80002432
B 1 Tap Mounting Plate................80002440
C 1 Tap Tower.......................80002445
D 1 ..............80002447
E 1 Pump..........................80002446
F 1 Drip Tray Assembly ...............80002441
Drip Tray Drain Hose
Key Qty Description Part #
G 1 Drip Tray Insert...................80002444
H 4 Prep Bin ........................80002434
1 Cover Kit........................3495439
1 Hardware Bag ...................80003048
1 Assembly Instructions .............80003010
A
B
C
E
F
G
D
H

4989940 • 5
ASSEMBLY – Model No. 4989940
1
2
Feed the tap hose into the large hole in the mounting plate.
Raise the base ring and assemble tap tower to mounting
plate using four screws, lock washers,
and hex nuts.
M6x15mm 6mm
6mm
: Tap spout must face toward tallest
edge of mounting plate.
IMPORTANT
Base ring
Align the six holes on the front of the
prep box with the six rivets on the back
of your grill cart. Place prep box over
rivets and press box downward to
secure to cart.
Prep box assembly
80002432
Tap tower
80002445
Mounting plate
80002440

6 • 4989940
4Attach drip tray assembly to front edge of mounting
plate by inserting rivets on tray into holes on plate.
Press tray downward to secure to plate. Place drip tray
insert into drip tray.
3Insert the tap hose through the top of the prep box on
the left side. Place mounting plate with tap tower over
left side of prep box and secure using four
screws and lock washers. Tap spout should be
facing toward front of grill cart.
M5x10mm
5mm
Drip tray insert
80002444
Drip tray assembly
80002441

4989940 • 7
6Slide the hose clamp over the
end of the tap hose and press
the end of the hose over the
barb on the pump. Slide hose
clamp down to pump and
tighten to secure hose to barb.
5Insert drip tray drain hose
into large hole in prep box
beneath drip tray. Press
opposite end of tube onto
drain at bottom of tray.
Drip tray drain hose
80002447
Hose clamp
Tap hose
Pump
80002446

8 4989940•
7Insert the four prep bins into the prep box.
Prep bins (4)
80002434

ON OFF
Tap lever
Pump
lever
12
3
4
5
6
4989940 • 9
USE AND CARE
Pump Connection
Your bar kit is equipped with a Sankey style pump which will fit most American kegs .
Make sure tap lever is in the OFF position.
Insert pump into keg and twist pump clockwise until it stops.
Pull pump lever out and push downward until locked in position.
Pull the tap lever to the ON position.
If no liquid flows from tap, turn tap lever off and pump the keg to increase pressure.
Repeat steps 5 and 6 until liquid flows freely from tap.
(keg not included)
1.
2. IMPORTANT: Before connecting pump to keg, pull the pump lever out and then upward.
3.
4.
5.
6.
Troubleshooting
Problem
Liquid shoots from keg
when attaching pump.
Liquid does not flow
from tap.
Possible Cause
• Pump lever locked in down position.
• Tap lever is in OFF position.
• Not enough pressure from keg.
• Keg is empty.
Prevention/Solution
• Pull pump lever out and then upward before attaching to keg.
• Move tap lever to ON position.
• Pump keg several times to increase pressure.
• Replace with full keg.

10 4989940•
CARE AND CLEANING OF STAINLESS STEEL
Routine cleaning is necessary to preserve the appearance and corrosion resistance of Stainless Steel. The methods below are
suggestions for cleaning stainless steel surfaces. Choose a cleaning method appropriate to the requirement. If you choose to use
scouring powder or solvents, consult with the solvent manufacturer or supplier before use.
Before cleaning, first test any cleaning product in an inconspicuous location and consider the possibility of scratching and the
potential for corrosion caused by not completely removing cleaners. Never use brushes or steel wool as they will scratch and leave
particles embedded on stainless steel surfaces, which can lead to rusting. Always rub or wipe in the direction of the polish lines in
the stainless steel surface, not across them. Thorough rinsing with clean water is recommended after all cleaning procedures. Dry
all surfaces completely after rinsing. Be careful not to let any stainless steel cleaner come in contact with painted or plastic
components as damage may occur.
The Char-Broil® Stainless Steel Grill Cleaner and the Thermos® Stainless Steel Grill Cleaner are good choices for routine cleaning
of stainless steel surfaces. Mild stains and loose dirt and soil can also be removed with a soft cloth and clean warm water. Rinse
with clean water and wipe dry.
Stubborn stains, discoloration and possibly rust and rust pitting can occur from cooking, exposure to harsh outdoor conditions, or
extreme cooking temperatures. There are many cleaning agents commercially available formulated to restore the finish of stainless
steel. Obtain advice from the solvent manufacturer or supplier when choosing the appropriate cleaner for your requirement. These
cleaners can be acidic. Care should be taken to avoid contact with eyes or mouth. Be careful not let any powder or solvent come in
contact with painted or plastic components as damage may occur.
The chart below has been reproduced with permission from the Specialty Steel Institute of North America. For additional details
regarding the care and cleaning of stainless steel, visit their website at www.ssina.com for more information. For the latest new
products for the care and cleaning of stainless steel go to www.charbroil.com.
Routine Care
Stubborn Stains
Job
Routine Cleaning
Fingerprints and Smears
Stubborn Stains
and Discoloration
Grease and Blood
Burnt-on or
Baked-on Foods
Grease and Oil
Cleaning Agents*
Warm Water, Soap, Ammonia, Detergent
3M Stainless Steel Cleaner and Polish, Arcal 20, Lac-O-Nu,
Lumin Wash, O’Cedar Cream Polish, Stainless Shine
3M Stainless Steel Cleaner and Polish, All chem Concentrated
Cleaner, Samae, Twinkle, Cameo Copper Cleaner, Grade FFF
or Grade F Italian Pumice, Whiting or Talc, Liquid Nu Steel,
Copper’s or Revere Stainless Steel Cleaner, Household
Cleaners, Lumin Cleaner, Zud Restoro, Sta-Clean, Highlite,
Allen Polish, Penny-Brite, Copper-Brite
Scotch-Brite Power Pad 2001, Easy-Off, De-Grease-It, 4% to
6% hot solution of such agents as tri-sodium polyphosphate,
5% to 15% caustic soda solution
Any good commercial detergent or caustic cleanser.
Comments
Apply with sponge or soft cloth.
Can be used on all finishes.
Provides barrier film to minimize
fingerprints. Can be used on all finishes.
Rub lightly, using dry damp cloth, in
the direction of polish lines on the
stainless steel.
Excellent removal on acids, all finishes.
Particularly useful where rubbing
is not practical.
Apply with sponge or soft cloth in
direction of polish lines.
*NOTE: Use of proprietary names is intended only to indicate a type of cleaner and does not constitute an endorsement. Omission of
any proprietary cleanser does not imply its inadequacy. All products should be used in strict accordance with instructions on package.