Char-Broil RED SIDEBURNER User manual

80017152 •12/21/07
SIDEBURNER
WARRANTY REPAIR KIT
FOR OUTDOOR USE ONLY
Repair kit
For use with Char-Broil® RED™ Series Grills Only.
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.
INSTALLER/ASSEMBLER:
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).
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.
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)

DANGER
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: Indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
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.
Installation Safety Precautions
•This kit provides the parts necessary to repair a broken or
damaged sideburner Orifice Holder Bracket. DO NOT use
power tools to drive the screws contained in this kit. These
screws are small and will be damaged by the use of power
tools.
DANGER
Incorrect connection can result in a gas leak with possibility of
fire.
TABLE OF CONTENTS
ForYourSafety......................................1
GrillServiceCenter...................................2
Installation Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SafetySymbols......................................2
LeakTesting........................................2
Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Assembly Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Call Grill Service Center for Help and Parts
• If you need assistance with your product or warranty parts call
1-800-241-7548 (USA) or 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 www.charbroil.com 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.
80017152 • 2
PARTS LIST/DIAGRAM
Key Qty. Description
A. . . . . 1 . . . . . Orifice Holder, Side Burner Valve
B. . . . . 1 . . . . . Orifice Removal Tool
AB
Note: Illustrations are not to scale.
C.....2..... #5-40UNC x 5mm Screw
– 1 . . . . . Instruction Manual, Side Burner Repair Kit
C
Tools required for assembly:
Estimated assembly time: 30 - 45 minutes
Orifice Removal Tool - Provided
2Adjustable Wrenches - Not provided
Standard #1 Phillips Screwdriver - Not provided
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 rushing sound, 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” bubbles appear, there is a leak. Close gas source
immediately and tighten connection. If leaks cannot be stopped do
not try to repair. Call for replacement parts. Order new parts by
giving the serial, model number and name of items needed to the
Grill Service Center at
.
6. Always close gas source after performing leak test.
1-800-241-7548 (USA) or 1-800-387-6057
(Canada)

- Open the sideburner cover. Remove the griddle and cooking grate. (Sideburner cover not shown for clarity.) Your grill may not have a griddle.
- Pull the sideburner control knob off the valve stem. Remove the existing bezel by removing the two screws securing bezel to shelf fascia. Save
the bezel for converting back to LP gas. Save screws for reuse.
- Removing these screws will cause the gas valve to disengage from the back of the shelf fascia. This is normal.
1
6
Bezel
Va elv
S et m
Screws
Sideburner
Control Knob
Main Burner
Control Knob
Shelf Fascia
2
6
- Remove the burner cap retainer clip. Pull down on clip from underneath the burner and pull it out through the center of the burner.
- Remove the burner cap and wind diverter by lifting up from the burner.
Burner Cap
Burner Cap
Retainer Clip
Wind Diverter
Pull down on clip
from underneath
burner
Remove clip
through center of
burner
80017152 • 3
Yo r r m y or may notu G ill a
h ve a r dle, dependa g id ing
on he Grill mod l p h sed.t e urc a

- Remove the ignitor wire from the electrode. Shown in view “A”
- Remove the two burner mounting screws and washers from the side shelf pan. Shown in view “B”
- Lift up the burner to disengage the stud from it’s locating hole and maneuver the burner out of the side shelf pan. Shown in view “C”
- Locate the Sideburner Venturi underneath the sideburner shelf.
- Using a Phillips Screwdriver, remove the #5-40 screw from the Orifice Holder Bracket. Save this screw for reassembly later.
-After removing the #5-40 screw, CAREFULLY pull Orifice Holder Bracket away from the Sideburner Venturi as shown in detail #1.
NOTE: The convoluted GasTubing is flexible and will allow sufficient clearance to complete this conversion. DO NOT twist or crimp the
Convoluted (flexible) Gas Tubing. To do so may result in Gas Leakage.
3
6
e a 1D t il #
#5-40
Screw
Orifice
Holder
Bracket
Conv lute (Flexible)o d
Gas Tub ngi
de eSi burn r
a eV lv
eView from b low sideburner shelf.
Sideburner
Venturi Side r rbu ne
Venturi
Orifice
eHold r
Bracket
O cerifi
4
6
Rem ve Igni ro to
wire from
Electrode
5m Si com li ne
Wa hes r
#10 L ck Washero
#1 -2 x3 8” Scre s0 4 / w
c nLo ati g Stud
AB
C
Electrode
m e rRe ov Burne
fr m ide urne ano s b r p
DO NOT USE POWER TOOLS
TO DRIVE THESE SCREWS!
D OT USE PO OLS
O N WER TO
TO D H REWS!
RIVE T ESE SC
80017152 • 4

- Using a Phillips Screwdriver, not provided, remove the 4 sideburner pan screws.
- Remove the sideburner pan by lifting it straight up.
-At this point the orifice holder will be loose and more convenient to work with.
NOTE: DO NOT twist or crimp the Corrugated Gas Tubing. To do so may result in gas leakage.
5
6
Orifice H ldero
B acket
r
Vie back orne of s e hew from c r id s lf
- Using an adjustable wrench, not provided, place the wrench securely on the Orifice Holder in the area shown below. (A)
- While holding the adjustable wrench firmly, use the Orifice Driving Tool to loosen and remove the Orifice by turning it counter-clockwise.
- Save the Orifice for reinstallation later. DO NOT use any tool other than the Orifice Removal Tool to tighten the Orifice.
- Using a second adjustable wrench, Loosen the Flare Nut from the Orifice Holder Bracket. (B)
- Discard the broken/damaged Orifice Holder Bracket.
6
6
Or ice H ld
if o er
Orifice - turn
counter-clockwise
to remove. DO NOT
DISCARD!
HOrifice older
Bracket
Place adjustable wrench here to remove
bracket. Turn Flare Nut in the direction shown.
Orifice Removal
Tool
Place adjustable wrench
here to hold bracket.
A
B
80017152 • 5
Side Burner Pan
The Orifice Holder Bracket
will be more accessible
from the top.

- With the new Orifice installed into the Orifice Holder, push the Orifice Holder Bracket onto the Sideburner Venturi.
-Align the screw holes in the Orifice Holder Bracket and Sideburner Venturi, and using a Phillips Screwdriver, install two #5-40 screws. Shown B
NOTE: The convoluted GasTubing is flexible and will allow sufficient clearance to complete this conversion. DO NOT twist or crimp the
Corrugated Gas Tubing. To do so may result in gas leakage.
6
#5-40
Screw
Or ficei
Holder
Brac etk
vCon oluted
ubGas T ing
eSid burner
Valve
eView from b low sideburner shelf.
de r eSi bu n r
eV nturi
eOrific
deHol r
tBracke
Orifice
Correct orifice- to-venturi
engagement.
-Assemble the replacement Orifice Holder Bracket to the Flare Nut.Tighten the Flare Nut by hand. Shown inA.
- Using two adjustable wrenches, tighten the Flare Nut to the Orifice Hoder Bracket. DO NOT OVER TIGHTEN. Shown inA.
- Reinstall the Orifice using the Orifice Removal Tool. DO NOT use any tool other than the Orifice Removal Tool to tighten the Orifice.
7
6
ice HOrif older
Orifice - turn
counter-clockwise
to remove.
Orifice H ldero
B acket
r
Place adjustable wrench here to tighten
bracket. Turn Flare nut in the direction shown.
Orifice Removal
Tool
Place adjustable wrench
here to hold bracket.
B
A
8
Place adjustable wrench
here to hold bracket.
A
B
DO NOT USE POWER TOOLS
TO DRIVE THESE SCREWS!
ODO NOT USE POWER TO LS
RTO DRIVE THESE SC EWS!
80017152 • 6

10
- Place side burner wind diverter over side burner aligning cutout
- Place burner cap onto side burner and attach side burner cap clip. Shown B.
- Place sideburner cooking grate onto side burner shelf, aligning grate legs with holes in shelf shownA.
- Place griddle onto side burner shelf shownA. Your grill may not have a griddle.
6
Locked Position
A
Burner Cap
Retainer Clip
9
- Install the Sideburner Pan with the 4 sheet metal screws removed previously. Tighten screws only enough to secure Sideburner Pan. ShownA.
- Carefully maneuver the burner into position. Shown B
NOTE: The convoluted Gas Tubing is flexible and will allow sufficient clearance to complete this step. DO NOT twist or crimp the Corrugated
Gas Tubing. To do so may result in gas leakage.
- Reinstall 2 #10-24X3/8” screws and washers through Sideburner Pan and into burner. Shown C.
A
Rein tal thes l
Sideburner Pan
C
B
1 3 ” re s# 0-24x /8 Sc w
m Si o W h5 m lic ne as er
#10 L ck Washero
c nLo ati g Stud R in tal B rnere s l u
to ide burne ans r p
6
80017152 • 7
B
Your Grill may or may not
dhave a griddle, epending
on the Grill model purchased.

11
- While holding the sideburner valve from the back of the shelf fascia, align the screw holes in the appropriate bezel, shelf fascia and valve.
- Install screws previously removed.Assure proper alignment with control knob before fully tightening the screws. Tighten screws with a #2 Phillips
screwdriver.
- Press the Control Knob back onto the valve stem.
- Perform Leak Testing procedure found on page 2 of this manual.
Bezel
Valve
Stem
Screws
Sideburner
Control Knob
Main Burner
Control Knob
Shelf Fascia
80017152 • 8
• Columbus, GA31902 • Assembly Instructions © 2007 •
Char-Broil, LLC ®
Printed in China