™

NATURAL GAS

CONVERSION KIT

Model # 2218932

For use with Char-Broil® and Thermos® Heatwave™

Series Grills Only.

FOR OUTDOOR USE ONLY

This Natural Gas Conversion Kit can be used ONLY with

Dual Fuel™ grills.

If you have questions or need assistance during assembly, please call

1-888-430-7870

To insure your satisfaction and for follow-up service, register your grill online at www.grillregistration.com

Estimated assembly time: 45-60 minutes

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:

® ®

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.

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

TM REVISION 00

© 2008 Char-Broil, LLC • Columbus, GA 31902 • Printed in USA • Assembly Instructions © 2008

Natural Gas Conversion Kit 2218932 • 3499222 •10/31/08

TABLE OF CONTENTS

For Your Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Safety Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Installation Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Food Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Use and Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Parts List/ Parts Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Main Burner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-18

Natural Gas Hose Conversion. . . . . . . . . . . . . . . . . . . . . . . . . .19

Sideburner Conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-27

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Call Grill Service Center for Help and Parts

• To order non-warranty replacement parts or accessories please visit us on the web at www.charbroil.com or call

1-800-888-7870 and one of our friendly and knowledgeable agents will be glad to assist you.

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.

Safety Symbols

The symbols and boxes shown below explain what each heading means. Read and follow all of the messages found throughout the manual.

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.

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.

2

DANGER

DANGER: Indicates an imminently hazardous situation

which, if not avoided, will result in death or serious injury.

CAUTION:

Some parts may contain sharp edges – especially as noted in the manual! Wear protective gloves if necessary.

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.

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.

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:

Clean: Wash hands, utensils, and surfaces with hot soapy water before and after handling raw meat and poultry.

Separate: 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: Cook meat and poultry thoroughly to kill bacteria. Use a thermometer to ensure proper internal food temperatures.

Chill: Refrigerate prepared foods and leftovers promptly.

For more information call: USDA Meat and Poultry Hotline at 1-800-535-4555 in Washington, DC (202) 720-3333,

10:00 am-4:00 pm .

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

Using pots larger than 6 quarts in capacity could exceed weight limit of the side burner shelf, resulting in failure of grill cart components.

CAUTION

For residential use only. Do not use for commercial cooking.

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 cylinder not connected for use shall not be stored in the vicinity of this or any other appliance.

3

LP Cylinder

USE AND CARE

The LP cylinder used with your grill must meet the following requirements:

DANGER

NEVER store a spare cylinder under or near the applience or in an enclosed area.

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.

Never fill a cylinder beyond 80% full.

3. 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

OPD Hand Wheel

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.

An over filled or improperly stored cylinder is a hazard due to possible gas release from the safety relief valve.

4 f you see, smell or hear gas escaping, immediately get away from the LP cylinder/appliance and call your fire department.

LP cylinder in upright position for vapor withdrawal

This could cause an intense fire with risk of property damage, seriouse injury or death.

LP Cylinder Removal, Transport and Storage

1. 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. Failure to use safety cap as directed may result in

serious personal injury and/or property damage.

2. A disconnected LP cylinder in storage or being

LP Cylinder Valve

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.

Safety

Cap

Retainer Strap

3. Do not store an LP cylinder in an area where children play.

LP (liquefied Petroleum Gas)

LP gas is nontoxic, odorless and colorless when produced. For

Your Safety, 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.

LP Cylinder Filling

Use only licensed and experienced dealers.

LP dealer must purge new cylinder 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.

LP Cylinder Exchange

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. Exchange your cylinder only

for an OPD safety feature-equipped cylinder as described in the “LP Cylinder” section of this manual.

Always keep new and exchanged LP cylinders in upright position during use, transit or storage.

Leak test new and exchanged LP cylinders BEFORE connecting to grill.

LP Cylinder Leak Test

For your safety

Leak test must be repeated each time LP cylinder is exchanged or refilled.

Connecting Regulator to the LP Cylinder

1. LP cylinder must be properly secured onto grill. (Refer to assembly section of your grill manual).

2. Turn all control knobs to the OFF position.

3. Turn LP cylinder OFF by turning hand wheel clockwise to a

Full Stop.

4. Remove the protective cap from LP cylinder valve. Always use cap and strap supplied with valve.

O f f

C l o ck w is e

OPD Hand Wheel

Do not smoke during leak test.

Type 1 outlet with thread on outside

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.

Safety Relief Valve

Use a clean paintbrush and a 50/50 mild soap and water solution. Brush soapy solution onto areas indicated by arrows in figure below.

Do not use household cleaning agents. Damage to gas train components can result.

Strap and Cap

Do not use a POL transport plug (plastic part with external threads)! It will defeat the safety feature of the valve.

5. Hold regulator and insert nipple into LP cylinder valve. Hand-tighten the coupling nut, holding regulator in a straight line with LP cylinder valve so as not to cross-thread the connection.

WARNING

If “growing” bubbles appear do not use or move the

LP cylinder. Contact an LP gas supplier or your fire department!

Nipple has to be centered into the LP cylinder valve.

5

6

Straight

Hold coupling nut and regulator as shown for proper connection to LP cylinder valve.

Leak Testing Valves, Hoses and Regulator

1. Turn all control knobs to the OFF position.

2. Be sure regulator is tightly connected to LP cylinder.

3. Completely open LP cylinder valve by turning hand wheel counterclockwise. 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 areas circled below.

Never remove threaded orifice at end of valve during leak testing of valves.

Connecting Regulator to the LP Cylinder (Con’t.)

6. Turn the coupling nut clockwise and tighten to a Full Stop.

The regulator will seal on the back-check feature in the LP cylinder valve, resulting in some resistance. An additional

one-half to three-quarters turn is required to complete the connection. Tighten by hand only - do not use tools.

NOTE:

If you cannot complete the connection, disconnect regulator and repeat steps 5 and 6. If you are still unable to complete the connection, do not use this regulator!

DANGER

Do not insert any tool or foreign object into the valve outlet or safety relief valve. You may damage the valve and cause a leak. Leaking propane may result in explosion, fire, severe personal injury, or death.

WARNING

Outdoor gas appliance is not intended to be installed in or on a boat.

Outdoor gas appliance is not intended to be installed in or on an RV.

Never attempt to attach this grill to the self-contained LP gas system of a camper trailer or motor home.

Do not use grill until leak-tested.

If a leak is detected at any time, STOP and call the fire department.

If you cannot stop a gas leak IMMEDIATELY close LP cylinder valve and call LP gas supplier or your fire department!

5. If “growing” bubbles appear there is a leak. Close LP cylinder valve immediately and retighten connections. 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 and part number of items needed (see parts list) to the Grill

Service Center at 1-888-430-7870.

6. Always close LP cylinder valve after performing leak test by turning hand wheel clockwise.

WARNING

For Safe Use of Your Grill and to Avoid Serious

Injury:

-Do not let children operate or play near grill.

-Keep grill area clear and free from materials that burn.

-Do not block holes in sides or back of grill.

-Check burner flames regularly.

-Use grill only in well-ventilated space. NEVER use in

enclosed space such as carport, garage, porch, covered

patio, or under an overhead structure of ant kind.

-Do not use charcoal or ceramic briquets in a gas grill.

(Unless briquets are supplied with your grill)

-Use grill at least 3 ft. from any wall or surface.

Maintain 10ft. clearance to objects that can catch fir or

sources of ignition such as pilot lights on water heaters,

live electrical appliances, etc.

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.

- Use long-handled barbecue utensils and oven mitts to avoid burns and splatters.

- Maximum load for sideburner and side shelf is 10 lbs.

- The grease tray must be inserted into grill and emptied after each use. Do not remove grease tray until grill has completely cooled.

- Clean grill often, preferably after each cookout. If a bristle brush is used to clean any of the grill cooking surfaces, ensure no loose bristles remain on cooking surfaces prior to grilling. It is not recommended to clean surfaces while grill is hot.

- If you notice grease or other hot material dripping from grill onto valve, hose or regulator, turn off gas supply at once. Determine the cause, correct it, then clean and inspect valve, hose and regulator before continuing. Perform a leak test.

- Keep ventilation openings in cylinder enclosure (grill Cart) free and clean of debris.

- Do not store objects or materials inside the grill cart enclosure that could block the flow of combustion air to the underside of either the control panel or the firebox bowl.

- The regulator may make a humming or whistling noise during operation. This will not affect safety or use of grill.

- If you have a grill problem see the “Troubleshooting Section” of your grill manual.

- If the regulator frosts, turn off grill and LP cylinder valve immediately. This indicates a problem with the cylinder and it should not be used on any product. Return to supplier!

Apartment Dwellers:

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.

NEVER attempt to light burner with lid closed. A buildup of non-ignited gas inside a closed grill is hazardous.

Never operate grill with LP cylinder out of correct position specified in assembly instructions.

Always close LP cylinder valve and remove coupling nut before moving LP cylinder from specified operation position.

CAUTION

Putting out grease fires by closing the lid is not possible.

Grills are well ventilated for safety reasons.

Do not use water on a grease fire. Personal injury may result. If grease fire develops, turn knobs and LP cylinder off.

Do not leave grill unattended while preheating or burning off food residue on Hi. If grill has not been regularly cleaned, a grease fire can occur that may damage the product.

Main Burner Ignitor Lighting

Do not lean over grill while lighting.

1. Turn OFF all Gas Burner Control Valves.

2. Turn ON gas source or tank.

3. Open lid during lighting.

4. To ignite turn burner control valve to .

5. Once burner has ignited (use flame viewing ports on front of control panel to verify ignition), turn knob to desired setting.

6. If ignition does not occur in 5 seconds, turn the burner controls

OFF, wait 5 minutes, and repeat the lighting procedure.

7. Ignite remaining burners by repeating steps 4 through 6 for each burner.

Lighting instructions continued on next page.

7

8

WARNING

Turn controls and gas source or tank OFF when not in use.

CAUTION

If ignition does NOT occur in 5 seconds, turn the burner controls OFF, wait 5 minutes and repeat the lighting procedure. If the burner does not ignite with the valve open, gas will continue to flow out of the burner and could accidently ignite with risk of injury.

Burner Flame Check

Remove cooking grates and troughs. Light burners, rotate knobs from to . You should see a bigger flame in position than seen on . Perform burner flame check on side burner, also. Always check flame prior to each use. If only low flame is seen refer to “Sudden drop or low flame” in the

Troubleshooting Section of your grill manual.

Main Burner Match-Lighting

Do not lean over grill while lighting.

1. Open lid during lighting.

2. Place match into match holder (hanging from side of cart).

Light match, place into lighting hole on right or left side of

firebox.

3. Push in and turn far right or far left knob to position. Be sure burner lights and stays lit.

4. If ignition does not occur in 5 seconds, turn the burner control knob OFF, wait 5 minutes, and repeat the lighting procedure.

5. Light other burners by pushing knob in and turning to position.

Side Burner Ignitor Lighting

Do not lean over grill while lighting.

1. Turn OFF all Gas Burner Control Valves.

2. Turn ON gas source or tank.

3. To ignite side burner, open side burner cover.

4. Turn side burner knob to , to ignite burner.

5. Once burner has ignited, turn knob to desired setting.

6. If side burner does not light, turn knob to OFF, wait 5 minutes, and repeat the lighting procedure.

Side Burner Match-Lighting

1. Open lid during lighting. Turn on gas at LP cylinder.

2. Place lit match near burner.

3. Turn side burner knob to .

Warning:

Top cover must be open when side burner(s) is in operation.

Turning Grill Off

Turn all knobs to OFF position. Turn LP cylinder off by turning hand-wheel clockwise to a full stop.

Ignitor Check

Turn Gas OFF at LP cylinder. Press and hold electronic ignitor button. “Click” should be heard and spark seen each time between collector box or burner and electrode. See

“Troubleshooting” in your grill manual if no click or spark.

Valve Check

IMPORTANT: Make sure gas is OFF at LP cylinder before

checking valves. Knobs lock in OFF position. To check valves, first push in knobs and release, knobs should spring back. If knobs do not spring back, replace valve assembly before using grill. Turn knobs to LOW position then turn back to OFF position.

Valves should turn smoothly.

Hose Check

Before each use, check to see if hoses are cut or worn. Replace damaged hoses before using grill. Use only valve/hose/regulator specified by manufacturer.

General Grill Cleaning

Do not mistake brown or black accumulation of grease and smoke for paint. Interiors of gas grills are not painted at the factory (and should never be painted). Apply a strong solution of detergent and water or use a grill cleaner with scrub brush on insides of grill lid and bottom. Rinse and allow to completely air dry. Do not apply a caustic grill/oven cleaner to painted

surfaces.

Plastic parts: 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.

Porcelain surfaces: Because of glass-like composition, most residue can be wiped away with baking soda/water solution or specially formulated cleaner. Use non-abrasive scouring powder of stubborn stains.

Painted surfaces: Wash with mild detergent or non-abrasive cleaner and warm soapy water. Wipe dry with a soft nonabrasive cloth.

Stainless steel surfaces: To maintain your grill’s high quality appearance, wash with mild detergent and warm soapy water and wipe dry with a soft cloth after each use. Baker-on grease deposits may require the use of an abrasive plastic cleaning pad.

Use only in direction of brushed finish to avoid damage. Do not use abrasive pad on areas with graphics.

Cooking surfaces: If a bristle brush is used to clean any of the grill cooking surfaces, ensure no loose bristles remain on cooking surfaces prior to grilling. It is not recommended to clean cooking surfaces while grill is hot.

CAUTION

SPIDER ALERT!

SPIDER AND WEBS

INSIDE BURNER TUBE

If you notice that your grill is getting hard to light or that the flame isn’t as strong as it should be, take the time to check and clean the venturi’s.

CONTROL PANEL

Cleaning the Burner Assembly

Follow these instructions to clean and/or replace parts of burner

assembly or if you have trouble igniting grill.

1. Turn gas OFF at control knobs and LP cylinder.

2. Remove cooking grates and flame tamers.

3. Remove screws and carryover tubes from rear of burners.

4. Remove screw and washers to disengage burner from bracket

on firebox.

5. Remove screws to detach electrode from burner. Electrode

should remain in firebox.

6. Carefully lift each burner up and away from valve openings.

We suggest three ways to clean the burner tubes. Use the one

easiest for you.

A. Bend a stiff wire (a light weight coat hanger works well)

into a small hook. Run the hook through each burner

several times.

VALVE

SPIDER WEBS

INSIDE VENTURI

In some areas of the country, spiders or small insects have been known to create “flashback” problems. The spiders spin webs, build nests and lay eggs in the grill’s venturi tubes(s) obstructing the flow of gas to the burner. The backed-up gas can ignite in the venturi behind the control panel. This is known as a flashback and it can damage your grill and even cause injury.

To prevent flashbacks and ensure good performance the burner and venturi assembly should be removed from the grill and cleaned before use whenever the grill has been idle for an extended period.

B. Use a narrow bottle brush with a flexible handle (do not

use a brass wire brush), run the brush through each

burner tube several times.

C. Wear eye protection: Use an air hose to force air into the

burner tube and out the burner ports. Check each port to

make sure air comes out each hole.

7. Wire brush entire outer surface of burner to remove food

residue and dirt.

8. Clean any blocked ports with a stiff wire such as an open paper

clip.

9. Check burner for damage, due to normal wear and corrosion

some holes may become enlarged. If any large cracks or holes

are found replace burner.

VERY IMPORTANT: Burner tubes must re-engage valve openings.

See illustration at right.

Correct burner-to-valve engaement

Storing Your Grill

-Clean cooking grates.

-Store in a dry location.

-When LP cylinder is connected to grill, store outdoors in a

well-ventilated space and out of reach of children.

-Cover grill if stored outdoors. Choose from a variety of grill

covers offered by manufacturer.

-Store grill indoors ONLY if LP cylinder is turned off and

disconnected, removed from grill and stored outdoors.

-When removing grill from storage, follow “Cleaning the

Burner Assembly” instructions before starting grill.

10. Attach electrode to burner.

11. Carefully replace burners.

12. Attach burners to brackets on firebox.

13. Reposition carryover tubes and attach to burners. Replace

flame tamers and cooking grates.

Burner

Electrode

9

This unit should be hard plumbed using components that meet National Fuel Gas Code.

WARNING

Do not use flexible gas hose supplied for Drop-in Models.

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.

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 wrench-tighten.

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). Figure C, below, shows properly connected hose and socket.

CAUTION

The quick disconnect socket should never be connected to the grill. Direction of gas flow is indicated on the socket.

Quick disconnect socket House piping

Figure C

With proper assembly, the gas hose cannot be removed without

pushing the quick disconnect sleeve back. To disconnect, push 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.

10

Figure A

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.

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).

Gas hose

Sleeve

Figure B

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.

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.

CAUTION

CAUTION: Sideburner lid must be open when sideburner is in operation, if so equipped.

Burner Flame Check

• Remove cooking grates and flame tamers. Light burners, rotate knobs from HIGH to LOW. You should see a smaller flame in low position than seen on HIGH. Perform burner flame check on sideburner also. Always check flame prior to each use. If only low flame is seen refer to "Sudden drop or low flame" in the Troubleshooting Section.

HIGH

LOW

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 1-800-241-7548

(USA) or 1-800-387-6057 (Canada) .

6. Always close gas source after performing leak test.

Hose Check

• Before each use, check to see if hoses are cut, worn or kinked.

Replace damaged hoses before using grill. Use only valve/hose/regulator specified by manufacturer.

Safety Tips

s When grill is not in use, turn off all control knobs and gas source.

Normal

Hose

Kinked

Hose

Tools required for assembly:

Orifice Removal Tool - Provided

Adjustable Wrench - Not provided

Standard #2 Phillips Screwdriver - Not provided

NOTE: Magnetic tip screwdrivers are recommended, but not required.

Estimated assembly time: 45-60 minutes

11

PARTS LIST/DIAGRAM

Note: Illustrations are not to scale.

Key Qty.

Description Part No.

A . . . . . 4 . . . . . Main Burner Natural Gas Bezel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80007876

B . . . . . 1 . . . . . Sideburner Natural Gas Bezel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80007877

C . . . . . 1 . . . . . Orifice Driving Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80004378

D . . . . . 1 . . . . .

10 ft., 3/8” Natural Gas Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3496263

E . . . . . 3 . . . . .

Main Burner NG Orifice - 3 Burner Grill (Black Dot- #54) . . . . . . . . . . . . . . . . . . . . . 80007767

F. . . . . 3 . . . . .

Main Burner NG Orifice - 3 Burner Grill (No Color Dot- #56) . . . . . . . . . . . . . . . . . . 3499617

G . . . . 1 . . . . .

Sideburner/Griddle NG Orifice (Red Dot-1.45mm) . . . . . . . . . . . . . . . . . . . . . . . . . .80007768

H . . . . 4 . . . . .

#8 x3/8” Self-Tapping Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HAB016038CPNBD

12

A

B

D

Black Dot No Color Dot

E F

Red Dot

G

H

C

Main Burner Conversion

1

- 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 Troughs.

Your Grill may differ from illustrations shown. This manual covers 3 & 4 burner grills, use pictures as reference only.

Warming Rack

Cooking Grates

(3 or 4 depending on Unit purchased)

Trough

Trough

NOTE: Grill lid is shown removed for clarity. DO NOT remove the grill lid.

2

Remove Burners

- Remove screws from each burner assembly. There are four (4) screws per burner assembly.

- Lift each burner assembly up and out of the firebox.

Firebox

Remove Burner

Attachment

Screws

(4 per burner)

Burners shown in place.

(4 burner grill shown.)

Lift and remove burner assembly from firebox.

13

Main Burner Conversion (Cont.)

3

Install Screws in Burner Venturi Tube

- Locate the screw hole in the burner assembly venturi tube.

- Install one #8x3/8” self-tapping screw into the venturi tube screw hole. Screw should be threaded completely into the hole.

- Repeat for all burner assemblies.

- Lay burner assemblies aside.

Burner assembly

Screw Hole

Install #8x3/8”

Self-Tapping

Screw into screw hole. Thread screw COMPLETELY into the screw hole.

Burner Venturi Tube

4

Remove LP tank Heat Shield

- Open the cabinet doors. Remove any stored items from the cabinet.

- Using a #2 Phillips screwdriver, remove the two #8x3/8” screws that attach the LP Tank Heat Shield to the door brace. Note: The rear of the

LP Tank Heat Shield is held in place with tabs and slots.

- 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.

Door Brace

LP Tank

Heat Shield

LP Tank

Heat Shield

In Stored

Position

14

Remove 2 #8x3/8” screws from LP Tank

Heat Shield.

NOTE: Cabinet doors are shown removed to enhance clarity

DO NOT remove cabinet doors

Main Burner Conversion (Cont.)

5

Remove LP Orifices

- DO NOT completely remove the orifices at this point.

- Insert the Orifice Driving Tool provided with Kit into the Firebox Burner opening, engage the tool with the orifice, and loosen each orifice 1-2 turns, counter-clockwise, from its orifice holder.

Firebox Burner

Opening

Firebox

Orifice Driving Tool

Orifice

Top view of 3 burner firebox with burner assemblies removed.

Firebox Burner

Opening

6

Remove LP Orifices

- Using your fingers in the area illustrated below, unscrew each orifice by hand.

- Save the removed orifices for converting back to LP gas.

Orifice

Using your fingers, turn the orifice counter-clockwise to remove.

Orifice

Holder Orifice

Holder

Bracke

t

15

Main Burner Conversion (Cont.)

7

Install Natural Gas (NG) Orifices

- Using your fingers, thread the Main Burner NG Orifices into each orifice holder 2-3 turns, clockwise. Do not fully tighten the orifices at this time.

- If your grill is a 3 Burner Black & Gray lid grill use Main Burner NG Orifice - 3 Burner Grill (Black Dot- #54)

- If your grill is a 3 Burner Stainless lid grill use Main Burner NG Orifice - 3 Burner Grill (No Color Dot- #56)

Orifice

Using your fingers, thread the orifice into

the orifice holder two turns. (Clockwise)

Orifice

Holder

8

Install Natural Gas (NG) Orifices

- Insert the Orifice Driving Tool into the Firebox Burner opening, and engage the orifice with the tool.

- Tighten each orifice securely, turning it clockwise. NOTE: Tighten the orifice sufficiently to prevent gas leakage. DO NOT over-tighten

Do not use any tool other than the Orifice Driving Tool!

Orifice Driving Tool

Firebox

Firebox Burner

Opening

Orifice

16

Top view of 3 burner firebox with burner assemblies removed.

Engage the Orifice

Driving Tool with

the orifice

Main Burner Conversion (Cont.)

9

Reinstall Burners

- Place all burner assemblies into place in the firebox, align the burner assembly screw holes with the mating holes in the firebox.

- Carefully insert the #8x3/8” screws through the burner assembly and into the firebox. Insert 4 screws per burner assembly.

- Using a #2 Phillips screwdriver, not provided, barely tighten each screw. DO NOT over-tighten the burner attachment screws. These screws are used to hold the burner in place. Overtightening will cause problems later when attempting to clean your grill.

Firebox

I nstall Burner

Attachment

Screws

(4 per burner)

NOTE:

Do not over-tighten the burner attachment screws.

Burners shown in place .

10

Replace Main Burner Bezels and Control Knobs

NOTE: REPLACE ONE BEZEL AT A TIME. DO NOT REMOVE ALL THE BEZELS AT THE SAME TIME.

- Pull the Tube Burner Control Knobs off of Valve Stems.

- Remove screws and washers that secure each Bezel to the Control Panel. Save removed Bezels for converting back to LP Tank Gas.

- Install new Natural 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. Note: New bezels will change the rotation

for the control knob to properly control ignition and flames for your grill.

- Press Control Knobs back onto Valve Stems. Make adjustments needed to Bezels for free movement of Control Knobs.

Natural Gas Bezel

80007876

NOTE: Replace only one bezel at a time!

Valve

Stem

Bezels

Screws

Main Burner

Control Knobs

17

Main Burner Conversion (Cont.)

11

Reinstall LP Tank Heat Sheild

- Insert tabs without screw holes(at rear of heat shield) into back panel slots.

- Align the tabs with screw holes at the front of the heat shield to the cross brace.

- Carefully insert the #8x3/8” screws through the tabs and into the cross brace.

- Using a #2 Phillips screwdriver, not provided, tighten both screws. DO NOT over-tighten the screws.

Tabs without screwholes at rear of Heat

Shield.

18

Insert screws through front tabs and into door brace, then tighten.

Tabs with screwholes at front of Heat

Shield.

Insert Tabs into Slots.

Door brace.

LP Tank Heat

Shield in place.

Natural Gas Hose Conversion

12

- 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 Connection. Save removed LP Manifold Connection for converting back to LP Tank Gas.

6

Manifold

Connection

Cabinet doors shown removed for clarity. DO NOT remove cabinet doors.

13

- Secure the Natural Gas Hose Assembly using a wrench, not provided, to Manifold Connection.

LP Regulator

Hose Assembly

Manifold

Connection

Natural Gas

Hose Assembly

If you have a model with a sideburner proceed to “Sideburner Conversion” on page 20

19

Sideburner Conversion

NOTE: Your Grill will have one of the TWO sideburner styles shown in this manual. Check your grill to make sure you follow the correct assembly steps. The assembly steps for the second style of sideburner begins on page 25.

14

- Open the sideburner cover. Remove the cooking grate. (Sideburner cover not shown for clarity.)

- 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.

6

- Removing these screws will cause the gas valve to disengage from the back of the shelf fascia. This is normal.

Griddle (If equipped)

Cooking Grate

Screws

Bezel

Valve

Stem

Sideburner

Control Knob

Shelf Fascia

Main Burner

Control Knob

15

- 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.

STYLE 1 Sideburner

Burner Cap

Wind Diverter

6

20

Pull down on clip from underneath burner

Remove clip through center of burner

Burner Cap

Retainer Clip

Burner

Sideburner Conversion (Cont.)

16

- 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”

NOTE: The convoluted gas tubing 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

A

Locating Stud

B

6

Electrode

5mm Silicone

Washer

#10 Lock Washer

#10-24x3/8” Screws

C

Remove Ignitor wire from

Electrode

Remove Burner from side burner pan

17

- Locate the Sideburner Venturi underneath the sideburner shelf. The Sideburner Venturi will be suspended by the convoluted gas tubing.

Carefully position the Sideburner Venturi so that you can access the Orifice Holder Bracket screws

- Using a Phillips Screwdriver, remove two #5-40 screws from the Orifice Holder Bracket. Save these screws for reassembly later.

- After removing the #5-40 screws, CAREFULLY pull Orifice Holder Bracket away from the Sideburner Venturi as shown in detail #1.

NOTE: The convoluted gas tubing 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.

Sideburner

Venturi

Sideburner

Venturi

Orifice

#5-40

Screws

Convoluted (Flexible)

Gas Tubing

Orifice

Holder

Bracket

6

Sideburner

Valve

View from below sideburner shelf.

Convoluted (Flexible)

Gas Tubing

Detail #1

Orifice

Holder

Bracket

21

Sideburner Conversion (Cont.)

18

- 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.

Orifice Holder

Bracket

6

View from back corner of side shelf

19

- Using an adjustable wrench, not provided, place the wrench securely on the Orifice Holder in the area shown below.

- While holding the adjustable wrench firmly, use the Orifice Driving Tool to loosen and remove the Orifice by turning it counter-clockwise.

- Thread the new Orifice, Sideburner NG Orifice (Red Dot- 1.45mm), into the Orifice Holder by hand.

- While holding the adjustable wrench firmly on the Orifice Holder, Tighten the Orifice with the Orifice Driving Tool by turning it clockwise. Tighten the orifice sufficiently to prevent gas leakage.

DO NOT use any tool other than the Orifice Driving Tool to tighten the Orifice.

6

Orifice Holder

Bracket

Orifice Holder

Orifice - turn counter-clockwise to remove.

Orifice Driving

Tool

Place adjustable wrench here while removing Orifice.

22

Sideburner Conversion (Cont.)

20

- With the new Orifice installed into the Orifice Holder, push the Orifice Holder Bracket onto the Sideburner Venturi.

- Align the screw hole in the Orifice Holder Bracket and Sideburner Venturi, and using a Phillips Screwdriver, reinstall the #5-40 screw.

NOTE: The convoluted Gas Tubing 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

Sideburner

Venturi

#5-40 Screw

Orifice

Correct orifice- to-venturi engagement.

#5-40

Screws

Orifice

Holder

Bracket

Convoluted

Gas Tubing

#5-40 Screw

Orifice

Holder

Bracket

Sideburner

Valve

View from below sideburner shelf.

21

- Install the Sideburner pan with the 4 sheet metal screws removed previously. Tighten screws only enough to secure sideburner pan. Shown A.

6

- Carefully manuever 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

B

C

Reinstall the

Sideburner Pan

Locating Stud

5mm Silicone Washer

#10 Lock Washer

#10-24x3/8” Screws

Reinstall Burner to side burner pan

23

24

Sideburner Conversion (Cont.)

22

- 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 shown A.

A

Griddle (If equipped)

6

Cooking Grate

B

Locked Position

Burner Cap

Retainer Clip

Sideburner Conversion (Cont.)

NOTE: Steps 23 through 26 apply to style 2 sideburner. Disregard these steps if you have a style 1 sideburner.

23

- Open the sideburner cover. Remove the cooking grate. (Sideburner cover not shown for clarity.)

- 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.

6

- Removing these screws will cause the gas valve to disengage from the back of the shelf fascia. This is normal.

Screws

Bezel

Griddle (If equipped)

Cooking Grate

Valve

Stem

Sideburner

Control Knob

Shelf Fascia

Main Burner

Control Knob

24

- Remove the wingnut from the burner, Shown A.

- Remove the Ignitor wire from the electrode, Shown B.

- Remove the burner from the sideburner pan, Shown C.

A

Wingnut

Wingnut

NOTE: Sideburner lid not shown for clarity.

Electrode

Sideburner ignitor

Wire

C

Sideburner

6

25

Sideburner Conversion (Cont.)

25

- Locate the Sideburner Valve underneath the sideburner shelf. The Sideburner Valve will be attached to the Sideburner Fascia.

- Using the supplied Orifice Driving Tool, remove the orifice from the sideburner valve as shown below.

- This style Sideburner is designed to work with Natural Gas once Orifice is removed. Do not replace any Orifices when using Natural Gas.

6 6

B B

Orifice

Orifice Driving

Tool

Sideburner Valve

Sideburner Fascia

26

- Reinstall the burner, Shown A.

- Make sure the burner tube is properly aligned with the sideburner valve, Shown B.

- Reinstall the wingnut to the burner stud. Attach the ignitor wire to the electrode. Shown C.

B A

Sideburner

Proper Alignment

C

Wingnut

6

Electrode

Sideburner ignitor wire

26

NOTE: Sideburner lid not shown for clarity.

Sideburner Conversion (Cont.)

27

- Place sideburner cooking grate onto side burner shelf, aligning grate legs with holes in shelf. Shown A.

Griddle (If equipped)

A

Cooking Grate

6

28

NOTE: Step 28 applies to both styles of sideburner. You must perform this step in order to complete your grill conversion.

FOR SIDEBURNER UNITS: Use bezel part number 80007877.

- While holding the sideburner valve from the back of the shelf fascia, align the screw holes in the 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.

Screws

Bezel

Valve

Stem

Sideburner Natural Gas Bezel

80007877

Sideburner

Control Knob

Shelf Fascia

Main Burner

Control Knob

27

EMERGENCIES: If a gas leak cannot be stopped, or a fire occurs due to gas leakage, call the fire department.

Emergencies

Gas leaking from cracked/cut/burned hose.

Possible Cause

• Damaged hose.

Prevention/Solution

• Turn off gas at at source. If anything but burned, replace parts. If burned, discontinue use of product until a plumber has investigated cause and corrections are made.

Troubleshooting

Problem

Burner(s) will not light using ignitor.

Possible Cause

GAS ISSUES:

• No gas flow.

Burner(s) will not match light.

• See “GAS ISSUES:” .

• Match will not reach.

• Improper method of match-lighting.

Flames blow out.

• Natural gas valve not fully open.

• Inadequate gas pressure.

Prevention/Solution

• Make sure gas hose is properly connected to grill. If hose is properly connected, make sure gas source is turned on.

• Use long-stem match (fireplace match).

• See “Match-Lighting” section of Grill Use and Care.

• Open Natural Gas Valve to full open position.

• Call gas company.

28