Introduction
This instruction manual provides comprehensive guidance for the safe and proper installation, operation, and maintenance of your Char-Broil Modular Outdoor Kitchen Natural Gas Conversion Kit. This kit is designed to convert Char-Broil Modular Outdoor Kitchen 3-Burner and 5-Burner grill modules from liquid propane (LP) to natural gas (NG) fuel sources. Please read all instructions thoroughly before beginning the conversion process.
Important Safety Information
Failure to follow these instructions could result in fire, explosion, or carbon monoxide poisoning, which could cause property damage, personal injury, or death.
- Installation must be performed by a qualified gas installer or service agency.
- All gas connections must be leak-tested after installation.
- Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
- Ensure adequate ventilation when operating gas appliances.
- Keep children and pets away from the grill during operation.
- Always turn off the gas supply at the source when the grill is not in use.
- Never attempt to convert the grill back to LP gas after converting to natural gas using this kit.
Package Contents
Verify that all components listed below are present and undamaged before proceeding with installation.
Image Description: This image displays the complete Char-Broil Natural Gas Conversion Kit. It includes a silver gas regulator with brass fittings, a chrome L-shaped hex wrench, a coiled grey 5-foot natural gas hose with quick-connect fittings, and a shorter black hose with brass fittings, likely an adapter hose. These components are essential for converting a grill from propane to natural gas.
- Natural Gas Regulator
- 5 ft Natural Gas Hose with Quick-Connect Fittings
- Adapter Hose
- Hex Wrench
- Assorted Hardware (e.g., seals, connectors)
- Instruction Manual (this document)
Setup and Installation
This section outlines the steps required to convert your Char-Broil Modular Outdoor Kitchen grill module from LP to natural gas. It is highly recommended that a qualified gas technician perform this installation.
Tools Required (Not Included):
- Adjustable Wrench
- Pipe Thread Sealant (gas-rated)
- Leak Detection Solution (soap and water mixture)
Pre-Installation Steps:
- Ensure the grill is completely cool and all gas supply is turned off and disconnected.
- Remove any existing LP regulator and hose from the grill module.
- Familiarize yourself with the components of the Natural Gas Conversion Kit.
Conversion Steps:
- Install Natural Gas Orifices: Locate the burner orifices on your grill module. Carefully remove the existing LP orifices and replace them with the natural gas orifices provided in this kit. Refer to your grill module's specific manual for orifice location and replacement instructions. This step is critical for proper gas flow and safety.
- Connect Natural Gas Regulator: Attach the natural gas regulator to the grill's manifold inlet. Ensure a tight seal using pipe thread sealant on all threaded connections.
- Connect Hoses:
- Connect the adapter hose (if applicable) to the regulator.
- Connect the 5 ft natural gas hose to the adapter hose or directly to the regulator, depending on your grill module's configuration.
- Connect the quick-connect end of the 5 ft natural gas hose to your home's natural gas supply line quick-connect fitting.
- Leak Test All Connections:
- Turn on the natural gas supply slowly.
- Apply a leak detection solution (soap and water mixture) to all new gas connections.
- If bubbles appear, there is a leak. Immediately turn off the gas supply, tighten the connection, and re-test. Repeat until no bubbles are present.
- Never use an open flame to check for gas leaks.
- Verify Burner Flame: After confirming no leaks, light the grill burners according to your grill module's operating instructions. Observe the flame for proper appearance (blue flame with minimal yellow tipping). Adjust air shutters if necessary, as per your grill manual.
Operating Instructions
Once converted to natural gas, operate your grill module according to its original operating instructions, keeping in mind the following:
- Always ensure the natural gas supply valve is fully open when operating the grill.
- After use, turn off the grill burners, then close the natural gas supply valve at the source.
- Do not leave the grill unattended while in operation.
Maintenance
Regular maintenance ensures the longevity and safe operation of your natural gas conversion kit and grill.
- Hose Inspection: Periodically inspect the natural gas hose for cuts, abrasions, or excessive wear. Replace immediately if any damage is found.
- Connection Checks: Annually, or if you suspect a leak, perform a leak test on all gas connections using a soap and water solution.
- Cleaning: Keep the exterior of the regulator and hoses clean and free from debris.
Troubleshooting
| Problem | Possible Cause | Solution |
|---|---|---|
| No gas flow to burners |
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| Weak or yellow flame |
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| Gas odor detected |
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Specifications
- Model: 8259778W06
- Fuel Type: Natural Gas (NG)
- Compatibility: Char-Broil Modular Outdoor Kitchen 3-Burner and 5-Burner Grill Modules
- Hose Length: 5 ft
- Material: Stainless Steel (fittings), Rubber/PVC (hoses)
- Product Dimensions: Approximately 19.05 x 15.24 x 7.62 cm (Kit components)
- Weight: Approximately 1.42 kg
Warranty and Support
For warranty information, technical support, or to purchase replacement parts, please contact Char-Broil customer service. Refer to the official Char-Broil website or your original grill module manual for specific contact details and warranty terms.
Website: www.charbroil.com
