SIDEBURNER WARRANTY REPAIR KIT FOR OUTDOOR USE ONLY Repair kit For use with Char-Broil RED Series Grills Only.

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1 SIDEURNER WRRNTY REPIR KIT FOR OUTDOOR USE ONLY Repair kit For use with Char-roil RED Series Grills Only. WRNING CLIFORNI PROPOSITION 5 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. WRNING 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, NFP 54/NSI Z223.1 (In Canada must conform to CS 149.1). DNGER 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. CUTION 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. INSTLLER/SSEMLER: Leave this manual with consumer. If you have questions or need assistance during assembly, please call (US) or (Canada) To insure your satisfaction and for follow-up service, register your grill online at /21/07

2 TLE OF CONTENTS For Your Safety Grill Service Center Installation Safety Precautions Safety Symbols Leak Testing Parts List ssembly Instructions Safety Symbols The symbols and boxes shown below explain what each heading means. Read and follow all of the messages found throughout the manual. DNGER DNGER: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WRNING Installation Safety Precautions This kit provides the parts necessary to repair a broken or damaged sideburner Holder racket. 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. Call Grill Service Center for Help and Parts If you need assistance with your product or warranty parts call (US) or (Canada) Hours of Service Center Operation are 8:00.M. To :00 P.M. EST Monday - Friday. To order non-warranty replacement parts or accessories please visit us on the web at or call (US) or (Canada) and one of our friendly and knowledgeable agents will be glad to assist you. DNGER Incorrect connection can result in a gas leak with possibility of fire. CUTION WRNING: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. PRTS LIST/DIGRM Key Qty. Description Holder, Side urner Valve Removal Tool C #5-40UNC x 5mm Screw Instruction Manual, Side urner Repair Kit Tools required for assembly: Removal Tool - Provided 2 djustable Wrenches - Not provided Standard #1 Phillips Screwdriver - Not provided Estimated assembly time: minutes Note: Illustrations are not to scale. CUTION: Indicates a potentially hazardous situation or unsafe practice which, if not avoided, may result in minor or moderate injury. C Leak Testing 1. Turn all grill control knobs to OFF. 2. e 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. rush 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 (US) or (Canada).. lways close gas source after performing leak test

3 1 - Open the sideburner cover. Remove the griddle and cooking grate. ( 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. You r Gr ill may or may not have a griddle, depend ing on the Grill model purchased. Screws ezel Va e lv Stem Control Knob Shelf Fascia Main urner Control Knob 2 - 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. urner Cap Wind Diverter Pull down on clip from underneath burner Remove clip through center of burner urner Cap Retainer Clip

4 3 - Locate the Venturi underneath the sideburner shelf. - Using a Phillips Screwdriver, remove the #5-40 screw from the Holder racket. Save this screw for reassembly later. - fter removing the #5-40 screw, CREFULLY pull Holder racket away from the 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. D O NOT USE PO WER TOOLS TO DRIVE THESE SCREWS! #5-40 Screw Venturi Holder Venturi racket Convolute d (Flexible) Gas Tubing DO NOT USE POWER TOOLS TO DRIVE THESE SCREWS! 4 Valve View from below sideburner shelf. - Remove the ignitor wire from the electrode. Shown in view - Remove the two burner mounting screws and washers from the side shelf pan. Shown in view Deta il # 1 - 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 Holder racket Locating Stud Electrode 5m m Silicone Washer #10 Lo ck Washer #10-24 x3/ 8 Screws C Remo ve Ignitor wire from Electrode Remov e urner from s ide burner pan

5 5 - Using a Phillips Screwdriver, not provided, remove the 4 sideburner pan screws. - Remove the sideburner pan by lifting it straight up. - t 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. Holder racket The Holder racket will be more accessible from the top. Side urner Pan Vie w from back corner of side shelf - Using an adjustable wrench, not provided, place the wrench securely on the Holder in the area shown below. () - While holding the adjustable wrench firmly, use the Driving Tool to loosen and remove the by turning it counter-clockwise. - Save the for reinstallation later. DO NOT use any tool other than the Removal Tool to tighten the. - Using a second adjustable wrench, Loosen the Flare Nut from the Holder racket. () - Discard the broken/damaged Holder racket. Removal Tool - turn counter-clockwise to remove. DO NOT DISCRD! Holder racket Holder Place adjustable wrench here to remove bracket. Turn Flare Nut in the direction shown. Place adjustable wrench here to hold bracket

6 7 - ssemble the replacement Holder racket to the Flare Nut. Tighten the Flare Nut by hand. Shown in. - Using two adjustable wrenches, tighten the Flare Nut to the Hoder racket. DO NOT OVER TIGHTEN. Shown in. - Reinstall the using the Removal Tool. DO NOT use any tool other than the Removal Tool to tighten the. Place adjustable wrench here to tighten bracket. Turn Flare nut in the direction shown. Holder racket Holder - turn counter-clockwise to remove. Removal Tool Place adjustable wrench here to hold bracket. Place adjustable wrench here to hold bracket. 8 - With the new installed into the Holder, push the Holder racket onto the Venturi. - lign the screw holes in the Holder racket and Venturi, and using a Phillips Screwdriver, install two #5-40 screws. Shown 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. Venturi Correct orifice- to-venturi engagement. Holder racket Convoluted Gas Tubing #5-40 Screw Holder racket DO NOT USE POWER TOOLS TO DRIVE THESE SCREWS! DO NOT USE POWER TOOLS TO DRIVE THESE SCREWS! Valve View from below sideburner shelf

7 9 - Install the Pan with the 4 sheet metal screws removed previously. Tighten screws only enough to secure Pan. Shown. - Carefully maneuver the burner into position. Shown 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 Pan and into burner. Shown C. C Reinstal l the Pan Locating Stud 5mm Silicone Washer #10 Lo ck Washer # 10-24x 3 /8 Screws Reinstall urner to s ide burner pan 10 - Place side burner wind diverter over side burner aligning cutout - Place burner cap onto side burner and attach side burner cap clip. Shown. - Place sideburner cooking grate onto side burner shelf, aligning grate legs with holes in shelf shown. - Place griddle onto side burner shelf shown. Your grill may not have a griddle. Your Grill may or may not have a griddle, depending on the Grill model purchased. Locked Position urner Cap Retainer Clip

8 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. ssure 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. Screws ezel Valve Stem Control Knob Shelf Fascia Main urner Control Knob Char-roil, LLC Printed in China Columbus, G ssembly Instructions