Use & Care Guide Model: 7116572 Char-Broil FOP Natural Gas Conversion Kit ® This Natural Gas Conversion Kit can be used ONLY with Dual Fuel™ grills. If you have questions or need assistance during assembly, please call 1-800-241-7548 (USA) or 1-800-387-6057 (Canada) To insure your satisfaction and for follow-up service, register your grill online at www.grillregistration.
WARNING DANGER 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. If you smell gas: 1. Shut off gas to the appliance. 2. Extinguish any open flame. 3.
TABLE OF CONTENTS Warning & Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Table Of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Use and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Parts List/ Parts Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 CONNECTING YOUR GRILL TO THE NATURAL GAS SOURCE: 1.
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). USE AND CARE CON’T.
Model 415.16135110 For Conversion Use Sections: A, B, F Parts Required: 5- Large Bezels 1 -10’ Hose 1-Orifice Driving Tool Model 415.16138110 415.16167210 415.16164210 For Conversion Use Sections: A, B, F Parts Required: 5 -Large Bezels 1 - 10’ Hose 1 -Orifice Driving Tool Model 415.16649011 For Conversion Use Sections: A, B, D, E Parts Required: 6 -Large Bezels 1 -Small Bezel 1 - 10’ Hose 1 -Orifice Driving Tool 1 -Orifice (1.45MM Red Dot) Model 415.16139110 415.
Section A A1 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 Heat Diffusers. Your Grill may differ from illustrations shown. This manual covers a variety of grills styles, use pictures as reference only.
A3 Position Natural Gas Hose Assembly behind cart up to Manifold Connection. Secure the Natural Gas Hose Assembly, to Manifold Connection, using a wrench (not provided). Manifold Connection Natural Gas Hose Assembly A4 Leak Testing Natural Gas Hose Turn all grill knobs to OFF. Brush soapy solution onto areas where bubbles are shown in picture. If “growing” bubbles appear, there is a leak. Retighten connections. If leak cannot be stopped do not try to repair. Call Sears for replacement parts.
Section B B1 Remove Hitch Pins and remove Carryover Tubes. Remove Hitch Pins at back of Burners to detach Burners from Burner Brackets. Lift back of Burner while sliding Burner out of Firebox, disengaging burners from Valves. Burner Hitch Pin Front of Firebox Hitch Pin Carryover Tube Burner B2 Insert Orifice Driving Tool into Firebox Burner openings and unscrew Orifices from ends of Valves. Save removed orifices for converting back to LP Tank Gas.
Section B Con’t. B3 WARNING Bezels must be replaced one at a time. Removing more than one bezel at a time may cause misalignment of manifold. Pull the Tube Burner Control Knob off of Valve Stem. Remove two Screws and two Washers that secure Bezel to the Control Panel. Save removed Bezel for converting back to LP Tank Gas. Install new Natural Gas Bezel provided with Kit (see illustration below) in place of old Bezel onto Control Panel, and secure using previously removed Screws and Washers.
Section C C1 Remove Hitch Pins and remove Carryover Tubes. Remove Hitch Pins at back of Burners to detach Burners from Burner Brackets. Lift back of Burner while sliding Burner out of Firebox, disengaging burners from Valves. Burner Hitch Pin Front of Firebox Hitch Pin Burner Carryover Tube C2 Insert Orifice Driving Tool into Firebox Burner openings and unscrew Orifices from ends of Valves. Save removed orifices for converting back to LP Tank Gas. Do not mix with other Orifices removed from grill.
Section C Con’t. C3 Remove two Screws, two Lock Washers and two Flat Washers at the back of Searing Burner. Slide Searing Burner back and up to remove Burner. Screw Lock Washer Flat Washer Searing Burner C4 Insert Orifice Driving Tool into Firebox Burner openings and unscrew Orifice from end of Valve. Save removed orifice for converting back to LP Tank Gas. Do not mix with Orifices removed from Main Burners. Replace with Natural Gas Orifice 1.65 (Green Dot) and secure tightly to Valve.
Section C Con’t. C5 WARNING Bezels must be replaced one at a time. Removing more than one bezel at a time may cause misalignment of manifold. Pull the Tube Burner Control Knob off of Valve Stem. Remove two Screws and two Washers that secure Bezel to the Control Panel. Save removed Bezel for converting back to LP Tank Gas. Install new Natural Gas Bezel provided with Kit (see illustration below) in place of old Bezel onto Control Panel, and secure using previously removed Screws and Washers.
Section D D1 Remove Screws, Washers, and Nuts that secure Rotisserie Cover to back of grill Firebox. Remove Rotisserie Cover. Screw Flat Washer Lock Washer Nut Rotis Coverserie D2 Using a wrench (not provided) remove Securing Nut from Rotisserie Connector.
Section D Con’t. D3 Using Orifice Driving Tool provided with Kit, unscrew Orifice from Rotisserie Connector. Save Orifice for converting back to LP Tank Gas. Do not mix with Orifices removed from Main Burners. For Grill Model 415.16649011 replace with Natural Gas Orifice 1.45mm (Red Dot) and secure tightly to Rotisserie Connector. For Grill Model 415.16139110 replace with Natural Gas Orifice #53 (Yellow Dot) and secure tightly to Rotisserie Connector. Orifice Orifice #53 Yellow Dot Orifice 1.
Section D Con’t. D5 Pull the Rotisserie Control Knob off of Valve Stem. Remove screws and washers that secure Bezel to the Control Panel. Save removed Bezel for converting back to LP Tank Gas. Install new Natural Gas Bezel provided with Kit (see illustration below) in place of old Bezel onto Control Panel, and secure using previously removed screws and washers. Assure proper alignment with control knob before fully tightening.
Section E Con’t. E2 Remove two Screws at the back of Sideburner. 6 Remove Sideburner from Shelf. Screws E3 From inside the Shelf unscrew Orifice from end of Sideburner valve using the Orifice Driving Tool provided with kit. Save Orifice for converting back to LP Tank Gas. Do not mix with Orifices removed from Tube Burners. DO NOT replace the Orifice. This valve is designed to work with Natural Gas once Orifice is removed.
Section E Con’t. E4 Pull the Sideburner Control Knob off of Valve Stem. Remove the existing Bezel by removing the two Screws and two Washers securing Bezel to Shelf fascia. Save removed Bezel for converting back to LP Tank Gas. Install new Natural Gas Bezel (see illustration below) and press Control Knob back onto Valve Stem. OFF Hi Low Bezel Screw Med Valve stem Large Bezel Washer Sideburner control knob E5 Return sideburner to shelf. Make sure burner engages sideburner valve.
Section E Con’t. E6 Slide Sideburner Electrode into Collector Box. Secure Sideburner Electrode to Sideburner with Screw. Replace Sideburner Cooking Grate. Screw Collector box Sideburner cooking grate Sideburner Electrode Sideburner Electrode Reinstall Heat Diffusers, Cooking Grates and Warming Rack, reference illustration Section A1. for reinstallation. Section F F1 Open Sideburner Lid and remove the Sideburner Grate. From beneath Sideburner Shelf, remove Wingnut. Remove Sideburner from Shelf.
Section F Con’t. F2 Using the provided Orifice Driving Tool, unscrew the Orifice from the end of the Sideburner Valve. Save removed Orifice and Orifice Driving Tool for converting back to LP. DO NOT replace the Orifice. This Valve is designed to work with Natural Gas once Orifice is removed. Orifice Orifice Driving Tool Valve Orifice Driving Tool F3 Pull the Sideburner Control Knob off of Valve Stem. Remove the existing Bezel by removing the two Screws and two Washers securing bezel to Shelf fascia.
Section F Con’t. F4 Return Sideburner to Shelf. Make sure Burner engages Sideburner Valve. See illustration below for correct burner-to-valve engagement. Secure Burner to Shelf with Wingnut. Place Sideburner Grate onto Sideburner Pan. Sideburner Grate Sideburner Sideburner Valve CORRECT BURNER-TO-VALVE ENGAGEMENT Wingnut Reinstall Heat Diffusers, Cooking Grates and Warming Rack, reference illustration Section A1. for reinstallation.
Section G Con’t. G2 Using the provided Orifice Driving Tool, unscrew the Orifice from the end of the Sideburner Valve. Save removed Orifice and Orifice Driving Tool for converting back to LP. Replace Orifice with Natural Gas Orifice # 53 (Yellow Dot) and secure tightly to Sideburner Valve. Orifice #53 Yellow Dot Orifice Orifice Driving Tool Valve Orifice Driving Tool G3 Pull the Sideburner Control Knob off of Valve Stem.
Section G Con’t. G4 Return Sideburner to Shelf. Make sure Burner engages Sideburner Valve. See illustration below for correct burner-to-valve engagement. Secure Burner to Shelf with two Washers and two Screws. Reconnect Ignitor wire to Electrode. Place Sideburner Grate onto Sideburner Pan. Sideburner Grate Sideburner Electrode Washers Screws Sideburner Valve CORRECT BURNER-TO-VALVE ENGAGEMENT Reinstall Heat Diffusers, Cooking Grates and Warming Rack, reference illustration Section A1.
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