Thermos Gas Grill 461240504 User Manual

To insure your satisfaction and for follow-up service,  
register your grill online at  
461240504 • 80001916 • 05-24-04  
Download from Www.Somanuals.com. All Manuals Search And Download.  
TABLE OF CONTENTS  
WARRANTY  
For Your Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
Grill Service Center. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
Product Record Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
Installation Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
Safety Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  
Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
Parts Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15  
Use and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-24  
Registration Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25  
Manufacturer warrants to the original consumer-purchaser  
only that this product shall be free from defects in workmanship  
and materials after correct assembly and under normal and  
reasonable home use for the periods indicated below beginning  
with the date of purchase.  
Stainless steel - Limited Lifetime against perforation  
Burners - 3 years  
Electronic ignition (excluding battery) - 3 years  
Remaining parts (excluding battery) - 1 year  
This limited warranty is for replacement of defective parts only.  
Manufacturer will not be responsible for failure or damage resulting  
from use, accident, alteration, misuse, transportation, commercial  
use, abuse, hostile environments, improper installation or  
installation not in accordance with local codes.  
Manufacturer will, at its option, refinish or replace any product  
or part found to be defective during its respective warranty period.  
Manufacturer will require return of the part(s) claimed to be  
defective, for its inspection, freight or postage prepaid.  
Manufacturer may require reasonable proof of purchase and  
suggests that receipts be retained.  
This limited warranty does not cover scratches, dents,  
corrosion or discoloring by heat, abrasive and chemical cleaners or  
any tools used in the assembly or installation of the appliance. This  
limited warranty does not include the cost of any inconvenience,  
personal injury or property damage due to failure of the product.  
To insure your satisfaction  
and for follow-up service,  
register your grill  
THIS EXPRESS WARRANTY IS THE SOLE WARRANTY  
GIVEN BY THE MANUFACTURER AND IS IN LIEU OF ALL  
OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING  
IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR  
A PARTICULAR PURPOSE OR USE.  
online at:  
Neither dealers nor the retail establishment selling this product  
has any authority to make any additional warranties or to promise  
remedies in addition to or inconsistent with those stated above.  
Manufacturer’s maximum liability, in any event, shall not exceed the  
purchase price of the product paid by the original consumer-  
purchaser.  
NOTE: Some states do not allow an exclusion or limitation of  
incidental or consequential damages, so the above limitations or  
exclusions may not apply to you. This limited warranty gives you  
specific legal rights as set for herein. You may also have other  
rights which vary from state to state. In the state of California only, if  
refinishing or replacement of the product is not commercially  
practicable, the retailer selling this product or the Manufacturer will  
refund the purchase price paid for the product, less the amount  
directly attributable to use by the original consumer-purchaser prior  
to discovery of the nonconformity. In addition, in the state of  
California only, you may take the product to the retail establishment  
selling this product in order to obtain performance under this limited  
warranty.  
Stainless Steel Use and Care  
Stainless steel grills can provide many years of reliable  
service and an attractive appearance in normal outdoor  
exposure. Consider the following tips to extend the  
appearance of your stainless steel grill:  
• Cooking smoke from normal use of the grill will eventually  
coat and discolor the stainless steel surface. Periodic  
cleaning of the surface with readily available stainless  
steel cleaners is recommended. (In coastal areas, small  
rust pits may develop on the surface of your grill that  
cannot be fully removed by a cleaner.)  
If you wish to obtain performance of any obligation under this  
limited warranty, you should write to:  
• Periodic cleaning of the cooking grates also helps  
decrease the risk of a grease fire which can irreversibly  
darken the stainless steel surface. (Please note that the  
integrity of the steel is not affected by the flame, only the  
appearance.)  
Consumer Warranty / P.O. Box 1240  
Columbus, GA 31902-1240  
461240504 • 3  
Download from Www.Somanuals.com. All Manuals Search And Download.  
PARTS LIST – Model No. 461240504  
Key Qty Description  
Part #  
Key Qty Description  
Part #  
A
B
C
D
E
F
1
1
1
1
1
1
1
Lid Insert. . . . . . . . . . . . . . . . . . . . . . . . 80000503  
1
1
1
Side Shelf Assembly . . . . . . . . . . . . . 80000808  
Side Shelf. . . . . . . . . . . . . . . . . . . . . . . 80000060  
Side Shelf Panel. . . . . . . . . . . . . . . . . . 80000518  
Lid End Cap - Left . . . . . . . . . . . . . . . . 80000501  
Lid End Cap - Right . . . . . . . . . . . . . . . 80000502  
Lid Handle . . . . . . . . . . . . . . . . . . . . . . 80000506  
Thermometer . . . . . . . . . . . . . . . . . . . . 80000096  
Bezel for Thermometer. . . . . . . . . . . . . 80000097  
Logo Plate . . . . . . . . . . . . . . . . . . . . . . 80001002  
AA  
BB  
CC  
DD  
EE  
FF  
1
1
1
4
1
1
Cart Side w/Panel, Left. . . . . . . . . . . . . 80000066  
Cart Side w/Panel, Right . . . . . . . . . . . 80000071  
Back Panel. . . . . . . . . . . . . . . . . . . . . . 80000080  
Caster Socket. . . . . . . . . . . . . . . . . . . . 80000076  
Bottom Shelf. . . . . . . . . . . . . . . . . . . . . 80000317  
Bottom Rail. . . . . . . . . . . . . . . . . . . . . . 80000800  
G
H
I
1
1
1
1
3
3
1
1
1
1
4
3
1
Grill Bottom Front Assembly. . . . . . . . . 80000651  
Grill Bottom Rear Assembly . . . . . . . . . 80000018  
Bottom End Cap - Left . . . . . . . . . . . . . 80000021  
Bottom End Cap - Right . . . . . . . . . . . . 80000022  
Main Burner . . . . . . . . . . . . . . . . . . . . . 80000023  
Flame Tamer . . . . . . . . . . . . . . . . . . . . 80000273  
Burner Brace/Carryover . . . . . . . . . . . . 80001438  
Ignitor Assembly. . . . . . . . . . . . . . . . . . 80000653  
Manifold Heat Shield . . . . . . . . . . . . . . 80000031  
Control Panel . . . . . . . . . . . . . . . . . . . . 80001909  
Control Knob . . . . . . . . . . . . . . . . . . . . 80000035  
Bezel for Main Control Knob . . . . . . . . 80000034  
Manifold/Hose/Regulator Assembly . . . 80000036  
GG  
HH  
J
K
L
I I  
1
1
2
1
1
1
1
1
2
2
1
1
1
1
1
1
Door Assembly - Left . . . . . . . . . . . . . . 80000805  
Door Assembly - Right . . . . . . . . . . . . . 80000802  
Door Handle. . . . . . . . . . . . . . . . . . . . . 80000086  
Grease Tray . . . . . . . . . . . . . . . . . . . . . 80000831  
Door Brace. . . . . . . . . . . . . . . . . . . . . . 80000801  
SwingAway Warming Rack . . . . . . . . . 80000263  
Condiment Basket - Left. . . . . . . . . . . . 80000266  
Condiment Basket - Right . . . . . . . . . . 80000267  
Locking Caster . . . . . . . . . . . . . . . . . . . 80000268  
Fixed Caster. . . . . . . . . . . . . . . . . . . . . 80000269  
Grease Receptacle. . . . . . . . . . . . . . . . 80000834  
Cooking Grate Set . . . . . . . . . . . . . . . . 80000293  
Sideburner Grate . . . . . . . . . . . . . . . . . 80000282  
Hardware Pack. . . . . . . . . . . . . . . . . . . 80001915  
Warranty Hardware Pack . . . . . . . . . . . 80002136  
Product Guide . . . . . . . . . . . . . . . . . . . 80001916  
JJ  
M
N
O
P
Q
R
S
T
KK  
LL  
MM  
NN  
OO  
PP  
QQ  
RR  
SS  
TT  
UU  
1
1
1
1
1
1
1
Sideburner Shelf Assembly. . . . . . . . 80000809  
Sideburner Frame . . . . . . . . . . . . . . . . 80000045  
Sideburner Lid . . . . . . . . . . . . . . . . . . . 80000316  
Sideburner Pan . . . . . . . . . . . . . . . . . . 80000051  
Sideburner Electrode . . . . . . . . . . . . . . 80000055  
Sideburner Control Panel. . . . . . . . . . . 80001301  
Sideburner Assembly . . . . . . . . . . . . . . 80000277  
U
V
W
X
Y
Z
Certified Grill Parts And Accessories®, Char-Broil and Design®, Char-Broil (Gas Grill Briquettes)®, Char-Diamonds®, Cooking Zone and Design®, Diamond Flame®, Executive Chef®, Faststart®, Flare  
Fighter®, FlavorMaster®, Gas Grill Silouette and Design®, H2O Smoker®, Lava Flame®, MasterFlame®, MasterFlame Precision Cooking System®, PowerSpark®, Quantum®, VIP®, PrecisionFlame and  
Design®, Sierra®, and TruFlame® are registered Trademarks of the W.C. Bradley Company. Thermos® is a registered trademark of the Thermos Company and its affiliates.  
Artisan Collection by Char-Broil ™, C3 and Design™, Char-Broil and Design™, Flame Design™, FlavorTents™, Grill 2 Go™, Grillin’ Stick™, Keeper of the Flame™, Keepers of the Flame™, Natural Grip™,  
Outdoor Cooking Collection and Design™, Patio Bistro™, PrecisionFlame™, Pro-Check™, QuickSet Grills and Design™, SmokerTents™, The Big Easy™, The Minute Grill™, The Edge™, The Tuscan  
Collection™, and The Urban Grill™ are Trademarks of the W.C. Bradley Company. Universal Grill Parts and Design™ is a trademark of the Thermos Company and its affiliates.  
Protected under one or more of the following U.S. Patents: 4,598,692; 4,624,240; 4,747,391; 4,747,391; 4,817,583; 4,924,846; 4,989,579; 5,003,960; 5,076,256; 5,076,257; 5,090,398; 5,109,834; 5,224,676;  
5,277,106; 5,421,319; 5,441,226; 5,452,707; 5,458,309; 5,566,606; 5,566,606; 5,579,755; 5,582,094; 5,613,486; 5,649,475; 5,706,797; 5,711,663; 5,765,543; 5,931,149; 5,996,573; 6,095,132; 6,135,104;  
6,173,644B1; 6,279,566; 6,397,731; 6,418,923; 6,439,222; 6,523,461; D282,619; D339,714; D341,292; D343,337; D358,059; D361,466; D364,535; D372,637; D373,701; D377,735; D383,035; D397,910;  
D405,643; D405,643; D406,005; D406,009; D413,043; D413,229; D413,229; D414,982; D415,388; D416,164; D416,441; D416,441; D417,587; D422,516; D423,274; D423,876; D428,303; D435,396; D436,004;  
D438,059; D438,060; D438,427; D439,110; D442,505; D443,179; D443,354; D447,384; D447,385; D447,909; D448,610; D448,614; D448,615; D448,616; D448,975; D449,492; D451,759; D456,202S; D460,313,  
D461,359 and D477,501. Canada: 87743; 87744; 92607; 92608 and 1,316,424. Other Patents Pending.  
4 • 461240504  
Download from Www.Somanuals.com. All Manuals Search And Download.  
PARTS DIAGRAM – Model No. 461240504  
G
A
E
C
F
TT  
B
M
M
M
TT  
D
K
I
NN  
N
AA  
L
L
L
BB  
P
T
J
H
UU  
Q
LL  
Z
S
S
S
SS  
V
R
R
O
U
MM  
Y
X
CC  
DD  
FF  
R
QQ  
FF  
EE  
W
RR  
RR  
FF  
PP  
FF  
QQ  
JJ  
GG  
HH  
I I  
KK  
KK  
OO  
461240504 • 5  
Download from Www.Somanuals.com. All Manuals Search And Download.  
NOTE: Some grill parts shown in the assembly steps may differ slightly in appearance from  
those on your particular grill model. However, the method of assembly remains the same.  
ASSEMBLY – Model No. 461240504  
1
First, remove door brace from rear legs. Place door  
Door brace  
brace onto front legs as shown. Tabs on brace fit  
inside legs. Secure brace to back of front legs using  
one 4.2X10mm self-tap screw (ZZ) on each side.  
Rear view  
Rear view  
Left front leg  
ZZ  
2
Locking casters  
on front legs.  
Attach locking casters to front legs, non-locking  
casters to rear legs. Tighten casters using the  
caster wrench provided.  
Caster  
wrench  
6 • 461240504  
Download from Www.Somanuals.com. All Manuals Search And Download.  
3
This step requires two people to lift and position grill  
head onto cart.  
Carefully lower the grill head onto the cart between the  
two braces. Align the two holes on each side of the grill  
head with the two holes on each brace. Make sure the  
regulator hose is hanging outside the cart.  
Align  
holes  
Regulator  
hose  
4
Secure grill head to leg braces using four 1/4-20x3/4” screws  
(AAA), 7mm lock washers (BBB), and 7mm flat washers (CCC).  
Screws must be attached from inside of grill head into brace.  
Do not fully tighten screws until side shelf and sideburner  
shelf are assembled.  
CCC  
BBB  
AAA  
461240504 • 7  
Download from Www.Somanuals.com. All Manuals Search And Download.  
5
CAUTION  
SHARP EDGES! Wear gloves if necessary.  
Place side shelf over right cart legs. Lip of shelf should fit between grill bottom and leg brace.  
Secure shelf brackets to cart legs using one 1/4-20x3/4” screw (AAA), 7mm lock washer  
(BBB), and 7mm flat washer (CCC) on each bracket.  
AAA  
BBB  
CCC  
Repeat on front bracket  
Place sideburner shelf over left cart legs. Lip of shelf should fit between grill  
bottom and leg brace. Secure shelf brackets to cart legs using one  
1/4-20x3/4” screw (AAA), 7mm lock washer (BBB), and 7mm flat washer  
6
(CCC) on each bracket.  
Fully tighten screws inside grill bottom at this time.  
CAUTION  
SHARP EDGES! Wear gloves if necessary.  
AAA  
BBB  
CCC  
Repeat on front bracket  
8 • 461240504  
Download from Www.Somanuals.com. All Manuals Search And Download.  
7
Remove the two screws and washers from the sideburner valve bracket.  
Place sideburner valve under front of sideburner control panel so that  
valve stem comes through large hole. Secure valve to panel using the  
two screws and washers you removed from the valve bracket. Press  
control knob onto valve stem.  
First, remove  
screws and  
washers from  
bracket.  
Sideburner  
valve  
8
Insert sideburner into shelf, placing end of burner over  
sideburner valve. Valve should be in center hole of burner  
tube. Make sure pin on bottom of burner is in center hole  
in shelf bracket. Secure burner to bracket with two  
#10-24x3/8” screws (DDD), 5mm lock washers (EEE),  
and 5mm flat washers (FFF). See illustration below for  
correct burner-to-valve engagement.  
Sideburner  
Valve should be  
in center hole in  
burner tube.  
Pin  
in hole  
Correct  
burner-to-valve  
engagement  
FFF  
EEE  
DDD  
461240504 • 9  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Insert valve clip into small hole in bottom of burner, then snap other end of clip over sideburner valve. Beneath sideburner  
shelf, attach sideburner ignitor wire to electrode. Place brass top on sideburner, then place sideburner grate onto shelf.  
9
Valve clip  
Sideburner  
ignitor wire  
Place flametamers (3) over burners by inserting tabs into slots in front of firebox.  
Opposite ends of flametamers rest on pins in back of firebox.  
10  
10 • 461240504  
Download from Www.Somanuals.com. All Manuals Search And Download.  
11  
Place cooking grates into grill bottom.  
Grate wires running front to back should  
be facing upward . . . side to side wires  
downward.  
Side-to-side  
wires on bottom.  
To assemble SwingAway, first insert  
pivot wire into holes in side of grill lid.  
Second, insert leg wires into holes in  
sides of grill bottom.  
12  
Pivot  
wire  
461240504 • 11  
Download from Www.Somanuals.com. All Manuals Search And Download.  
13  
Insert bottom door pin into hole in bottom  
shelf. Press the top door pin down, align  
with hole in door brace, release door pin.  
Press pin  
on door top  
CAUTION  
SHARP EDGES! Wear gloves if necessary.  
14  
Slide condiment  
baskets into brackets on  
back of both doors.  
Smaller basket on left  
door, larger basket on  
right door.  
12 • 461240504  
Download from Www.Somanuals.com. All Manuals Search And Download.  
15  
Hang the match-lighting sticks and chains from the small  
hooks on the left and right side panels.  
16  
Slide grease tray into back of grill.  
Make sure drain hole  
is on left side  
461240504 • 13  
Download from Www.Somanuals.com. All Manuals Search And Download.  
17  
Slide grease receptacle into rails beneath grease tray.  
CAUTION  
• Failure to install receptacle on tray will cause hot  
grease to drip from bottom of grill with risk of fire or  
property damage.  
Grease  
receptacle  
LP tank is sold separately. Fill and leak check the tank (see Use & Care section) before attaching to grill and regulator.  
18  
Once tank has been filled and leak checked, place tank into tank hole in bottom shelf. Make sure tank valve is facing front  
of grill. Secure tank with tank screw at rear of bottom shelf.  
See Use & Care manual to perform the “Burner Flame  
Check” and for important safety instructions before using.  
CAUTION  
Tank valve must face to front of cart once tank is attached.  
Failure to install tank correctly may allow gas hose to be  
damaged in operation, resulting in the risk of fire.  
Tank screw  
Tank valve  
facing front.  
14 • 461240504  
Download from Www.Somanuals.com. All Manuals Search And Download.  
VERY IMPORTANT!  
19  
Regulator and hose must pass UNDER hose bracket before connecting to LP tank. Read “Connecting Regulator  
to the LP Tank” in the Use and Care section of this manual.  
NOTE: Doors not  
shown for clarity.  
Regulator and hose  
Hose  
must pass UNDER  
Bracket  
hose bracket.  
20  
Unscrew ignitor cap and place AA  
battery into ignitor slot with positive end  
(+) facing outward. Screw ignitor cap  
onto ignitor.  
+
AA Battery  
461240504 • 15  
Download from Www.Somanuals.com. All Manuals Search And Download.  
LP Tank  
USE AND CARE  
• The LP tank used with your grill must meet the following  
requirements:  
DANGER  
Use LP tanks only with these required measurements: 12"  
(30.5cm) (diameter) x 18" (45.7 cm) (tall) with 20 lb. (9 kg.)  
capacity maximum.  
• Never fill the cylinder beyond 80% full. An overfilled  
spare LP tank is hazardous due to possible gas  
released from the safety relief valve.  
• LP tanks must be constructed and marked in accordance with  
specifications for LP tank of the 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 LP tank collar for marking.  
• The safety relief valve on the LP tank could activate,  
releasing gas, and cause an intense fire with risk of  
property damage, serious injury or death.  
LP tank valve must have:  
• Type 1 outlet compatible with  
regulator or grill.  
• NEVER store a spare LP tank under or near grill or in  
enclosed areas.  
• If you see, smell or hear escaping gas, immediately get  
away from the LP tank/grill and call your fire  
department.  
• Safety relief valve.  
• UL listed Overfill Protection  
OPD Hand Wheel  
Device (OPD). This OPD safety  
feature is identified by a unique triangular hand wheel. Use  
• All spare LP tanks must have safety caps installed on  
the LP tank outlet.  
only LP tanks equipped with this type of valve.  
• LP tank must be arranged for vapor withdrawal and include  
collar to protect LP tank valve.  
LP Tank Removal, Transport And Storage  
• Turn OFF all control knobs and LP tank valve. Turn coupling  
nut counterclockwise by hand only - do not use tools to  
disconnect. Loosen tank screw beneath bottom shelf, then lift  
LP tank up and out of cart. Install safety cap onto LP tank  
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.  
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 Tank Valve  
LP Tank Filling  
Use only licensed and experienced dealers.  
LP dealer must purge new tank before filling.  
Dealer should NEVER fill LP tank more than 80% of LP tank  
volume. Volume of propane in tank will vary by temperature.  
A frosty regulator indicates gas overfill. Immediately close LP  
tank valve and call local LP gas dealer for assistance.  
• Do not release liquid propane (LP) gas into the atmosphere.  
This is a hazardous practice.  
Safety Cap  
• To remove gas from LP tank, contact an LP dealer or call a  
local fire department for assistance. Check the telephone  
directory under “Gas Companies” for nearest certified LP  
dealers.  
Retainer Strap  
• A disconnected LP tank in storage or being transported must  
have a safety cap installed (as shown). Do not store an LP tank  
in enclosed spaces such as a carport, garage, porch, covered  
patio or other building. Never leave an LP tank inside a vehicle  
which may become overheated by the sun.  
• Do not store an LP tank in an area where children play.  
16 • 461240504  
Download from Www.Somanuals.com. All Manuals Search And Download.  
LP Tank Exchange  
Connecting Regulator To The LP Tank  
• Many retailers that sell grills offer you the option of replacing  
your empty LP tank through an exchange service. Use only  
those reputable exchange companies that inspect, precision fill,  
test and certify their cylinders. Exchange your tank only for  
an OPD safety feature-equipped tank as described in the  
"LP Tank" section of this manual.  
1. LP tank must be properly secured onto grill. (Refer to  
assembly section.)  
2. Turn all control knobs, including sideburner, to the OFF  
position.  
3. Turn LP tank OFF by turning hand-wheel clockwise to a full  
stop.  
Always keep new and exchanged LP tanks in upright position  
during use, transit or storage.  
4. Remove the protective cap from LP tank valve. Always use  
cap and strap supplied with valve.  
Leak test new and exchanged LP tanks BEFORE  
connecting to grill.  
ck  
LP Tank Leak Test  
For your safety  
OPD Hand Wheel  
Leak test must be repeated each time LP tank is exchanged or  
refilled.  
Type 1 outlet with  
thread on outside  
Do not smoke during leak test.  
Safety Relief Valve  
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.  
Strap and Cap  
• 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 a POL transport plug  
(plastic part with external threads)!  
It will defeat the safety feature of  
the valve.  
s Do not use household cleaning agents. Damage to gas  
train components can result.  
5. Make sure hose and regulator pass  
UNDER hose bracket on cart (see  
assembly step 19). Hold regulator and  
insert nipple into LP tank valve. Hand-  
tighten the coupling nut, holding  
regulator in a straight line with LP tank  
valve so as not to cross-thread the  
connection.  
Nipple has to be centered  
into the LP tank valve.  
WARNING  
If “growing” bubbles appear do not use or move the LP tank.  
Contact an LP gas supplier or your fire department!  
461240504 • 17  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Leak Testing Valves, Hose and Regulator  
1. Turn all grill control knobs to OFF.  
2. Be sure regulator is tightly connected to LP tank.  
3. Completely open LP tank 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.  
Hold coupling nut and regulator  
as shown for proper connection  
to LP tank valve.  
6. Turn the coupling nut clockwise and tighten to a full stop. The  
regulator will seal on the back-check feature in the LP tank  
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.  
• 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.  
NOTE: Sideburner  
control panel not  
shown for clarity.  
• If a leak is detected at any time, STOP and call the fire  
department.  
• If you cannot stop a gas leak, immediately close LP tank  
valve and call LP gas supplier or your fire department!  
5. If “growing” bubbles appear, there is a leak. Close LP tank  
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  
of items needed to the Grill Service Center at 1-800-241-7548  
(U.S.) or 1-800-387-6057 (CANADA).  
6. Always close LP tank valve after performing leak test by  
turning hand wheel clockwise.  
18 • 461240504  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Safety Tips  
WARNING  
s Before opening LP tank valve, check the coupling nut for  
tightness.  
For Safe Use Of Your Grill And To Avoid Serious  
Injury:  
s When grill is not in use, turn off all control knobs and LP tank  
valve.  
Do not let children operate or play near grill.  
Keep grill area clear and free from materials that burn.  
Do not block holes in bottom or back of grill.  
Check burner flames regularly.  
s Never move grill while in operation or still hot.  
s Use long-handled barbecue utensils and oven mitts to avoid  
burns and splatters.  
s Maximum load for sideburner and side shelf is 10 lbs.  
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 any kind.  
s The grease receptacle must be attached to grease tray and  
emptied after each use. Do not remove grease receptacle  
until grill has completely cooled.  
Do not use charcoal or ceramic briquets in a gas grill.  
(Unless briquets are supplied with your grill.)  
s 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.  
• Use grill at least 3 ft. from any wall or surface. Maintain  
10 ft. clearance to objects that can catch fire or sources of  
ignition such as pilot lights on water heaters, live electrical  
appliances, etc..  
s Keep ventilation openings in cylinder enclosure (grill cart) free  
and clear of debris.  
s The regulator may make a humming or whistling noise during  
operation. This will not affect safety or use of grill.  
s If you have a grill problem see the "Troubleshooting Section".  
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 a grease fire develops, turn knobs and LP tank  
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.  
• Apartment Dwellers:  
Ignitor Lighting  
Check with 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.  
s Do not lean over grill while lighting.  
1. Open lid. Turn on gas at LP tank.  
2. To ignite, turn center knob to HI, push and hold ELECTRONIC  
IGNITOR button.  
• NEVER attempt to light burner with lid closed. A buildup  
of non-ignited gas inside a closed grill is hazardous.  
3. If ignition does NOT take place within 5 seconds, turn all  
burner valves to OFF, wait 5 minutes, then repeat lighting  
procedure.  
• Never operate grill with LP tank out of correct position  
specified in assembly instructions.  
• Always close LP tank valve and remove coupling nut  
before moving LP tank from specified operation  
position.  
4. To ignite left burner, turn left knob to HI.  
5. To ignite right burner, turn right knob to HI.  
Lighting instructions continued on next page.  
461240504 • 19  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Burner Flame Check  
• Remove grates and flametamers. Light burner, rotate knobs  
from HI to LOW. You should see a smaller flame in LO position  
than seen on HI. Always check flame prior to each use.  
Perform flame check on sideburner. If only low flame is seen  
refer to "Sudden drop or low flame" in the Troubleshooting  
CAUTION  
If burner does not light, turn knobs to OFF , wait 5  
minutes, and try again. 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.  
Section.  
HI  
LO  
Match-Lighting  
s Do not lean over grill while lighting.  
1. Open lid. Turn on gas at LP tank.  
Turning Grill Off  
2. Place lit match into match lighting stick, then into lighting hole  
on left and/or right side of grill.  
• Turn all knobs to OFF position. Turn LP tank off by turning  
hand-wheel clockwise to a full stop.  
3. Push in and turn far left or right burner knob to HI. Be sure  
burner lights and stays lit.  
Ignitor Check  
• Turn gas off at LP tank. Press and hold electronic ignitor  
button. "Click" should be heard and spark seen each time  
between collector box or burner and electrodes. See  
"Troubleshooting" if no click or spark.  
4. Light adjacent burners in sequence by pushing knobs in and  
turning to HI.  
Valve Check  
• Important: Make sure gas is off at LP tank 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 LO 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.  
Ignitor Lighting The Sideburner  
General Grill Cleaning  
s Do not lean over grill while lighting.  
1. To ignite sideburner, open sideburner cover.  
• 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.  
2. Turn sideburner knob to HI, push and hold ELECTRONIC  
IGNITOR button.  
3. If sideburner does NOT light, turn knob to OFF, wait 5 minutes,  
then repeat lighting procedure or use match.  
Match Lighting  
1. To match light sideburner, open sideburner cover.  
2. Place lit match near burner.  
Plastic parts: Wash with warm soapy water and wipe dry.  
s Do not use citrisol, abrasive cleaners, degreasers or a  
concentrated grill cleaner on plastic parts. Damage to and  
failure of parts can result.  
3. Push in and turn sideburner  
knob counterclockwise.  
Be sure burner lights  
and stays lit.  
• Porcelain surfaces: Because of glass-like composition, most  
residue can be wiped away with baking soda/water solution or  
specially formulated cleaner. Use nonabrasive scouring powder  
for stubborn stains.  
• Painted surfaces: Wash with mild detergent or nonabrasive  
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. Baked-on grease  
deposits may require the use of an abrasive plastic cleaning  
pad.  
20 • 461240504  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Cleaning The Burner Assembly  
CAUTION  
NATURAL HAZARD • SPIDERS  
FACT: Sometimes spiders and other small insects climb into  
the burner tubes attached to the burners. The spiders spin  
webs, build nests and lay eggs. The webs or nests  
can be very small, but they are very strong  
and can block the flow of gas. Clean  
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 tank.  
2. Remove cooking grates, flametamers, grease tray and  
grease receptacle.  
3. Remove cotter pins from beneath each burner "foot" using a  
screwdriver or needle nose pliers.  
4. Carefully lift each burner up and away from valve openings.  
burners prior to use after storing, at the  
beginning of grilling season or after a period  
of one month not being used.  
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  
tube and burner several times.  
Spider guards are on the air intakes in an effort to reduce this  
problem, but it will not eliminate it! An obstruction can result  
in a "flashback" (a fire in the burner tubes). The grill may still  
light, but the obstruction does not allow full gas flow to the  
burners.  
IF YOU EXPERIENCE THE FOLLOWING:  
1. Smell gas.  
(B) Use a narrow bottle brush with a flexible handle (do not  
use a brass wire brush), run the brush through each  
burner tube and burner several times.  
2. Burner(s) will not light.  
(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.  
5. Wire brush entire outer surface of burner to remove food  
residue and dirt.  
6. Clean any blocked ports with a stiff wire such as an open  
paper clip.  
7. 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.  
3. A small yellow flame from burner (should be blue).  
4. Fire coming from around or behind control knob.  
STOP!  
Immediately turn off gas at LP tank!  
SOLUTION:  
Wait for grill to cool.  
VERY IMPORTANT: Burner tubes must reengage valve  
openings. See illustrations below.  
8. Carefully replace burners.  
9. Replace cotter pin beneath each burner.  
10. Replace grease tray, grease receptacle, flametamers, and  
cooking grates.  
Follow the “Cleaning The Burner Assembly” instructions.  
Clean burners often. Use a 12” pipe cleaner to clean out the  
burner tubes. You may also force a stream of water from a  
hose nozzle through burner tubes to clean them.  
Storing Your Grill  
• Clean cooking grates.  
• Store in dry location.  
Burner  
Valve  
• When LP tank 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 tank 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.  
461240504 • 21  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Indirect Cooking  
Food Safety  
Poultry and large cuts of meat cook slowly to perfection on  
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:  
the grill by indirect heat. The heat from selected burners  
circulates gently throughout the grill, cooking meat or poultry  
without the touch of a direct flame. This method greatly reduces  
flare-ups when cooking extra fatty cuts because there is no direct  
flame to ignite the fats and juices that drip during cooking.  
Clean: Wash hands, utensils, and surfaces with hot soapy water  
before and after handling raw meat and poultry.  
Separate: Separate raw meats and poultry from ready-to-eat  
foods to avoid cross contamination. Use a clean platter and  
utensils when removing cooked foods.  
Indirect Cooking Instructions  
• Always cook with the lid closed.  
Cook: Cook meat and poultry thoroughly to kill bacteria. Use a  
thermometer to ensure proper internal food temperatures.  
• Due to weather conditions, cooking times may vary. During  
cold and windy conditions the temperature setting may need  
to be increased to insure sufficient cooking 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 EST.  
How To Tell If Meat Is Grilled Thoroughly  
Meat and poultry cooked on a grill often browns very fast on the  
outside. Use a meat thermometer to be sure food has reached  
a safe internal temperature, and cut into food to check for  
visual signs of doneness.  
Whole poultry should reach 180° F; breasts, 170° F. Juices  
should run clear and flesh should not be pink.  
Hamburgers made of any ground meat or poultry should reach  
160° F, and be brown in the middle with no pink juices. Beef,  
veal and lamb steaks, roasts and chops can be cooked to 145°  
F. All cuts of pork should reach 160° F.  
1 Burner Cooking  
Cook with direct or indirect heat.  
Best for smaller meals or foods.  
Consumes less fuel.  
NEVER partially grill meat or poultry and finish cooking later.  
Cook food completely to destroy harmful bacteria.  
When reheating takeout foods or fully cooked meats like hot  
dogs, grill to 165° F, or until steaming hot.  
2 Burner Cooking  
Great indirect cooking on low.  
Produces slow, even heating.  
Ideal for slow roasting and baking.  
22 • 461240504  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Troubleshooting  
Problem  
Possible Cause  
Prevention/Solution  
Burner(s) will not light  
using ignitor.  
• Wire and/or electrode covered with  
cooking residue.  
• Electrode cracked or broken "sparks at  
crack”.  
• Electrode tip not in proper position.  
• Clean wire and/or electrode with rubbing alcohol and clean swab.  
• Replace electrode(s).  
• Main Burners: Tip of electrode should be pointing toward tip of  
collector box. The distance should be 1/8” to 1/4”, adjust if  
necessary.  
• Sideburner: Tip of electrode should be pointing toward gas port  
opening on burner. The distance should be 1/8” to 3/16”, adjust if  
necessary.  
• Wires are loose or disconnected.  
• Wires are shorting (sparking) between  
ignitor and electrode.  
• Reconnect wires or replace electrode/wire assembly.  
• Replace ignitor wire/electrode assembly.  
• Dead battery.  
• Replace with a new AA battery.  
Burner(s) will not  
match light.  
• No gas flow.  
• Check to see if LP tank is empty. If LP tank is not empty, refer to  
"Sudden drop in gas flow".  
• Coupling nut and regulator not fully  
connected.  
• Obstruction of gas flow.  
• Turn the coupling nut about one-half to three quarters additional  
turn until solid stop. Tighten by hand only-do not use tools.  
• Clear burner tube(s).  
• Disengagement of burner to valve.  
• Is grill assembled correctly?  
• Reengage burner and valve.  
• Check steps in assembly instructions.  
Sudden drop in gas  
flow or low flame.  
• Out of gas.  
• Excess flow valve tripped.  
• Check for gas in LP tank.  
• Turn off knobs, wait 30 seconds and light grill. If flames are still low,  
turn off knobs and LP tank valve. Disconnect regulator. Reconnect  
regulator and leak test. Turn on LP tank valve, wait 30 seconds and  
then light grill.  
Flames blow out.  
Flare-up.  
• High or gusting winds.  
• Low on LP gas.  
• Excess flow valve tripped.  
• Turn front of grill to face wind or increase flame height.  
• Refill LP tank.  
• Refer to "Sudden drop in gas flow" above.  
• Grease buildup.  
• Excessive fat in meat.  
• Excessive cooking temperature.  
• Clean grill.  
• Trim fat from meat before grilling.  
• Adjust (lower) temperature accordingly.  
Persistent grease fire.  
• Grease trapped by food buildup around  
burner system.  
• Turn knobs to OFF. Turn gas off at LP tank. Leave lid in position and  
let fire burn out. After grill cools, remove and clean all parts.  
Flashback...  
(fire in burner tube(s)).  
• Burner and/or burner tubes are blocked.  
• Turn knobs to OFF. Clean burner and/or burner tubes.  
Unable to fill LP tank.  
• Some dealers have older fill nozzles  
with worn threads.  
• The worn nozzles don't have enough "bite" to engage the valve. Try  
a second LP dealer.  
461240504 • 23  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Troubleshooting - Electronic Ignition  
Problem  
Possible Cause  
Check Procedure  
Prevention/Solution  
No sparks appear at  
any electrodes when  
ignition button is  
pushed; no noise can  
be heard from spark  
module.  
• Battery not installed  
properly.  
• Check battery orientation.  
• Install battery (make sure that “+” and “–”  
connectors are oriented correctly, with “+” end up  
and “–” end down.)  
• Dead battery.  
• Has battery been used  
previously?  
• Replace battery with new AA-size alkaline battery.  
• Button assembly not  
installed properly.  
• Check to insure threads are  
properly engaged. Button  
should travel up and down  
without binding.  
• Unscrew button cap assembly and reinstall, making  
sure threads are aligned and engaged fully.  
• Faulty spark module.  
• If no sparks are generated  
with new battery and good  
wire connections, module is  
faulty.  
• Replace spark module assembly.  
No sparks appear at  
any electrodes when  
ignition switch is  
pushed; noise can be  
heard from spark  
module.  
• Output lead  
connections not  
complete.  
• Are output connections on  
and tight?  
• Remove and reconnect all output connections at  
module and electrodes.  
Sparks are present  
but not at all  
electrodes and/or not  
at full strength  
• Output lead  
connections not  
complete.  
• Are output connections on  
and tight?  
• Remove and reconnect all output connections at  
module and electrodes.  
• Arcing to grill away  
from burner(s).  
• If possible, observe grill in  
dark location. Operate  
ignition system and look for  
arcing between output wires  
and grill frame.  
• If sparks are observed other than from burner(s),  
wire insulation may be damaged. Replace wires.  
• Weak battery.  
• All sparks present but weak  
or at slow rate.  
• Replace battery with a new AA-size alkaline battery.  
• Use paper towel to remove moisture.  
• Electrodes are wet.  
• Has moisture accumulated  
on electrode and/or in burner  
ports?  
• Electrodes cracked or  
broken “sparks at  
crack”.  
• Inspect electrodes for  
cracks.  
• Replace cracked or broken electrodes.  
24 • 461240504  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Please register your grill online at:  
WWW.GRILLREGISTRATION.COM  
(If you register online, you do not need to send in this registration card.)  
PLEASE FILL OUT THIS CARD AND RETURN IT WITHIN 10 DAYS OF PURCHASE.  
FAILURE TO RETURN MAY AFFECT YOUR WARRANTY COVERAGE.  
S’IL VOUS PLAIT REMPLIR CETTE CARTE ET LA RETOURNER DANS 10 JOURS APRÈS L’ACHAT.  
LE MANQUE DE RETOURNER PEUT AFFECTER VOTRE GARANTIE.  
Upon completion, remove this page from your  
manual and mail to:  
PRODUCT REGISTRATION DEPT.  
PO BOX 1240  
COLUMBUS, GA 31902-1240  
461240504 • 25  
Download from Www.Somanuals.com. All Manuals Search And Download.  
26 • 461240504  
Download from Www.Somanuals.com. All Manuals Search And Download.  
461240504 • 27  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A Division of W.C. Bradley Co. • Columbus, GA 31902  
Download from Www.Somanuals.com. All Manuals Search And Download.  

Tech Craft TV Video Accessories BCE48 User Manual
Tiger Products Co Ltd Lawn Mower CNH T6010 80 User Manual
Toastmaster Iron 3314 User Manual
Toro Lawn Mower 20055 User Manual
Toshiba CRT Television 32ZT29B User Manual
Toshiba Digital Camera IK DP01A User Manual
Transition Networks Cable Box CPSVT26XX User Manual
Trek Indoor Fireplace SSDVPF CNE User Manual
TRENDnet Router TEW 637AP User Manual
Ultra Products Network Card ULT31434 User Manual