Installation & Operation Instructions - K-and-W
Contents
1. BBQ Backwall Flexible Connection 1 2 2 Propane LP Bottle Connection You must use a fuel pressure regulator with your propane bottle because the gas is stored under pressure We recommend using iron gas pipe to extend outside of the body of your unit before connecting to the hose and regulator 90 Elbow 1 2 in eae fpt to flared 3 8 in 1 2 in pipe nipple Length to fit through back of BBQ tube ui a _ BBQ Backwall 7 BBQ manifold 1 2 pipe coupling Hose and Regulator A e the Propane Bottle Propane Bottle Connection CAUTION Propane also known as LP is a gas that is heavier than the surrounding air You should not store your propane bottle in an area that can trap any escaping gas This means that your storage area must be vented at the level of the base of your tank 1 3 Natural Gas to Propane LP Conversion Your barbecue equipment normally comes from the factory tecrew to adjust ready to use natural gas Valve Stem Orifice air shutter To use propane you need to change the orifice on your gas 7 valve s The orifice is on the end of the valve opposite from the stem where the control knob mounts 2 You will need to slide the ven2. F la BBroil BARBECUE EQUIPMENT Manufactured by K amp W Mfg Co Inc Corona California Installation amp Operation Instructions For Gas Barbecues Models 5453 and 5457 A Note to You Thank you for buying a Flame Broil barbecue grill To ensure that you enjoy your barbecue equipment for many years we developed these instructions They contain valuable information about how to install operate and maintain your barbecue equipment Please read them carefully Keep this booklet and your sales receipt together in a safe place for future reference Itis important for you to save your sales receipt showing the date of purchase Proof of purchase will assure you of warranty service If you need assistance or service you can reach us at K amp W Mfg Co Inc 23107 Temescal Canyon Road Corona CA 92883 5045 Phone 909 277 3300 FAX 909 277 2070 www k and w mfg com Happy Barbecuing Limited Warranty K amp W Mfg Co Inc warrants Flame Broil Barbecue Equipment to be free from defects in design materials and workmanship at the time of manufacture For a period of five 5 years following purchase K amp W Mfg Co Inc will repair or replace at the discretion of K amp W Mfg Co Inc any Flame Broil Barbecue unit found to be defective by K amp W Mfg Co Inc or their authorized representative This warranty does not cover the normal wear and tear that occurs from operation of
3. Then remove the four screws retaining the face to the frame Carefully lift the face away from the frame Occasionally we need to add spacers between the face and the frame to ensure that the cooking grills will fit correctly Be sure to save any spacers you may find there Gas Valve Rotary Ignitor Rotary Ignitor Gas Manifold Spark Generator Spark Wire Barbecue with Face Removed 1 2 1 Permanent Gas Connection Standard 1 2 in iron gas pipe is recommended to make the connection from your household gas supply to your barbecue equipment A shut off valve in the gas line is recommended for safety and convenience If the barbecue unit is accessible to children a shut off valve with a removable key is highly recommended 1 2 in pipe nipple Length to fit through back of BBQ 90 Elbow i Coe BBQ Backwall os BBQ manifold 1 2 pipe coupling ieee DE Rigid Connection Stainless steel flexible connectors may be used for difficult locations A 7 8 in outside diameter connector is the recommended size Smaller sizes may cause a gas flow restriction This problem is usually indicated by a whistling sound in the gas line and not enough heat available for cooking The barbecue manifold will require a 1 2 in female end fitting Stainless steel Flexible Connector 7 8 in Outside Diameter BBQ manifold 1 2 in female end fitting
4. the unit nor does it including neglect or abuse The Flame Broil Barbecue unit must be installed and operated in accordance with the installation and operating instructions of K amp W Mfg Co Inc and any local area building and fire codes K amp W Mfg Co Inc shall not be responsible for any indirect incidental or other damage In order claim remedy under the five year warranty the unit must be returned to the factory at the owner s expense with a copy of the purchase receipt If the unit is found to be defective K amp W Mfg Co Inc will repair or replace the unit at their discretion and return the unit to the owner at the company s expense At any time K amp W Mfg Co Inc will repair or replace any Flame Broil Barbecue unit returned to the factory at the owner s cost for a cost of no more that half of the current suggested retail price of the most similar current model Unpacking your Barbecue When you unpack your barbecue unit you should find The main body of the barbecue unit with the burner s installed A drip tray at the bottom of the unit A box inserted into the inner liner of the barbecue unit This box should contain v These instructions Two small hex head orifices for converting from natural gas to propane LP Two smaller cooking grills One larger briquet grate Three or four bags of stainless steel Broilettes SSS 1 Installation 1 1 Setting up your stand or enclosure Flame Broil b
5. when you light the unit Follow the maintenance procedure on cleaning the burner s and venturis 3 Maintenance Periodic inspection and cleaning of your barbecue equipment will ensure its proper operation The following checklist is recommended e Clean the cooking grills broilettes and briquet grate e Clean the burner s venturis and valves e Clean the grill interior e Check the rotary ignitor e Reassemble and test If you live in an area where inclement weather prevents you from using your barbecue equipment during certain times of the year it is a good idea to remove and store the unit This practice will extend the life of your equipment and its components If you cannot remove the unit try to cover it completely from the elements 3 1 Preparation Always shut off the gas supply at the source before doing any maintenance or repairs Many parts will have a greasy film or rusty residue Wear protective clothing and protect the area around the barbecue equipment Before removing any components have a notebook handy to keep notes on the order and placement of the parts You will need e Bucket or small tub e Philips screwdriver e Vegetable oil e Wire brush e 1 4 inch wrench e WD40 or similar lubricant e Steel wool or nylon pad e Putty knife or scraper e Venturi spider brush optional e Fine sandpaper or emery cloth Strong detergent or degreaser e Toothpick or small piece of wire e Rubbing Alcohol 3 2 Clean the
6. A common problem is to use a pipe or flexible connector with a smaller diameter than recommended when installing the gas connections Review the gas connection instructions in the Installation section 2 3 3 It gets too hot The natural gas valve orifice is being used when the barbecue equipment is burning LP propane gas The table Valve Stem on the left gives the drill size of the holes in the orifice s If you do not have a drill set to test your orifice s try comparing all of the orifices that came with your equipment The hole in 3 the natural gas orifice s is larger than the hole in the LP W orifice s If your barbecue equipment is burning LP propane gas the orifice s with the smaller holes should be ungs installed in the gas control valve s Modei Natural LP r k 5453 49 54 2 3 4 There is a whistling noise 5457 43 51 5703 52 56 There is a restriction in your gas supply lines A common problem is to use a pipe or flexible connector with a smaller Orifice Hole Drill Size Table diameter than recommended when installing the gas connections Review the gas connection instructions in the Installation section 2 3 5 Flames around the gas control knob This is known as a flashback fire There is an obstruction in the venturi and or the burner This obstruction causes gas to back up and escape out the venturi air shutter where it ignites
7. Cooking Grills Broilettes and Briquet Grate Mi Cooking grills are most efficiently and easily cleaned on an ongoing basis by simply pre heating the grill on high for 10 minutes before each use After heating scrubbing with a brass bristle brush to remove the loose residue and then carefully wipe down with a wet paper towel Tip Coating the cooking grills with vegetable oil before cooking helps prevent ii N i y the food from sticking and makes cleaning easier il i IE H il For a thorough cleaning remove and inspect the cooking grills If you find broken welds or excessive rust you may opt to replace the grills If the cooking grills are not too badly deteriorated soak in a hot soapy water solution to loosen accumulated grease a degreaser may also be used then scrub with a steel wool pad or a stiff nylon pad Rinse thoroughly and lightly coat with vegetable oil before use Next remove and inspect the stainless steel Broilettes Any badly deteriorated ones should be replaced A light coating of rust is okay Knock off any loose rust or deposits with a wire brush You may wash them if you desire Finally inspect the briquet grate This component is subject to very high temperatures and will weaken and deteriorate over time If the grate is very thin or sags excessively replace it with a new grate Otherwise knock off any loose rust and scale with a wire brush 10 3 3 Clean the Burner s Venturi s and Valve
8. ad 5455 123 2 Venturi Flex 5521 2 Cooking Grill Chrome 15 x 18 5455 007 1 Drip Tray 30 2 x 18 2 Gas Control Knob 5455 005 1 Gas Manifold 5455 130 2 Gas Valve 5455 132 2 Orifice LP Gas 5455 131 2 Orifice Natural Gas 5450 116 2 Ignitor Collector Box 5450 117 2 Ignitor Wire 5450 119 2 Rotary Spark Bracket 5450 118 2 Rotary Spark Generator 5450 800 1 Instructions 1 1 2 1 7 1 4 0903 607 Washer Nylon 8 screw
9. any blockage of the gas control valve or the venturi and burner Follow the maintenance procedure on cleaning the valve s burner s and venturi s Check for any restriction in your gas supply lines A common problem is to use a pipe or flexible connector with a smaller diameter than recommended when installing the gas connections Review the gas connection instructions in the Installation section 2 3 2 It won t get hot a The LP gas valve orifice is being used when the barbecue equipment is burning natural gas Valve Stem The table on the left gives the drill size of the holes in the Ks orifice s If you do not have a drill set to test your om orifice s try comparing all of the orifices that came with your equipment The hole in the natural gas orifice s is larger than the hole in the LP orifice s If your barbecue Orifice equipment is burning natural gas the orifice s with the larger holes should be installed in the gas control valve s An obstruction is partially blocking the gas supply to the burner s Natural mo 43 51 52 56 Orifice Hole Drill Size Table Check that the source of your gas supply is turned on at your shut off valve or your propane bottle Check for any blockage of the gas control valve or the venturi and burner Follow the maintenance procedure on cleaning the valve s burner s and venturi s Check for any restriction in your gas supply lines
10. arbecue equipment may be installed in many different types of enclosures or stands If you are planning to build a permanent enclosure and or change your gas plumbing it is highly recommended that you check with your local building department concerning building codes and permits The following diagram will provide you with the dimensions your equipment needs to fit its enclosure or stand 5453 24 75 18 25 12 5457 31 75 20 25 12 5703 13 25 18 25 12 Enclosure Dimensions in Inches 1 Gas Line Placement at Back of Enclosure 1 1 1 Combustible Materials Our barbecue units are intended for use in masonry or other fireproof locations They are not insulated They should never be in contact with any combustible materials While operating your barbecue equipment you should be at least 2 feet from any combustible house sidings In addition you should never operate your barbecue equipment under a roof overhang or patio cover made from combustible materials 1 1 2 Drainage Allowing water to pool in and around your barbecue equipment will increase the normal wear and tear to the components and lower their life expectancy We recommend that you provide for drainage when building your enclosure so that water will not pool underneath the barbecue or inside the enclosure Cooking Grill Area 1 1 3 Ventilation Blockage of fresh airflow into and around your barbecue equipment will cause overheat
11. bs with the directional arrows The gas control knob has a click stop at OFF position To start the gas the knob is depressed and turned Rotary Ignitor Knob counterclockwise to the HIGH position There is another click stop at the HIGH position To shut the gas off Gas Control Knob depress the knob and turn clockwise to the OFF position The rotary ignitor generates a spark as you turn the knob and this spark lights the gas It is very important to only turn the rotary ignitor knob clockwise in the direction of the arrows You will damage the ignitor by turning the knob in the opposite direction 2 1 1 To light the burner with the rotary ignitor Turn the gas on and immediately begin turning the rotary ignitor knob If the burner does not light after a few turns of the ignitor knob turn off the gas Allow any gas to dissipate for a few minutes Repeat this lighting procedure If the unit still does not light use the trouble shooting section on lighting If you have determined that the ignitor is not functioning you may use a match for lighting until you have a chance to clean or replace the ignitor 2 1 2 To light the burner with a match Strike the match first Drop the lit match into the unit close to the burner s edge Make sure the match stays lit and turn on the gas The burner should light within 5 seconds of turning on the gas If the burner does not light turn off the gas Use the troub
12. es Special care should be taken to make sure the brush passes through the entire venturi tube all the way to the burner Burner ae l If a spider brush is not available you may flush out ventur the venturi with a strong flow of water from a garden a hose Pay special attention to how the water exits the burner port holes as clogged holes are easily spotted Clogged holes can be opened with an awl or piece of wire Clogged holes can cause a grill to have hot and cold spots because of uneven flame characteristics Use spider brush to clean all the way up the venturi Burner with Venturi The valves can now be checked Temporarily slide the valve knobs back onto the valve stems The knobs Valve Stem should depress turn and release pop up freely If they are sluggish carefully spray a small amount of WD40 or similar lubricant onto the valve stem area Work knobs a few times to distribute the lubricant Valves that bind severely should be replaced Small insects can also block the valve orifice which will restrict gas flow Debris in the gas supply lines may also clog these tiny holes So remove the hex head orifice with Orifice a 1 4 inch wrench and make sure the hole is completely clean Also check the inner portion of the valve from where the orifice was removed Debris can be removed with a small piece of wire or toothpick Re install or
13. ifices and tighten Gas Valve 11 3 4 Clean the Grill Interior First protect the ignitor collector box with the electrode by covering it with a protective cloth or plastic or aluminum foil Gas Collector Box Secondly scrape off heavy grease or cooking debris accumulation with a putty knife or scraper You can vacuum this debris with a shop vacuum cleaner or brush it through the holes in the burner tray at the bottom of the liner onto the drip tray When you are done you should remove and dump the contents of the drip tray Lastly scrub the interior with a strong detergent solution a degreaser may 4 NG also be used Rinse and let dry Remove protective covers installed 3 iiaiai Tip earlier 3 5 Check the Rotary Ignitor The ignitor sends a high voltage along the wire to the ignitor electrode inside the collector box The collector box collects a quantity of gas which a spark lights To Grease dirt and or rust on the electrode or the collector box can prevent the electrode from sparking Clean any dirt and grease with alcohol Remove any Dooce ee rust by lightly sanding with emery cloth or fine sandpaper Collector Box Rotary Spark Pesaran T Check that the electrode insulation isn t cracked or broken and replace if it is Cracks collect moisture that keeps the spark from getting to the electrode It is normal for the wire to fit loosely in the porcelain Check the ignitor wire for abrasions cuts or bur
14. ing poor combustion and possible damage to components There is an air space at the bottom of the barbecue units below the face This air soace must remain open for your barbecue equipment to operate properly Our barbecues are also designed to vent though the cooking grill area Therefore air must be allowed to flow though the top of the unit Only use a Flame Broil barbecue accessory to cover the cooking grill area Bottom Air Space CAUTION Propane also known as LP is a gas that is heavier than the surrounding air You should not store your propane bottle in an area that can trap any escaping gas This means that your storage area must be vented at the level of the base of your tank 1 2 Gas Connections Please study this connection information carefully If you do not feel confident about making these connections yourself please get help from a professional plumber or gas appliance installer before proceeding Be sure to use pipe tape or pipe joint compound approved for gas when making your connections Check all connections for leaks with a soapy solution 50 water 50 detergent before lighting the barbecue unit for the first time Bubbles indicate a leak that must be repaired before proceeding We recommend that you remove the face of the unit for easier access Be sure to remove all of the loose components and accessories from the unit Next you remove the knobs by pulling them straight out from the face
15. le shooting section to check for an obstruction in your gas supply If you still cannot light the burner please contact us for help 2 2 Adjusting the Flame The highest flame setting is with the gas control knob set at the HIGH position To adjust to a lower flame depress the gas control knob and turn counterclockwise The lowest flame setting is at the MED LOW position The flame will adjust between these two settings To turn off the flame depress the gas control knob and turn clockwise to the OFF position 2 3 Trouble shooting Here are some of the common problems that sometimes occur with gas barbecue equipment If these solutions do not solve your problem please contact us for help 2 3 1 It won t light There are two possible reasons for the unit not to light a The rotary ignitor isn t sparking With the gas shut off watch the electrode tip inside the gas collector box while turning the ignitor knob It may be necessary to use a small hand mirror to see inside the collector box A spark should jump from the electrode tip to the inner roof of the collector box If there is no spark follow the maintenance procedure for the rotary ignitor The gas is not reaching the ignitor collection box or the burner s There is an obstruction somewhere in the gas supply Gas Collector Bon Check that the source of your gas supply is turned on at your shut off valve or your propane bottle Check for
16. ns in the insulation Also check that the wire is not broken inside the insulation Replace if you find any of these problems Check the wire connections for corrosion or looseness Clean or tighten as needed 3 6 Reassemble and Test Reinstall the burner s Slide the venturi air shutter back over the orifice end of the valves Re wrap the ignitor wire around the venturi and restore its connections Turn the ignitor knob while watching the connections from the underside of the grill to assure the spark isn t jumping from a connection to the grill body Then turn the ignitor Knob while watching the inside of the collector box to assure that the spark is jumping from the electrode to the inner Valve roof of the collector box It may be necessary to use ZF Burners a small hand mirror to see inside the collector box h D Pal Cooking Grills Broilettes Briquet Grate Face Inner Liner wan Venturi s Turn on the gas supply and test light the burner s Review the section on adjusting the fuel mixture and ignitor Wire check your flame Section View of Barbecue Interior Now you can replace the face Do not forget any spacers you may have found between face and frame Replace the briquet grate and the broilettes Distribute the broilettes evenly in the areas on the briquet grate surface above the flames from the burner
17. s At this point you should remove the face of the unit for easier access Remove the knobs by pulling them straight out from the face Next remove the four screws retaining the face to the frame Carefully lift the face away from the frame Occasionally we need to add spacers between the face and the frame to ensure that the cooking grills will fit correctly Be Gas Valve sure to save any spacers you may find there The wire which connects the rotary ignitor generator z to the collector box is usually loosely wrapped ez i X S around the venturi tube This wire must be Z7 disconnected from the spark generator and Pin See Se ha vere unwrapped from the venturi tube before the burner is removed ay Barbecue with Face Removed Carefully remove the burner s from the inner lining area With the model 5457 you may need to pry back the clips that hold the burners to the liner Lightly brush the burner with a wire brush to remove loose rust and scale Inspect the burner for holes or split seams and replace if necessary If the burner passes inspection next inspect the venturi IT IS EXTREMELY IMPORTANT to clean the venturi tubes of any obstructions such as spider or insect webs etc A small web can block the gas flow and cause poor burner performance or a flashback fire SS A flexible spider brush is the best tool for cleaning the Venturi Spider Brush venturi tub
18. s This will help the grill cook at an overall even temperature Finally you can replace the cooking grills If you purchased the oven accessory place the oven in the top shelf and the two cooking grills inside the oven 12 4 Parts Lists 4 1 Model 5453 Part Qty Description 5450 129 1 Briquette Grate 22 x 12 5423 3 Broilettes 12 Pack 5453 123 1 Burner Head 5455 123 2 Venturi Flex 5520 2 Cooking Grill Chrome 11 x 16 5450 007 1 Drip Tray 23 x 16 5450 127 2 Gas Control Knob 5453 005 1 Gas Manifold 5453 130 2 Gas Valve 5453 132 2 Orifice LP Gas 5453 131 2 Orifice Natural Gas 5450 116 1 Ignitor Collector Box 5450 117 1 Ignitor Wire 5450 119 1 Rotary Spark Bracket 5450 118 1 Rotary Spark Generator 5450 800 1 Instructions 5000 850 1 Label Flame Broil 5000 855 1 Label Model amp Serial No 0907 903 3 Screw SST 20 x 2 0907 992 11 Screw SST 8 x 0902 900 7 Nut SST 20 0902 710 11 U Nut 8 Screw 0903 607 4 Washer Nylon 8 screw 13 A Part Qty 2 Model 5457 Description 5455 129 5423 Briquette Grate 28 x 14 Broilettes 12 Pack 5000 850 Label Flame Broil 5000 855 0907 903 0907 992 Label Model amp Serial No Screw SST 20 x Screw SST 8 x 0902 900 0902 710 Nut SST 14 20 U Nut 8 Screw 4 5455 123 2 Burner He
19. turi air shutter from over the l orifice and move it out of the way Using a 1 4 inch wrench wr acacia remove the natural gas orifice and replace it with the LP enturi Air ee s Valve Shutter orifice that came with your equipment Replace the venturi by sliding the air shutter back over the orifice end of the valve Gas Valve with Venturi Air Shutter 1 4 Adjusting the Fuel Mixture After you have completed your gas connections you should check for the proper fuel and air mixture Please remember to check all of the gas connections for leaks with a 50 50 soap bubble solution With the face removed temporarily replace the control knobs Turn the gas on and light Set screw to adjust air shutter the BBQ See the lighting instructions in the Operation Set screw to adjust venturi length section If the flames burn with a slightly yellow tip and do not ee ee lift from the burner ports no further adjustment is necessary To adjust combustion loosen the air shutter set screw For ana INN UN excessive yellow flame you turn the air shutter to increase the air shutter opening For flame that lifts off the burner ports you Venturi Air Shutter turn air shutter to decrease the air shutter opening After adjusting the fuel mixture tighten the air shutter screw Flexible Metal Tubing Venturi 1 5 Finishing the Installation Now you can replace the face Do not forget an
20. y spacers you may have found between face and frame Cooking Grills Broilettes Briquet Grate Burner s Inner Liner Section View of Barbecue Interior The briquet grate goes on the first shelf above the burner s The briquet grate is the single grill piece Then the Broilettes are laid down Flame Broil barbecue units are equipped with stainless steel Broilettes No rock is used with Broilettes Your barbecue grill comes with sufficient Broilettes for efficient usage It is not necessary for the Broilettes to cover the entire briquet grate It is only important that the areas above the flames from the burners be covered Now place the two cooking grills on the top shelf If you purchased the oven accessory place the oven in the top shelf and the two cooking grills inside the oven You are ready to barbecue 2 Operation CAUTION Do not leave your barbecue equipment unattended after the burner has been lit Most fires and accidents occur when the unit has been left unattended while the flame is burning 2 1 Lighting the Burner Your barbecue equipment will have several knobs on the face for controlling the gas and lighting the gas The gas control knobs are labeled PUSH TO TURN in the center OFF at the twelve o clock position HIGH at the three o clock position and MED LOW at the six o clock position The rotary ignitor knobs are the smaller kno
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