Thermos 461644304 Gas Grill User Manual
Contents
1. 6 If ignitor does not work follow match lighting instructions 461644304 N 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 Match Lighting A Do not lean over grill while lighting 1 Open lid Turn on gas at LP tank 2 Place lit match into match lighting hole beneath grill bottom as shown below 3 Push in and turn RIGHT knob toO Ignite Be sure burner lights and stays lit 4 Light left burner by turning LEFT knob to Wak Ignite Before Your First Cookout e Light burners check to make sure they are lit then close the lid and warm up grill on th High for 15 minutes Curing of paint and parts will produce an odor only on first lighting Do not warm up grill with knobs on wt Ignite Knobs and handle may become uncomfortably hot if knobs are left on Ignite Burner Flame Check e Remove cooking grate and VapoRISER Bar Light burner rotate knobs from W High to amp Low You should see a smaller flame in Low position than seen on High Always check flame prior to each use If only low flame is seen refer to Sudden drop or low flame in the Troubleshooting Section High Low otID gt 0dr gt cD gt 0D gt cD gt 0D gt 8 461644304 Turning Grill Off e Turn all knobs to OFF posit2. 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 4 Remove the protective cap from LP tank valve Always use cap and strap supplied with valve Type 1 outlet with ihreadon outside Strap and Cap Do not use a POL transport plug plastic part with external threads It will defeat the safety feature of the valve 5 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 461644304 5 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 conn
3. dealers have older fill nozzles The worn nozzles don t have enough bite to engage the valve Try with worn threads a second LP dealer 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
4. load for side shelves is 10 Ibs A The grease cup must be attached to grease clip and emptied after each use Do not remove grease cup until grill has completely cooled A Ifyou 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 A Keep grill cart free and clear of debris A The regulator may make a humming or whistling noise during operation This will not affect safety or use of grill A If you have a grill problem see the Troubleshooting Section e Putting out grease fires by closing the lid is not possible Grills are well ventilated for safety reasons e 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 Ignitor Lighting A Do not lean over grill while lighting 1 Open lid Turn on gas at LP tank 2 Turn LEFT knob to pil Ignite 3 Push ignitor button rapidly up to 5 times to light Be sure burner lights and stays lit 4 If burner does not light turn knob s to OFF wait 5 minutes then try again 5 Turn RIGHT knob to Ignite to light right burner
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 6 173 644 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 461644304 11 THERMOS A Division of W C Bradley Co Columbus GA 31902
6. THERNOS 461644304 USE amp CARE MANUAL THIS GRILL IS FOR OUTDOOR USE ONLY CAUTION Read and follow all safety statements assembly instructions and use and care directions before attempting to assemble and cook INSTALLER ASSEMBLER Leave these instructions with consumer CONSUMER Keep this manual for future reference Read this manual before cooking on grill Failure to follow all manufacturer s instructions could result in fire or explosion which could cause property damage personal injury or death 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 461644304 Use amp Care 80000790 09 16 03 FOR YOUR SAFETY 1 Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance 2 An LP tank not connected for use shall not be stored in the vicinity of this or any other appliance FOR YOUR SAFETY If you smell gas 1 Shut off gas to the appliance 2 Extinguish any open flame 3 Open lid 4 If odor continues immediately call your gas supplier or your fire department Call Grill Service Center For Help And Parts e If you need help or warranty parts call 1 800 241 7548 or send a FAX to 1 706 576 6355 Business hours Open 24 hours Seven days a week T
7. d 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 e Whole poultry should reach 180 F breasts 170 F Juices should run clear and flesh should not be pink e 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 e NEVER partially grill meat or poultry and finish cooking later Cook food completely to destroy harmful bacteria e When reheating takeout foods or fully cooked meats like hot dogs grill to 165 F or until steaming hot Troubleshooting Problem Possible Cause Prevention Solution Burner s will not light e Wire and or electrode covered with e Clean wire and or electrode with rubbing alcohol and clean swab using ignitor cooking residue Electrode and burner are wet e Wipe dry with cloth Electrode cracked or broken sparks at e Replace electrode crack e Wire is loose or disconnected e Reconnect wire e Wires are shorting sparking between Replace ignitor wire electrode assembly ignitor and electrode e Bad Ignitor e Replace ignitor Burner s will not No gas flow e Check to see if LP tank is empty If LP tank is not empty refer to match light Sudden drop in gas flow Coupli
8. ection 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 Do not insert any foreign objects into the valve outlet You may damage the valve and cause a leak Leaking propane may result in explosion fire severe personal injury or death e 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 Ifa leak is detected at any time STOP and call the fire department Rear view of grill e 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 6 Always close LP tank valve after performing leak test by turning hand wheel clockwise 6 461644304 For Safe Use Of Your Grill And To Avoid Serious Injury Do not let children operate or play near grill e Keep grill area clear and free from materials that burn e Do not block holes in bottom or bac
9. ed measurements 12 30 5cm diameter x 18 45 7 cm tall with 20 Ib 9 kg capacity maximum e LP tanks must be constructed and marked in accordance with specifications for LP tank of the U S Department of Transportation DOT See LP tank collar for marking e LP tank valve must have e Type 1 outlet compatible with regulator or grill e Safety relief valve i T e UL listed Overfill Protection ne A This OPD safety ORD Mand Wha feature is identified by a unique triangular hand wheel Use only LP tanks equipped with this type of valve e LP tank must be arranged for vapor withdrawal and include collar to protect LP tank valve LP Liquefied Petroleum Gas e 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 e LP gas is highly flammable and may ignite unexpectedly when mixed with air LP Tank Filling e Use only licensed and experienced dealers LP dealer must purge new tank before filling e Dealer should NEVER fill LP tank more than 80 of LP tank volume Volume of propane in tank will vary by temperature e 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 To remove gas from LP tank contact an LP dealer or call a local fire departmen
10. from the safety relief valve e 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 NEVER store a spare LP tank under or near grill or in enclosed areas e If you see smell or hear escaping gas immediately get away from the LP tank grill and call your fire department All spare LP tanks must have safety caps installed on the LP tank outlet LP Tank Removal Transport And Storage e 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 Tank Valve Safety Cap Retainer Strap e Adisconnected 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 4 461644304 LP Tank e The LP tank used with your grill must meet the following requirements e Use LP tanks only with these requir
11. ion Turn LP tank off by turning hand wheel clockwise to a full stop Ignitor Check e Turn gas off at LP tank Press ignitor button rapidly Click should be heard and spark seen each time between collector box or burner and electrodes See Troubleshooting if no click or spark Valve Check e 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 Low position then turn back to OFF position Valves should turn smoothly Hose Check e 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 General Grill Cleaning 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 e Plastic parts Wash with warm soapy water and wipe dry A Do not use citrisol abrasive cleaners degreasers or a concentrated grill cleaner on plastic parts Damage to and failure of parts can result e Porcelain surfaces Because of glass
12. k of grill e Check burner flames regularly 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 e Do not use charcoal or ceramic briquets in a gas grill Unless briquets are supplied with your grill e 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 ES Son Apartment Dwellers 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 NEVER attempt to light burner with lid closed A buildup of non ignited gas inside a closed grill is hazardous e Never operate grill with LP tank out of correct position specified in assembly instructions e Always close LP tank valve and remove coupling nut before moving LP tank from specified operation position Safety Tips A Before opening LP tank valve check the coupling nut for tightness A When grill is not in use turn off all control knobs and LP tank valve A Never move grill while in operation or still hot A Use long handled barbecue utensils and oven mitts to avoid burns and splatters A Maximum
13. like composition most residue can be wiped away with baking soda water solution or specially formulated cleaner Use nonabrasive scouring powder for stubborn stains e Painted surfaces Wash with mild detergent or nonabrasive cleaner and warm soapy water Wipe dry with a soft nonabrasive cloth NATURAL HAZARD e 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 burners prior to use after storing at the B beginning of grilling season or after a period is of one month not being used QA 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 2 Burner s will not light 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 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
14. ng nut and regulator not fully e Turn the coupling nut about one half to three quarters additional connected turn until solid stop Tighten by hand only do not use tools Obstruction of gas flow e Clear burner tube s Disengagement of burner to valve e Reengage burner and valve e Is grill assembled correctly e Check steps in assembly instructions Sudden drop in gas Out of gas e Check for gas in LP tank flow or low flame e Excess flow valve tripped e 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 e High or gusting winds e Turn front of grill to face wind or increase flame height e Low on LP gas Refill LP tank e Excess flow valve tripped e Refer to Sudden drop in gas flow above Flare up e Grease buildup Clean grill e Excessive fat in meat Trim fat from meat before grilling e Excessive cooking temperature Adjust lower temperature accordingly Persistent grease fire Grease trapped by food buildup around e Turn knobs to OFF Turn gas off at LP tank Leave lid in position and burner system let fire burn out After grill cools remove and clean all parts Flashback e Burner and or burner tubes are blocked e Turn knobs to OFF Clean burner and or burner tubes fire in burner tube s Unable to fill LP tank Some
15. nozzle through burner tubes to clean them Storing Your Grill Clean cooking grates Store in dry location 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 e Store grill indoors ONLY if LP tank is turned off and disconnected removed from grill and stored outdoors e When removing grill from storage follow Cleaning the Burner Assembly instructions before starting grill Cleaning The Burner Assembly Follow these instructions to clean and or replace parts of burner assembly or if you have trouble igniting grill i 8 Turn gas off at control knobs and LP tank Remove cooking grate VapoRISER Bar and grease cup Disconnect ignitor wire from burner electrode and remove the two burner screws from beneath grill bottom Carefully lift burner assembly up and away from valves Clean ceramic portion of electrode with rubbing alcohol and a swab Clean outside of burner with soap and water Lay burner upside down on a flat surface insert garden hose to force water through tubes Make sure water comes out of all burner holes Open clogged holes with a thin wire Shake out excess water and examine holes Due to normal wear and corrosion some holes may become enlarged If any large cracks or holes are found replace burner If grill is to be stored coat burner ligh
16. o order non warranty replacement parts or accessories grill cover cleaners paint call 1 800 993 2677 or send a FAX to 1 706 565 2121 IMPORTANT Fill out the product record information below Model Number Serial Number See rating label on grill for serial number Date Purchased For residential use only Do not use for commercial cooking 2 461644304 Installation Safety Precautions e Use grill only with LP propane gas and the regulator valve assembly supplied e Grill installation must conform with local codes or in their absence with National Fuel Gas Code NFPA 54 ANSI 2223 1 Handling and storage of LP cylinders must conform to LP Gas Code NFPA ANSI 58 Grill is not for use in or on recreational vehicles and or boats All electrical accessories such as rotisserie must be electrically grounded in accordance with local codes or National Electrical Code ANSI NFPA 70 Keep any electrical cords and or fuel supply hoses away from any hot surfaces This grill is safety certified for use in the United States only Do not modify for use in any other location Modification will result in a safety hazard e Safety Symbols The symbols and boxes shown below explain what each heading means Read and follow all of the messages found throughout the manual DANGER Indicates an imminently hazardous situation which if not avoided will re
17. sult in death or serious injury WARNING Be alert to the possibility of serious bodily injury if the instructions are not followed Be sure to read and carefully follow all of the messages 2 gt CAUTION Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury WARRANTY Manufacturer warrants to the original consumer purchaser that this product shall be free from defects in workmanship and materials under normal and reasonable use and correct assembly if assembled by consumer purchaser for a period of one 1 year from date of purchase Manufacturer will at its option replace any product or part found to be defective during the warranty period Manufacturer will require you to return the part s claimed to be defective for its inspection freight or postage prepaid If you wish to obtain performance of any obligation under this limited warranty you should write to Consumer Warranty P O Box 1240 Columbus GA 31902 1240 Manufacturer may require reasonable proof of purchase and we suggest you keep your receipt In the state of California only if replacement of the product is not commercially practicable the retailer selling this product or 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 nonconformi
18. t for assistance Check the telephone directory under Gas Companies for nearest certified LP dealers LP Tank Exchange e 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 e Always keep new and exchanged LP tanks in upright position during use transit or storage Leak test new and exchanged LP tanks BEFORE connecting to grill LP Tank Leak Test For your safety e Leak test must be repeated each time LP tank is exchanged or refilled e Do not smoke during leak test Do not use an open flame to check for gas leaks e 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 e Use a clean paintbrush and a 50 50 mild soap and water solution Brush soapy solution onto areas indicated by arrows in figure below A Do not use household cleaning agents Damage to gas train components can result If growing bubbles appear do not use or move the LP tank Contact an LP gas supplier or your fire department Connecting Regulator To The LP Tank 1 LP tank must
19. tly with cooking oil Wrap in protective cover to keep insects out If not storing grill after cleaning replace burner into grill bottom VERY IMPORTANT Burner tubes must reengage valve openings See illustrations below Attach burner to grill bottom with screws and attach ignitor wire to burner electrode Reposition VapoRISER Bar and cooking grate Attach clean grease cup beneath grill bottom Before cooking again on grill perform a Leak Test and Burner Flame Check Do not use ceramic briquets or charcoal in your gas grill Proper valve burner tube engagement Burner Tube 461644304 9 Food Safety 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 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 Cook Cook meat and poultry thoroughly to kill bacteria Use a thermometer to ensure proper internal food 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 10 461644304 How To Tell If Meat Is Grilled Thoroughly e Meat an
20. ty In addition in the state of California only you may take the product to the retail establishment from which it was purchased or to any retail establishment selling this product in order to obtain performance under this warranty This warranty does not include the cost on any inconvenience or property damage due to failure of the product and does not cover damage due to misuse abuse accident damage arising out of transportation of the product or damage incurred through commercial use of the product 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 Neither Manufacturer dealers nor the retail establishment selling this product has any authority to make any 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 Some states do not allow the exclusion or limitation of incidental or consequential damages So the above limitations or exclusions may not apply to you This warranty gives you specific legal rights and may also have other rights which vary from state to state 461644304 3 USE AND CARE e Never fill the cylinder beyond 80 full An overfilled spare LP tank is hazardous due to possible gas released
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