Thermos Charcoal Grill 465630503 User Manual

Model Number 465630503  
Owner’s Manual  
Assembly, Operation,  
Use and Care  
Read and follow all safety  
statements, assembly  
instructions, and use and  
care directions before  
attempting to assemble  
and cook.  
WARNING  
Failure to follow all manufacturer’s instructions could  
result in fire or explosion which could cause property  
damage, personal injury or death.  
Installer/assembler:  
Leave these instructions  
with consumer.  
Consumer: Keep this  
manual for future  
reference.  
CAUTION  
Some parts may contain sharp edges – especially as  
noted in the manual! Wear protective gloves if necessary.  
Grill2Go-Express-E / 36-6047-050-208 (04-30-03)  
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LP (Liquefied Petroleum 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.  
CAUTION  
For residential use only. Do not use for commercial cooking.  
Call Grill Service Center for Help and Parts  
If you need help or warranty parts call 1-800-435-5194 U.S., 1-800-387-6057 CAN, or send a  
FAX to 1-706-576-6355. Business hours: Open 24 hours - Seven days a week.  
• To order non-warranty replacement parts or accessories (grill cover, 4’ adapter hose, carrying  
Installation Safety Precautions  
This grill is designed for use with LP (propane) gas. The regulator/valve supplied must be  
used. Replacement parts must be those specified by the manufacturer.  
Grill installation must conform with local codes, or in their absence with National Fuel Gas  
Code, NFPA 54 / ANSI Z223.1 or CAN/CGA-B149.2 Propane Installation Code. Handling  
and storage of LP cylinders must conform to LP Gas Code NFPA/ANSI 58. Grill is not to be  
installed in or on recreational vehicles and/or boats. 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 and Canada only. Do not modify for  
use in any other location. Modification will result in a safety hazard.  
This product is subject to patents pending in the U.S. and other countries.  
IMPORTANT: Fill out the warranty information below.  
Model Number  
Serial Number (on grill)  
Date Purchased  
Grill2Go Express • 3  
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Warranty  
Thermos 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) as follows:  
(1) The aluminized top and bottom for a period of three (3) years from date of purchase;  
excluding the paint finish;  
(2) The burner/venturi assembly for a period of three (3) years from date of purchase;  
(3) All other parts, for a period of one (1) year from date of purchase.  
Thermos will, at its option, refinish or replace any product or part found to be defective  
during the warranty period. Thermos 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:  
THERMOS GRILLS  
Consumer Warranty / P.O. Box 1240  
Columbus, GA 31902-1240  
Thermos may require reasonable proof of purchase and we suggest you keep your receipt.  
In the state of California only, if refinishing or replacement of the product is not commercially  
practicable, the retailer selling this product or Thermos 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 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. ALL  
IMPLIED WARRANTIES, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY  
AND FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED IN DURATION TO THE  
EXPRESS WARRANTY PERIODS SPECIFIED ABOVE FOR THE PARTS DESCRIBED  
THEREIN. Some states do not allow limitations on how long an implied warranty lasts, so the  
above limitation may not apply to you. Neither 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. Thermos' 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 l imitations or exclusions may not apply to you. The warranty gives you specific legal  
rights and may also have other rights which vary from state to state.  
4 • Grill2Go Express  
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Table of Contents  
For Your Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
Safety Symbols  
LP (Liquefied Petroleum Gas). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  
Grill Service Center  
Installation Safety Precautions  
Warranty Information  
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
Table of Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  
Parts Lists and Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 8  
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 15  
Use & Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 – 30  
1 lb. Disposable Propane Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16  
20 lb. Refillable Propane Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 – 20  
Safe Use of Your Grill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21  
Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22  
Lighting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 – 24  
Cleaning and Storing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 – 26  
Food Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27  
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28  
Grill2Go Express • 5  
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Parts List and Diagram – Grill Lid  
10  
F
A
B
6
11  
G
1
3
D
9
15  
7
16  
8
2
5
4
C
14  
E
13  
12  
Key Qty. Description  
Part No.  
Key Qty. Description  
Part No.  
A
B
C
D
E
F
1
2
1
1
1
1
Lid  
65-6047-063-202  
65-6047-093-200  
1
1
2
1
3
3
4
2
1
2
2
4
2
2
2
2
4
Coach Bolt  
Coach Bolt  
Washer  
41-9000-570-000  
41-9000-589-000  
42-9000-390-000  
42-9000-381-000  
43-9000-034-000  
42-9000-380-000  
13-6047-397-200  
13-6047-399-200  
41-9000-278-000  
41-9000-334-000  
41-9000-355-000  
42-9000-349-000  
Upper Hinge  
2
Handle Assembly 69-6047-057-200  
3
Upper Latch  
Heat Shield  
Torsion Bar  
65-6047-096-200  
21-6047-082-201  
65-6047-110-200  
4
Spring Washer  
Nut  
5
6
Spring Washer  
Side Spacer  
Center Spacer  
Self-Tap Screw  
Self-Tap Screw  
Self-Tap Screw  
Washer  
7
8
9
10  
11  
12  
13  
14  
15  
16  
Machine Screw 41-9000-709-000  
Nut  
43-9000-005-000  
42-9000-307-000  
Spring Washer  
Side Spacer Pin 13-6047-398-200  
6 • Grill2Go Express  
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Parts List and Diagram – Grill Bottom and Burner System  
I
21  
20  
J
K
L
W
M
N
19  
H
G
18  
X
17  
Q
Z
22  
V
O
23  
AA  
Key Qty. Description  
S
U
T
P
Y
R
Key Qty. Description  
Part No.  
Part No.  
G
H
I
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
Ignitor Wire  
69-6047-332-200  
69-6047-340-200  
65-6047-339-200  
21-6047-338-200  
69-6047-029-200  
V
1
1
1
1
1
1
Regulator/Valve 69-6047-031-200  
Side Shelf - Left 69-6047-008-200  
Side Shelf - Right 69-6047-009-200  
Regulator Lock  
Grate  
W
X
J
Collector Box  
Burner  
Y
Latch Clasp  
Venturi Guard  
Ignitor Shield  
11-6047-012-200  
21-6047-024-200  
21-6047-400-200  
K
L
Z
Lower Heat Shield 21-6047-023-201  
AA  
M
N
O
P
Q
R
S
T
U
Lower Hinge  
Grill Bottom  
Grease Bottle  
65-6047-095-200  
65-6047-064-204  
11-6047-020-200  
Key Qty. Description  
Part No.  
17  
18  
19  
20  
21  
22  
23  
2
4
2
1
1
4
1
Self-Locking Ring 42-9000-368-000  
Grease Bottle Rib 11-6047-085-200  
Grease Bottle Lid 13-6047-059-200  
Self-Tap Screw  
Hinge Pin  
41-9000-355-000  
41-6047-025-200  
Lower Latch  
Heat Indicator  
Sight Glass  
Ignitor  
65-6047-094-200  
69-6047-013-200  
69-6047-018-200  
69-6047-014-200  
Machine Screw 41-9000-088-000  
Nut  
43-9000-005-000  
41-9000-334-000  
42-9000-307-000  
Grill2Go Express • 7  
Self-Tap Screw  
Washer  
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Parts List and Diagram – Plinth and Legs  
KK  
37  
39  
NN  
38  
27  
35  
41  
OO  
LL  
HH  
BB  
CC  
40  
25  
28  
MM  
29  
26  
DD  
30  
31  
24  
FF  
33  
32  
34  
JJ  
EE  
GG  
36  
I I  
Key Qty. Description  
BB 1 Plinth  
Part No.  
Key Qty. Description  
Part No.  
Plastic Fasteners 11-6047-033-200  
Stand Offs 13-6047-026-200  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
4
4
4
1
1
1
1
2
2
1
5
64-6047-359-20  
11-6047-036-20  
11-6047-037-202  
21-6047-394-200  
21-6047-419-200  
11-6047-065-200  
63-6047-369-200  
69-6047-403-200  
24-6047-404-200  
21-6047-406-200  
21-6047-405-200  
CC 1 Leg - Left  
Coach Bolt Bracket 21-6047-021-200  
Stopper/Left Rear 22-6047-102-200  
Stopper/Left Front 22-6047-103-200  
Stopper/Right Rear 22-6047-104-200  
Stopper/Right Front 22-6047-105-200  
DD 1 Leg - Right  
EE 1 Leg Latch  
FF 1 Square Washer  
GG 4 Leveling Blocks  
HH 1 Match-Light Stick  
Washer  
Coach Bolt  
Coach Bolt  
Nut  
42-9000-391-000  
41-9000-588-000  
41-9000-570-000  
43-9000-034-000  
13-6047-088-200  
41-9000-694-000  
II  
2
1
Wheel  
Axle  
JJ  
KK 2 Handle Arm  
LL Handle  
1
35 16 Stand Off Pin  
MM 1 Handle Hub Front-LR 11-6047-401-200  
NN 1 Handle Hub Rear-RR 11-6047-402-200  
36  
37  
38  
39  
40  
41  
2
4
2
2
2
2
Long Screw  
Handle Hub Screw 41-9000-725-000  
OO 2 Handle Cap  
11-6047-407-200  
Short Screw  
Barrel  
41-9000-728-000  
41-9000-729-000  
41-9000-721-000  
11-6047-408-200  
Coach Bolt  
Bushing  
8 • Grill2Go Express  
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Assembly  
Your grill will require some assembly. You will need two flat or Phillips-head  
screwdrivers. The Grill2Go™ Express™ is packaged in three major components.  
Additional parts are stored beneath grill lid. Remove all protective packaging and  
product information cards before assembly.  
Spacer  
Grill  
Plinth  
NOTE: The rubber spacers on the  
grill lid help to protect the non-stick  
cooking surface and should not be  
removed.  
Legs  
Graphics  
in front  
Plinth is designed to fit into  
slots at each corner of legs.  
Plinth will only fit into legs  
correctly and easily when  
assembled as shown.  
Larger leg opening to right  
side during assembly.  
Grill2Go Express • 9  
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1. Assemble FRONT handle hub to leg as shown below.  
a. Insert “foot” into large hole.  
b. Press hub flat against leg.  
c. Align coach bolt hole with hole in aluminum block.  
d. Push long coach bolt through aluminum block on the back side of leg.  
e. Permanently attach hub to leg with two self-tapping handle hub screws. DO NOT  
OVERTIGHTEN SCREWS. Stripping may occur.  
Long coach bolt passes completely  
through holes in plinth and leg.  
Front Handle Hub (Part MM)  
Handle Hub  
Screw  
Graphics In Front  
Foot  
2. Assemble REAR handle hub to leg by repeating steps 1a–1e.  
Handle  
Hub Screw  
Rear Handle  
Hub (Part NN)  
Long coach bolt passes completely  
through holes in plinth and leg.  
Foot  
Graphics In Front  
10 Grill2Go Express  
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3. Assemble short coach bolts, washers, and plastic fasteners to plinth and legs as shown  
below.  
Short  
Coach  
Bolts  
Graphics In Front  
Plastic  
Fastener  
Washer  
4. Assemble handle as shown below with the short screws and barrels. Insert bushing with the  
shoulder out as shown in the detailed view.  
Handle  
Arm  
Handle  
Bushings  
Bushing  
Handle  
Cap  
Short  
Screw  
Barrel  
Handle  
Arm  
Grill2Go Express • 11  
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5. Assemble completed handle to plinth and legs as shown below with two plastic fasteners.  
NOTE: Do not fully tighten plastic fasteners at this time.  
Handle  
Assembly  
Plastic  
Fastener  
Graphics In Front  
NOTE  
Gently tap axle through leg with  
hammer if you have difficulty  
sliding the axle into the  
shown holes.  
Fully unfold legs to  
position shown below  
and hand-tighten the  
four plastic fasteners.  
Wheel  
Long  
Screw  
Axle  
Assemble wheels and axle  
as shown above.  
12 • Grill2Go Express  
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Grill fits firmly  
onto plinth.  
Tab on grill bottom  
snaps under front  
lip of plinth.  
Grease container slides  
onto slot on left side of  
plinth. Cap should be  
open when installing.  
Ignitor on grill bottom  
fits into slot in plinth.  
A Attach 1 lb. LP cylinder  
to regulator by twisting  
clockwise.  
NOTE: 1 lb. LP cylinder  
sold separately.  
Connect regulator to burner on right side  
of grill. Slide regulator lock to right to  
insert regulator. Regulator should rest  
firmly against burner.  
B
If necessary,  
loosen left  
fasteners, raise  
handle, and  
retighten  
Regulator lock  
should spring  
back to original  
position to lock  
regulator in  
fasteners.  
place.  
Grill2Go Express • 13  
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Insert shelf rods into holes in  
sides of grill bottom.  
Shelf with valve cutout attaches  
to right side of grill.  
WARNING  
Combustion by-products produced when using this product contain chemicals known  
to the State of California to cause cancer, birth defects, and other reproductive harm.  
14 • Grill2Go Express  
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Your Grill2Go™ Express™ can be used with the legs fully extended or folded beneath  
the grill. To use grill on a table-top, fully loosen plastic fasteners (A), fold legs inward  
until they latch together (B), then hand-tighten the fasteners to secure legs in the closed  
position (C).  
B
Fold right  
leg first  
Fold  
Second  
A
Counterclockwise  
Turn  
In order to use a long LP  
cylinder, the right side  
shelf must be removed  
and the bottle tilted to an  
angle of no greater than  
45 degrees.  
Turn Clockwise  
C
To transport your Grill2GoTM  
ExpressTM, loosen the left  
fasteners, rotate handle to  
position shown, then retighten  
fasteners.  
NOTE: Sideshelves and propane  
cylinder must be removed before  
transporting grill.  
Grill2Go Express • 15  
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Use and Care  
Propane Cylinder Use (1 lb. Disposable)  
Use only cylinder marked “Propane Fuel”.  
Size should be 4” diameter, 8” height, or 3” diameter, 10” height.  
Save cylinder cap and reinstall when not in use.  
Cylinder supply system must be arranged for vapor withdrawal. Gas cylinder must be upright  
in use.  
WARNING  
Use only 1 lb. propane bottles as specified above. Use of other gas bottles could  
cause gas leak or fire.  
Leak Testing (1 lb. Disposable) IMPORTANT!  
• During leak test, keep grill away from open flames or sparks and do not smoke. Grill must be  
leak tested outdoors in a well ventilated area.  
Leak test must be repeated each time gas cylinder is replaced or after storage.  
Materials needed include clean paint brush and 50/50 soap and water solution. Use mild soap  
and water. s Do not use household cleaning agents. Damage to components can result.  
1. Be sure control knob on regulator is in "OFF" position.  
2. Brush soapy solution onto connection between gas cylinder and regulator at (A).  
s If growing bubbles appear, there is a leak. Retighten connection  
and repeat steps 1 and 2  
A
If you cannot stop a leak, remove gas cylinder from regulator and  
check for damaged threads, dirt and debris on regulator and gas  
cylinder. Also check to see if anything is obstructing flow of gas at  
regulator and gas cylinder openings. Remove any obstruction that  
may be found and repeat leak test. If threads are damaged on  
either regulator or gas cylinder, replace. Order new parts by  
giving the serial, model number and name of items needed to the  
Grill Service Center at 1-800-435-5194 U.S. or 1-800-387-6057 CAN.  
16 • Grill2Go Express  
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Propane Cylinder Use (20 lb. Refillable)  
The 20 lb. LP tank used with your grill must meet the following requirements:  
Purchase LP tanks only with these required measurements:12" (30.5cm) (diameter) x 18"  
(45.7 cm) (tall) with 20 lb. (9 kg.) capacity maximum.  
Tank 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 B-339, cylinders,  
spheres, and tubes for transportation of dangerous goods, Transport Canada (TC). See LP  
tank collar for marking.  
LP tank valve must have:  
• Type 1 outlet compatible with adapter hose.  
• Safety relief valve.  
• UL listed Overfill Protection Device (OPD).  
This OPD safety feature is identified by a  
unique triangular hand wheel. Use only  
tanks equipped with this type of valve.  
Tank must be upright in use.  
OPD Hand Wheel  
• Supply system must be arranged for vapor withdrawal and include collar to protect LP tank  
valve.  
LP Tank Filling (20 lb. Refillable)  
Use only licensed and experienced dealers.  
LP tank must be purged before filling.  
Dealer should NEVER fill LP tank more than 80% of LP tank volume.  
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 department for  
assistance. Check the telephone directory under “Gas companies” for nearest certified LP  
dealers.  
LP Tank Exchange: You may choose to replace your empty LP tank through an exchange  
service. Use only those reputable exchange companies that inspect, precision fill, test and  
certify their cylinders. Exchange for OPD safety feature equipped tank as described in  
LP Tank.  
Always keep LP tank in upright position during use, transit or storage.  
Leak test LP tank BEFORE connecting to grill.  
DANGER  
• Do not store a spare LP gas cylinder under or near this appliance.  
• Never fill the cylinder beyond 80 percent full.  
• If the instructions above are not followed exactly, a fire causing death or serious  
injury may occur.  
Grill2Go Express • 17  
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Leak Testing (20 lb. Refillable) IMPORTANT!  
For your safety  
Leak test must be repeated each time LP tank is exchanged or refilled.  
Do not smoke during leak test.  
Do not use an open flame to check for gas leaks.  
Grill must be leak checked outdoors in 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.  
Use a clean paint brush and 50/50 soap and water solution. Use mild soap and water.  
s Do not use household cleaning agents. Damage to gas train components can result.  
Brush soapy solution onto the shaded areas shown below (A).  
CAUTION  
A
If “growing” bubbles appear do not use or move  
the LP tank. Contact an LP gas supplier or your  
fire department.  
Connecting The Adapter Hose (sold separately) To The LP Tank  
1. Use only adapter hose approved by safety testing  
Off Clockwise  
organizations (CSA, UL, etc).  
OPD Hand  
Wheel  
2. Turn all control knobs 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 thread  
on outside.  
(This section continued on next page.)  
Safety relief valve  
Use of this POL transport plug  
(plastic part with external threads)  
will defeat safety feature of valve.  
Strap and cap  
18 • Grill2Go Express  
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Connecting The Adapter Hose To The LP Tank (continued)  
5. Hold hose end, insert nipple (A) into LP tank valve. Hand tighten coupling nut,  
holding connector in a straight line (B) with LP tank valve so as not to cross thread  
the connection.  
Nipple must be centered  
into the LP tank valve.  
B
A
Coupling nut  
Position coupling nut  
and hose-end as shown  
for proper connection to  
LP tank valve.  
6. Turn the coupling nut clockwise to tighten to a full solid stop. The hose-end 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 connection. Tighten by hand  
only - do not use tools.  
NOTE: If you cannot complete connection, disconnect hose-end and repeat steps 5 and 6. If  
you are still unable to complete the connection, do not use this connector!  
Hose Check  
Before each use, check to see if hose is cut or worn. Replace damaged hose before using grill.  
Use only hose specified by manufacturer.  
WARNING  
• 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.  
• Never attempt to attach this grill to the self-contained LP gas system of a camper  
trailer or motor home.  
Grill2Go Express • 19  
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WARNING  
• Do not use grill until leak checked.  
• If 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!  
Leak Testing Valves, Hoses and Regulator  
1. Turn grill control knob to off.  
2. Be sure connector is tightly connected to LP tank.  
3. Completely open LP tank valve by turning hand wheel counter clockwise. 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 following connections:  
LP tank valve  
connection  
Regulator connection  
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 1-800-435-5194 U.S. or 1-800-387-6057 CAN.  
6. Always close LP tank valve after performing leak test by turning hand wheel clockwise.  
20 • Grill2Go Express  
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WARNING  
For Safe Use Of Your Grill:  
Do not leave the appliance  
unattended. Keep children and pets  
away from the appliance at all  
times.  
Never use regulator from this grill  
with any other LP appliance.  
When cooking, the appliance must  
be on a level surface in an area  
clear of combustible material.  
Do not block holes in bottom or  
back of grill.  
A
3 ft. (1m) minimum  
10 ft. recommended  
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 a  
surface that can catch fire.  
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.  
B
• Do not use charcoal in a gas grill.  
• This appliance is not intended for  
and should never be used as a  
heater.  
3 ft. (1m) minimum  
10 ft. recommended  
• Operate grill with 1 lb. cylinder in  
correct position as shown in A.  
• Always remove 1 lb. cylinder  
from grill when transporting.  
• Operate grill with 20 lb. cylinder  
in correct position as show in B.  
• Always remove 20 lb. cylinder  
from grill when transporting.  
Grill2Go Express • 21  
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Safety Tips  
s The use of alcohol, prescription or nonprescription drugs may impair the consumer’s ability  
to properly assemble or safely operate the appliance.  
s When grill is not in use, disconnect 1 lb. cylinder or turn off 20 lb. cylinder.  
s Never move grill while in operation or still hot. Allow the appliance to cool before moving or  
storing.  
s Use only tools supplied or plastic tools.  
s Maximum load for side shelf is 10 lbs.  
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.  
s Light burners (see lighting instructions on following page). Check to make sure they are lit,  
close the lid and warm up grill on high for 10 minutes. Curing of paint and parts will  
produce an odor only on first lighting.  
22 • Grill2Go Express  
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Ignitor Check  
Regulator/Valve must be in “Off” position. Remove cooking grid. Press ignitor button  
rapidly. “Click” should be heard and spark seen each time between burner and electrode.  
Replace cooking grid. See Troubleshooting if no click or spark.  
Ignitor Lighting  
1. Push regulator/valve counterclockwise to “PUSH TO TURN ON” (A), push in, then turn  
to “LIGHTING POSITION” (B).  
2. Push ignitor button rapidly to light. Use viewing glass (C) to be sure burner lights  
and stays lit.  
3. If ignitor does not work, follow match lighting instructions.  
A
Regulator/Valve  
OFF  
ARRET  
B
C
Viewing  
glass  
Grill2Go Express • 23  
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Vent hole  
MatchLighting  
1. Push Regulator/Valve in and turn  
counterclockwise to LIGHTING  
POSITION.  
2. Attach match to match lighting stick,  
light match.  
3. Insert match lighting stick into vent  
hole at rear of grill.  
WARNING  
If burner does not light within 5 seconds, turn knob to OFF, wait 5 minutes, try again.  
Burner Flame Check  
Light burner. Look through viewing glass on front of grill and make  
sure burner stays lit while rotating the regulator knob from HIGH to  
LOW. Always check flame prior to each use.  
Before Your First Cookout.  
Leak test your grill. Light burners, check to make sure they are lit, close the lid and warm up  
grill on HIGH for 10 minutes. Curing of paint and parts will produce an odor only on first lighting.  
Turning Grill Off  
• Turn knob to OFF position. Make sure regulator/valve pops up. If it does not, discontinue  
use and order new part.  
• Disconnect 1 lb. cylinder or turn off valve on 20 lb. cylinder.  
Heat Indicator  
Cooking Zone  
Indication of warming  
up or cooling down.  
Too hot. Will damage  
non-stick surface.  
24 • Grill2Go Express  
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LevelingGrillforGreaseDrainage  
• For proper grease drainage, the grill should be level left to right and angled slightly to the  
front. The bubble level on the plinth will indicate whether or not grill is level.  
• If ground is uneven, use leveling blocks provided and place as needed under feet to level the  
grill. In soft ground, such as beach sand, press the angled feet into ground to level the grill.  
Air Bubble  
Leveling Blocks  
Bubble Level  
Indicator  
GeneralGrillCleaning  
• 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.  
Plastic Side Shelves: Wash with warm soapy water and wipe dry. s Do not use citrisol,  
abrasive cleaners, degreasers or a concentrated grill cleaner on plastic side shelves.  
Damage to and failure of shelves can result.  
• Non-Stick Cooking Surface: Turn grill off before cleaning. While still warm, pour a cup of  
water over cooking surface to loosen grease and food particles and to speed cool-down.  
Use supplied cleaning comb to scrape off excess grease and food particles. Wipe cooking  
surface with a paper towel or sponge. Once completely cool, cooking surface can be  
removed and washed with warm soapy water or placed in dishwasher.  
• Grease Bottle: After each use, remove bottle and rinse with hot soapy water.  
Grill2Go Express • 25  
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CAUTION  
Clean burner prior to use after storing, at the beginning of grilling season or after a period of  
one month not being used. Spiders and insects like to build nests in burner tubes (especially  
during colder months). These nests can cause fires in burner tubes or under grill.  
Typical spider webs inside burner.  
Cleaning the Burner Assembly.  
1. Turn gas off at control knob and LP tank.  
2. Remove cooking surface.  
3. Remove regulator/valve from grill.  
4. Clean outside of burner with soap and water. Open clogged holes with a thin wire.  
Examine holes. Due to normal wear and corrosion some holes may become enlarged. If any  
large cracks or holes are found, replace burner. Burner can be cleaned either installed or  
removed.  
5. If grill is to be stored, coat burner lightly with cooking oil. Wrap in protective cover to keep  
insects out.  
6. Replace cooking surface.  
VERY IMPORTANT: Before cooking again on grill, follow Burner Flame Check and  
warnings on pages 2 and 19.  
Non-Stick Cooking Surface Use and Care.  
• Use only plastic tools.  
• Do not cut food on surface.  
• Do not put pots or pans on surface.  
• Do not leave lid down for more than 10 minutes without food on the grill.  
Non-stick surface may be damaged.  
Storing Your Grill  
• Clean cooking surface and grease container.  
• When LP tank is connected to grill, store outdoors in well-ventilated space and out of reach  
of children.  
• Cover grill if stored outdoors.  
• Store grill indoors ONLY if LP tank is turned off and disconnected, removed from grill and  
stored outdoors in well-ventilated space and out of reach of children.  
• Leak test the grill after removing from storage and follow Cleaning Burner Assembly  
instructions before starting grill.  
26 • Grill2Go Express  
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Food Safety  
Food safety is an 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 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.  
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. NOTE: Do not cut into food while it is on the grill’s  
cooking surface. This may damage the cooking surface. Move food to a plate to check,  
then return it to the cooking surface if necessary.  
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, lamb, steaks, roasts and chops can be cooked to  
145° F. All cuts of pork should reach 160° F.  
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.  
Grill2Go Express • 27  
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Troubleshooting  
Problem  
Possible Cause  
Prevention/Cure  
Wipe dry with cloth.  
Replace electrode.  
Burner will not  
light using  
ignitor.  
Electrode and burner are wet.  
Electrode cracked or broken,  
"sparks at crack".  
Wire is loose or disconnected.  
Reconnect or replace ignitor wire.  
Reconnect or replace ignitor wire.  
Wire is shorting (sparking)  
between ignitor and electrode.  
Bad ignitor.  
Replace ignitor.  
No gas flow.  
Check gas source.  
Clear burner.  
Burner will not  
match light.  
Obstruction of gas flow.  
Does valve cap stay down.  
Replace with Thermos parts.  
Disengagement of burner to  
valve.  
Check steps in assembly  
instructions.  
High or gusting winds.  
Burner is blocked.  
Turn front of grill to face wind or  
increase flame height.  
Flames blow out.  
Clean burner.  
Flashback (fire in  
burner tube)  
28 • Grill2Go Express  
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Recreational Vehicles  
THERMOS GRILLS has approved use of the Grill2Go™ with specific recreational vehicles  
subject to the following provisions:  
• The Grill2Go™ is to be directly connected to an additional 20 lb. or 30 lb. DOT/TC LP tank  
mounted on the RV. The Grill2Go™ cannot be attached to any part of the gas system of the  
RV except directly to the tank itself.  
• The additional 20 lb. or 30 lb. tank is available from your RV dealer and must be mounted on  
the RV complying with approved RV standards.  
• The connection from the tank to the grill must be with a minimum 15’ approved hose  
available from your RV dealer.  
• The Grill2Go™ must always be operated at least 10’ from the body of the RV.  
• Never use the Grill2Go™ in an enclosed space or under a surface such as an awning or a  
screen room or fire could result.  
Grill2Go Express • 29  
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30 • Grill2Go Express  
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Grill2Go Express • 31  
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®
A Division of W.C. Bradley Company  
P.O. Box 1240  
Columbus, GA 31902–1240  
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 and D461,359. Canada: 87743; 87744; 92607; 92608 and 1,316,424.  
Other Patents Pending.  
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