[CEN 025] G50205 BBQ Manual E 11/4/05 6:54 PM Page i
SERIAL #:
Barbecue Stainless 4000
S A F E U S E , C A R E A N D A S S E M B L Y M A N U A L
F O R Y O U R S A F E T Y
If You Smell Gas
1. Immediately turn off the flow
of gas to the unit.
2. Extinguish any open flame.
3. Open the lid of the unit.
4. If the odour does not stop quickly,
immediately call your gas supplier
or Fire Department for assistance.
F O R Y O U R S A F E T Y
1. Do not store or use gasoline or other
flammable vapours and liquids in the
vicinity of this or other appliance.
2. An LP Gas cylinder not connected for
use shall not be stored in the vicinity
of this or other appliance.
W A R N I N G
Failure to follow all of the manufacturer’s
instructions could result in hazardous
fires, explosions, property damage,
or serious personal injury or even death.
5 - Y E A R L I M I T E D W A R R A N T Y
W A R N I N G
Follow all leak check procedures carefully prior
to operation of barbecue, even if barbecue
was stored assembled. Do not try to light
this barbecue without reading the Lighting
Instructions section of this manual.
8 5 - 1 1 0 2 ( P R O P A N E ) ( G 5 0 2 0 5 )
8 5 - 1 1 0 6 - 2 ( N A T U R A L G A S ) ( G 5 0 2 0 7 )
Read and save this manual for future reference.
If pre-assembled, leave this manual with
unit for consumer’s future reference.
T H I S B A R B E C U E I S F O R
O U T D O O R U S E O N L Y
For product inquiries, parts, warranty
and troubleshooting support, please call
1-877-707-5463
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[CEN 025] G50205 BBQ Manual E 11/4/05 6:54 PM Page 1
I N S T A L L A T I O N
I N F O R M A T I O N
The installation of this appliance must be in accordance with all local codes, or in the
absence of local codes:
•
Canadian installation must conform to the current national standards, which at this time
are CAN/CGA-B149.1/2-Natural Gas/Propane installation code.
A D D I T I O N A L
W A R N I N G S
Minimum clearance to adjacent combustible materials:
•
76 cm (30˝) from furthest protruding edge on side of barbecue.
•
76 cm (30˝) from furthest protruding edge on back of barbecue.
See Drawing A
•
Always keep the area around this barbecue clean and clear of any and all combustible
materials such as gasoline or other inflammable liquids, paper or oily rags.
•
Do not operate this barbecue under any overhanging or unprotected construction.
•
Remember this barbecue is for outdoor use only and is not for use on any boat or
recreational vehicle.
•
Use this barbecue outdoors in a well-ventilated area and at least
3 m (10’) from any dwelling or other building.
•
Do not use in garages, or any other enclosed area.
•
Do not leave your barbecue unattended while in operation.
•
Do not obstruct the flow of combustion and ventilation air to the barbecue.
•
Do not use while under the influence of drugs or alcohol.
Minimum clearance of 76 cm (30”)
on both sides and back of the barbeque.
•
Do not store any spare L.P. (propane) cylinders, full or empty,
under or near your barbecue.
•
Drawing A
Do not allow children or pets to play anywhere near the barbecue.
U S E O F L P G A S C Y L I N D E R
The self-contained (propane) gas system barbecue is designed to be used with only a 9.1 kg
(20 lb) propane cylinder equipped with a type-1 cylinder valve. This barbecue cannot be
connected to an existing #510 P.O.L. type valve cylinder (which has left-handed threads).
Self-contained
Propane Gas System
Do not connect to a propane gas cylinder exceeding 9.1kg capacity or use a cylinder
with any other type of cylinder valve connection device.
The Type-1 valve can easily be recognized by the large external thread on the outside of the
valve. Older existing valves do not have this outer external thread. Any attempt to connect
a regulator to any connector other than the mating Type-1 connector (which comes with a
large, black coupling nut such as the #510 P.O.L.) could result in fires, injuries or property
damage, and could reduce the effectiveness of the important safety features built into the
Type-1 system. Also connecting the #510 P.O.L. fitting to the cylinder will negate the flow
control and the temperature shut-off features built into the new Type-1 connection system.
•
The cylinder should not exceed 472 mm (18 1/2˝) in height and
317 mm (12 1/2˝) in diameter.
When purchasing a cylinder for your barbecue, it must be constructed and marked
as meeting the specifications of:
•
Canada: Transport Canada.
1
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[CEN 025] G50205 BBQ Manual E 11/4/05 6:54 PM Page 2
The Cylinder must also be equipped with:
•
A shut-off valve with a correct cylinder valve outlet as specified in current standards.
Canada: CAN/CGA 1.6g-M97 Outdoor Gas Grilles.
•
a) A safety relief valve with direct connection to the vapour space of the cylinder.
b) A collar to protect the tank shut-off valve.
c) A device for vapour withdrawal.
d) A ring on the bottom to secure the tank to its support assembly.
•
Always turn off the cylinder valve completely when the barbecue is not in use.
•
Always handle the tank valve with utmost care.
•
Never connect an unregulated L.P. gas cylinder to the barbecue.
•
Always keep the cylinder, in use, securely fastened in an upright position.
•
Never store a spare cylinder, empty or full,
near or under the barbecue when in operation.
•
Never expose the cylinders to direct sunlight or excessive heat.
•
Never insert any kind of object into the valve outlet as this may damage the backcheck;
a backcheck that is damaged can leak, and a leaking propane cylinder can result in fires
or explosions, property damage, severe injuries or death.
T R A N S P O R T A T I O N
A N D S T O R A G E
The propane cylinder is totally safe when handled properly, but if misused, the result could
be an explosion or fire resulting in serious personal injury and/or property damage.
O F T H E L P C Y L I N D E R
To Avoid Unnecessary Risks
•
Always recap the cylinder with the cap provided when not connected to the barbecue.
•
Do not store the cylinder in any enclosed area such as a garage, and make sure the
storage area has lots of ventilation.
•
Do not store the cylinder near any appliances, or in any areas that may become hot,
such as the trunk of a vehicle.
•
Make sure the cylinder is out of reach of children.
•
When transporting or storing the cylinder, make sure it is in an upright position and
not on its side.
•
Do not smoke around the cylinder, especially when transporting it in a vehicle.
F I L L I N G T H E
L P C Y L I N D E R
The cylinder must be filled prior to use and must have the air purged. For safety, follow
these instructions when having your cylinder filled:
•
Have only your local qualified LP gas dealer fill or repair a cylinder.
•
Do not overfill the cylinder beyond the safe 80% fill level.
•
Make sure the dealer tests and checks the cylinder for leaks after filling.
W A R N I N G
If the above instructions are not completely adhered to,
it could cause a fire/explosion, resulting in death or serious Injury,
or property damage.
2
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[CEN 025] G50205 BBQ Manual E 11/4/05 6:54 PM Page 3
P R I O R T O U S I N G
Do not use your barbecue until you have carefully read and fully understand all the information
in this manual. Please ensure the following:
•
Your barbecue is properly assembled.
•
There are no leaks in the system (see “Leak Test”).
•
The burner is properly assembled, with the Venturi tubes seated over the valve outlets
(Drawing E) and that there is nothing blocking the Venturi tubes (Drawing F).
•
Ensure that all power cords and/or gas supply hoses will not touch or be
near surfaces that will get hot.
•
The barbecue is in a safe location (see Installation).
Insert valve outlets into Venturi tubes
approximately 6 mm (1/4”)
Ensure that the valve outlets (orifices) are assembled into the Venturi tubes approximately
6 mm (1/4˝) and that the valve outlets and Venturi tubes are approximately parallel to the
bottom of the lower body.
Drawing E
W A R N I N G
During shipment or storage, it’s possible that small insects like spiders could
find their way into the Venturi tubes and nest or make webs. This could block
the flow of gas through the Venturi tube causing a smoky yellowish flame, or
prevent a burner from lighting. It could even cause the gas to burn outside the
Venturi tube, which could seriously damage your barbecue. If these occur, turn
off the gas flow and wait for the barbecue to cool down. When the barbecue
has cooled, remove the burner and clean out the Venturi tubes with a brush or
pipe cleaner. Replace the burner and ensure that the Venturi tubes are seated
over the orifice located on the gas valves. Cleaning the Venturi tubes should be
conducted periodically, especially at the start of the season.
Natural Hazards
Insects and Spiders
Note: Damage resulting from blocked Venturi tubes is not covered under
Drawing F
the warranty.
Orifice Size: The orifice, in conjunction with the control valve, acts to regulate and restrict
the amount of gas delivered to the burner. The hole size in the orifice varies by the gas sup-
ply pressure and by the BTU rating of the burner. Grills equipped for LP gas operate at a
much higher gas pressure and therefore have a smaller size orifice.
Hose and Regulator Inspection
Adjustment: The regulator is factory set at a specified outlet pressure of 11” of water column
and is generally factory sealed and not adjustable. Do not try to adjust. The regulator can be
checked by measuring the pressure with a manometer.
Vent Hole: There is a vent hole on top of the regulator. Check that it is clear of dirt and
debris. If the hole is plugged, erratic and dangerous burning may result.
O-ring Seal: Before attaching the regulator to the cylinder, inspect the rubber O-ring on
the P.O.L. fitting. Do not operate the grill if the O-ring is damaged or missing. Seal damage
is common and we recommend replacement of the seal when the burner is replaced or
when the seal is damaged. Cracks, splits or distortion will allow gas to escape. Additionally,
the seal should be soft, pliable, and protrude slightly from the brass P.O.L. valve.
Chew Marks: The hose should be kept clean of grease and food drippings which attract
squirrels and other animals. The animals will often eat the drippings on the hose and chew
into the hose lining trying to get the last taste. Try cleaning the hose with an ammonia
cleaner solution to minimize the attration.
3
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[CEN 025] G50205 BBQ Manual E 11/4/05 6:54 PM Page 4
S A F E T Y H O S E
Propane Gas Models: Your barbecue is designed to operate on L.P. (Propane) gas at a
pressure of 2.74 Kpa (11˝ water column). A regulator preset to this pressure is supplied
with the barbecue and must be used.
A N D R E G U L A T O R
This regulator is equipped with the Type-1 quick-closing connecting system, which incor-
porates these safety features:
•
Will not allow gas to flow until a positive seal has been made.
•
Has a thermal component that will automatically shut off
the flow of gas between 115-150ºC (240-300ºF).
•
Has a flow limiting feature, which will restrict the flow of gas
to 10 cubic feet/hour.
Should the large, black thermal-sensitive coupling nut be exposed to any extreme temper-
atures above 115ºC it will soften and allow the regulator probe to disengage from the
valve, and will shut off the gas. Should this occur, do not try to reconnect the nut; instead
replace the whole regulator assembly with a new one (see the attached parts listing for
details). The regulator probe also contains a flow-sensitive feature, which limits the flow of
gas to 10 cubic feet/hour, in the event of a regulator malfunction or hose leak. If the flow
control feature is activated, the cause of this excessive gas flow should be investigated and
corrected before using the barbecue again.
Note: Improperly lighting the barbecue can activate the flow control feature,
resulting in lower heat output. If this occurs, the re-flow feature must be reset by
turning all the burner controls and the cylinder valve off. Wait at least 30 seconds
before slowly turning on the cylinder valve, and then after another 5 seconds turn
the burner valve on and light the barbecue.
•
Never connect this barbecue to an unregulated propane gas supply, or to another kind
of gas. Do not alter or change the hose or regulator in any way.
•
Visually inspect the whole hose assembly before each use for evidence of wear or
damage such as cracks, burns, or cuts. If any damage is found, replace the
assembly before using the barbecue. Use only the recommended replacement hose.
•
To avoid possible damage to the hose, do not allow any grease or other hot materials
to fall on the hose, and make sure the hose does not contact any hot surfaces of
the barbecue.
•
The connection fitting must be protected when it’s disconnected from the cylinder.
Do not allow the fitting to bump or drag on the ground as nicks and scratches could
help create a leak when connecting back to the cylinder.
•
It is important to do the “Leak Test” procedure every time a cylinder is refilled
or any of the components are changed, and especially at the beginning of a
new season.
4
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[CEN 025] G50205 BBQ Manual E 11/4/05 6:54 PM Page 5
To Reset The Gas Regulator Safety Device
1. Close the LP (propane) tank valve.
2. Turn all burner control knobs to the OFF position.
3. Disconnect the regulator from the LP tank.
4. Open the grill lid.
5. Open all of the control knobs to the high position.
6. Wait 2 minutes.
7. Close all of the control knobs.
8. Re-connect the regulator to the LP tank. Test for leaks.
9. With lid open, turn the left burner control knob to the”HIGH”position
and then ignite the grill by turning Rotary ignitor clockwise.
10. Once lit, close the grill lid.
11. Wait for 10 to 15 minutes for the Barbecue to preheat.
ATTENTION: Proper start up and shut down procedures should be Followed to
avoid regulator safety device activation.
W A R N I N G
If the heat output is too low, the flow control feature may have been
activated by a gas leak. If so, turn off the burner valve and cylinder valve,
and perform the “Leak Test”. If there aren’t any leaks, re-light the burner.
S A F E T Y
Perform a “Leak Test”
•
Before lighting your barbecue for the first time.
L E A K T E S T I N G
•
Every time the cylinder is refilled, or any component is replaced.
•
At least once every year, preferably at the start of the season.
The “Leak Test” must be done outdoors, away from heat, open flames and flammable liquids.
Do not smoke while performing the test. Use only a mixture of 50/50 liquid soap and water
for leak testing. Never use a match or open flame.
The Following Must Be Checked
•
The tank valve including the threads into the tank (Drawing C).
•
All tank welds (Drawing B).
•
Regulator fittings and tank connections (Drawing C).
•
All hose connections (Drawing D).
•
With a newly filled and tested propane tank attached to the
barbecue and all the barbecue controls turned “OFF”, slowly open
the cylinder valve one full turn.
Drawing B
Drawing C
•
Using a brush and soap, soak all the connections and components
listed above and shown in drawings B, C, D.
•
Look carefully for bubbles forming, which is an indication of leaking gas.
•
Tighten the connections at the bubbled areas until re-testing shows no
indication of any leaks (shut off cylinder while correcting any leaks).
•
Shut off the cylinder valve and ensure all control valves are off.
•
Do not use the barbecue if any leaks cannot be stopped. Turn off the
gas cylinder valve, remove the gas cylinder and seek assistance from
a qualified gas appliance service mechanic or gas dealer.
Drawing D
5
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[CEN 025] G50205 BBQ Manual E 11/4/05 6:54 PM Page 6
L I G H T I N G
T H E G R I L L
Make Sure you have followed all the safety checks, procedures and instructions
indicated in the previous section, before attempting to light the grill.
Lighting The Main Burners
1. Always open the hood completely and always inspect the grill and burners to confirm
that all components are properly positioned before lighting the main burners.
W A R N I N G
Never stand with your head directly over the Barbecue when preparing
to light the main burners, to prevent possible bodily injury.
2. Always confirm that all of the burner control knobs are in the OFF position before
opening the gas supply.
3. Slowly turn on the propane gas supply valve at the tank 1-2 turns.
4. Wait approximately 5 seconds before turning the selected burner control to the
HIGH position by pushing down on the knob and turning it counter-clockwise.
This procedure allows pressure to stabilize, and prevents the flow limiting feature
from being activated.
5. Immediately turn the Rotary Ignitor knob clockwise. As you turn the ignitor you
will hear a click as the Piexo module generates an ignition spark to the burner.
Rotate the ignitor knob until the burner lights. The selected burner should light
within 5 seconds. Light the burners sequentially from left to right.
W A R N I N G
IF THE SELECTED BURNER DOES NOT LIGHT,
immediately turn the burner control knob and cylinder valve to the OFF
position, to prevent gas buildup. Wait five minutes for the gas to
clear and then repeat the preceding starting procedure. IF the burner will
not light when using the Ignitor, follow the match lighting instructions.
6
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[CEN 025] G50205 BBQ Manual E 11/4/05 6:54 PM Page 7
6. Confirm that the burner is properly lit. If the flame pattern is other than normal,
consult the Troubleshooting Guide for corrective action.
7. Always preheat the Barbecue before starting to cook. Light all burners and adjust
them to the HIGH position for 5-10 minutes. Before placing any food on the Barbecue,
clean the cooking grids with a Porcelain cleaning brush.
8. Adjust the controls to a medium setting for most cooking requirements. A light
coating of cooking oil on the cooking grids, before heating the grill, will prevent
foods from sticking to the grill.
Turning The Burners Off
1. Always turn the burner control knobs to the off position when
cooking has been completed.
2. Promptly turn OFF the gas supply valve at the propane cylinder.
3. Close the hood of the grill.
Match Lighting The Main Burners
1. Always open the hood completely and inspect the grill and burners to confirm
that all components are properly positioned, before lighting the main burners.
W A R N I N G
Never stand with your head directly over the Barbecue when preparing
to light the main burners, to prevent possible bodily injury.
2. Always confirm that all of the burner control knobs are in the OFF position
before opening the gas supply.
3. Always turn on the propane gas supply valve at the tank (1-2 turns).
4. Insert a lit match or a butane lighter into the match lighting hole located
on the lower left hand side of the firebox (Drawing G).
5. Turn the left burner control knob to the HIGH position by pushing on the
knob and turning it counter-clockwise.
Drawing G
W A R N I N G
If the heat output is too low, the flow control feature may have
been activated by a gas leak. If so, turn off the burner valve
and cylinder valve, and perform the “Leak Test”. If there aren’t
any leaks, re-light the burner.
7
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[CEN 025] G50205 BBQ Manual E 11/4/05 6:54 PM Page 8
Lighting the Second Burner
•
Turn the second control knob on the main control panel to the
“HIGH” position. The unlit burner will automatically ignite.
Lighting the Side Burner
Use the push-button igniter on the main control panel and the right control knob on the
side burner panel.
•
Push in and turn the right control knob to the “HIGH” position.
•
Push the igniter button until a loud click is heard, which is the
spark being formed. Repeat several times if the burner does not light.
•
If the burner does not light after several tries, turn the right
control knob off and wait 5 minutes for the gas to clear.
•
Repeat the above instructions. If the side burner still does not light,
refer to the troubleshooting section for help or light the burner manually.
Note: The side burner is designed to accept a maximum weight of 20 lb. Do not overload
the side burner.
Lighting the Side Burner with a Match
•
Place match in front ring of provided match holder.
•
Place a lighted match through the hole to within 16 cm (1/2˝ ) of the side burner.
•
Push in and turn the burner knob to the “HIGH” position. At this point,
the burner should light, if it doesn’t after 5 seconds, turn the
control knob back to the “OFF” position and wait for the gas to clear.
•
Wait 5 minutes, and then repeat the manual lighting procedure. If after three
tries the burner still does not light, review the troubleshooting guide for help.
Shutting Down the Barbecue After Use
•
Turn off the gas cylinder valve.
•
Turn the burner control valve to the “OFF” position.
This sequence is important as it prevents residual gas from being left in the system under
pressure and will make the next use easier.
Visually Check Burner Flame
HI
Take off the grates and heat shield. Light burners. Adjust the flame by turning the knobs
from “HIGH” to “LOW”. The flames will be smaller when the knobs are in the “LOW” posi-
tion. Always check flame prior to each use. Perform flame check for side burner.
LOW
8
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[CEN 025] G50205 BBQ Manual E 11/4/05 6:54 PM Page 9
•
L I G H T I N G T H E
Turn all knobs to “OFF”
•
•
•
•
Open lid during lighting. Turn gas on at LP tank.
Push in and turn Rotisserie Burner knob to “HI”.
Push the Igniter. Be sure burner lights and stays lit.
If Igniter does not work , follow match light instruction.
I G N I T O R F O R T H E
R O T I S S E R I E B U R N E R
Match Lighting
•
Open Lid. Turn on gas at LP tank.
•
Place lit match near porthole of burner.
•
Push in and turn Rotisserie Burner knob to “HI”. Be sure burner lights and stays lit.
T I P S O N U S I N G
Guide to Rotisserie Cooking
Rotisserie cooking produces foods that are moist and flavourful. Most commonly used for
cooking meat or poultry, the rotisserie is designed to cook food slowly. You can place a
cooking pan beneath the food to collect juices for basting and gravy. To flavour the contents
of the cooking pan you may add herbs, onions, or other spices of your choice.
Y O U R R O T I S S E R I E
Balancing the Food
In rotisserie cooking, balancing the food is of utmost importance. The rotisserie must turn
evenly or the stopping and starting action will cause the food to cook unevenly and possibly
burn the heavier side.
The easiest foods to balance are those of uniform shape and texture. To test if the food is
balanced correctly when secured, place the ends of the rotisserie spit loosely in the palms
of your hands. If there is no tendency to roll, give the spit a quarter turn. If it is still stable,
give it a final quarter turn. It should rest without turning in each of these positions. It can
then be attached to your grill.
Food Preparation
When preparing poultry, truss the birds tightly so that wings and drumsticks are close to
the body of the bird. The cavity of bird may be stuffed prior to this. Pull the neck skin down
and, using a small skewer, fix it to the back of the bird. Push the rotisserie spit through
lengthwise, catching bird in the fork of the wishbone. Centre the bird and tighten with the
holding forks. Test the balance as described before.
A rolled piece of meat requires the rotisserie skewer to be inserted through the centre of
the length of meat, then secured and balanced.
For meats that contain bones, it is best to secure the rotisserie skewer diagonally through
the meaty section. If protruding bones or wings brown too quickly, cover with pieces of foil.
9
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[CEN 025] G50205 BBQ Manual E 11/4/05 6:54 PM Page 10
P A R T S L I S T I N G F O R
8 5 - 1 1 0 2 ( P R O P A N E ) G 5 0 2 0 5
Item No.
Quantity
Specification
Part No.
Item No.
CO
CA
CB
Quantity
Specification
Part No.
A
1
1
1
2
1
Top Lid Assembly
Top Lid Weldment
Thermometer
2
1
1
1
1
1
1
2
1
1
1
1
1
1
2
Caster Assy
G606-0027-01
G502-4200-01
G502-4300-01
G502-0059-01
G502-0018-01
G607-0033-01
G607-0034-01
G413-0016-01
G502-3400-01
G502-3500-01
G502-9000-01
G502-2600-01
G502-2500-01
G502-0068-01
G401-0061-01
AA
AB
AC
AD
G502-0100-02
G413-0029-01
G501-0005-01
G502-0001-01
Lower Side Panel, Left
Lower Side Panel, Right
Back Panel
Screw F/ Top Lid
Handle F/ Top Lid
CC
CD
CE
Heat Shield, Tank
Grease Tray Bar-1
Grease Tray Bar-2
Door Handle
B
1
1
1
1
1
1
1
1
2
1
1
1
3
1
1
1
1
5
5
1
1
1
Burner Box Assembly
Burner Box Weldment
Upper Side Panel, Left
Upper Side Panel, Right
Manifold Assembly
Regulator
CF
BA
BB
BC
BD
BE
BF
G502-3700-01
G502-2200-01
G502-2300-01
G502-3300-01
G601-0065-01
G502-0005-01
G502-0012-01
G607-0700-01
G502-1800-01
G502-0054-01
G502-0053-01
G502-0011-01
G411-4000-01
G502-0057-01
G502-0067-01
G502-0056-01
G401-0022-01
G413-0020-01
G502-0052-01
G502-0060-01
G608-0019-01
CG
CH
CI
Door Assembly, Left
Door Assembly, Right
Grease Tray
CJ
CK
Upper Rail
Electronic Ignition Kit
Carryover Assembly
Main Burner-A
CL
Bottom Shelf
BG
BH
BI
CM
CN
Bottom Rail
Caster Assembly w/ Lock
Main Burner-B
BJ
Cooking Grate, Burner Box
Warming Rack
D
1
1
1
1
1
1
1
1
1
Side Burner Shelves Assembly
Side Burner Shelf Weldment
Side Burner
BL
DA
DB
DC
DD
DE
DF
DG
DH
G502-2800-01
G401-0033-01
G401-0300-01
G502-0064-01
G409-0008-01
G502-2900-01
G502-0065-01
G602-0022-01
BM
BN
BO
BP
BQ
BR
BS
BT
BU
BV
Flame Tamer
Rotisseries Burner
Backburner Brace B
Wind Shield, Rotisseries
Control Panel
Side Burner Drip Pan
Cooking Grate, Sideburner
Lid F/ Sideburner
Side Shelf Weldment
Condiment Basket
Bezel F/ Control Knob
Control Knob
Towl Bar F/ Side Shelf
Heat Shield A
Upper Rear Panel
Match Holder
1 0
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[CEN 025] G50205 BBQ Manual E 11/4/05 6:54 PM Page 11
8 5 - 1 1 0 2 ( P R O P A N E ) G 5 0 2 0 5
AB
AA
AC
AD
BL
BJ
BP
BH
BI
BM
BO
DE
BB
BA
BG
BN
DD
BU
BC
DC
BD
BE
BT
DB
BR
BS
BF
BV
BQ
BR
CD
CC
CE
CF
BS
DA
CA
CH
CI
CG
CB
DF
CJ
CK
DH
CL
DG
CM
CN
CN
CO
CO
1 1
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[CEN 025] G50205 BBQ Manual E 11/4/05 6:54 PM Page 12
P A R T S L I S T I N G F O R
8 5 - 1 1 0 6 - 2 ( N A T U R A L G A S ) G 5 0 2 0 7
Item No.
Quantity
Specification
Part No.
Item No.
CO
CA
CB
Quantity
Specification
Part No.
A
1
1
1
2
1
Top Lid Assembly
Top Lid Weldment
Thermometer
2
1
1
1
1
1
1
2
1
1
1
1
1
1
2
Caster Assy
G606-0027-01
G502-4200-01
G502-4300-01
G502-0059-01
G502-0018-01
G607-0033-01
G607-0034-01
G413-0016-01
G502-3400-01
G502-3500-01
G502-9000-01
G502-2600-01
G502-2500-01
G502-0068-01
G401-0061-01
AA
AB
AC
AD
G502-0100-02
G413-0029-01
G501-0005-01
G502-0001-01
Lower Side Panel, Left
Lower Side Panel, Right
Back Panel
Screw F/ Top Lid
Handle F/ Top Lid
CC
CD
CE
Heat Shield, Tank
Grease Tray Bar-1
Grease Tray Bar-2
Door Handle
B
1
1
1
1
1
1
1
1
2
1
1
1
3
1
1
1
1
5
5
1
1
1
Burner Box Assembly
Burner Box Weldment
Upper Side Panel, Left
Upper Side Panel, Right
Manifold Assembly
Regulator
CF
BA
BB
BC
BD
BE
BF
G502-3700-01
G502-2200-01
G502-2300-01
G502-3300-01
G601-0065-01
G502-0005-01
G502-0012-01
G607-0700-01
G502-1800-01
G502-0054-01
G502-0053-01
G502-0011-01
G411-4000-01
G502-0057-01
G502-0067-01
G502-0056-01
G401-0022-01
G413-0020-01
G502-0052-01
G502-0060-01
G608-0019-01
CG
CH
CI
Door Assembly, Left
Door Assembly, Right
Grease Tray
CJ
CK
Upper Rail
Electronic Ignition Kit
Carryover Assembly
Main Burner-A
CL
Bottom Shelf
BG
BH
BI
CM
CN
Bottom Rail
Caster Assembly w/ Lock
Main Burner-B
BJ
Cooking Grate, Burner Box
Warming Rack
D
1
1
1
1
1
1
1
1
1
Side Burner Shelves Assembly
Side Burner Shelf Weldment
Side Burner
BL
DA
DB
DC
DD
DE
DF
DG
DH
G502-2800-01
G401-0033-01
G401-0300-01
G502-0064-01
G409-0008-01
G502-2900-01
G502-0065-01
G602-0022-01
BM
BN
BO
BP
BQ
BR
BS
BT
BU
BV
Flame Tamer
Rotisseries Burner
Backburner Brace B
Wind Shield, Rotisseries
Control Panel
Side Burner Drip Pan
Cooking Grate, Sideburner
Lid F/ Sideburner
Side Shelf Weldment
Condiment Basket
Bezel F/ Control Knob
Control Knob
Towl Bar F/ Side Shelf
Heat Shield A
Upper Rear Panel
Match Holder
1 2
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[CEN 025] G50205 BBQ Manual E 11/4/05 6:54 PM Page 13
8 5 - 1 1 0 6 - 2 ( N A T U R A L G A S ) G 5 0 2 0 7
AB
AA
AC
AD
BL
BJ
BE
BP
BH
BI
BM
BO
DE
BB
BA
BG
BN
DD
BU
BC
DC
BD
BT
DB
BR
BS
BF
BV
BQ
BR
CD
CC
CE
CF
BS
DA
CA
CH
CI
CG
CB
DF
CJ
CK
DH
CL
DG
CM
CN
CN
CO
CO
1 3
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[CEN 025] G50205 BBQ Manual E 11/4/05 6:54 PM Page 14
A S S E M B L Y I N S T R U C T I O N S
Hardware Pack List
No.
Description
Part Number
Quantity
Tools Needed for Assembly
1
1/4" x 38mm Screw
1/4" x 13mm Screw
Ø7 Lock Wsaher
Ø7 Wsaher
20120-13038-250
20120-13013-250
41400-07000-250
40300-07000-250
30220-13000-250
20124-10010-250
41400-05000-250
40300-05000-250
22500-42010-132
G413-0020-9084
G401-0022-0081
G413-0020-9084
G401-0022-0081
8
2
12
20
20
6
®
•
•
•
•
•
#2 Phillips screwdriver
1/4˝ slotted screwdriver
Adjustable wrench
Pliers
3
Rubber mallet
4
5
1/4"-20UNC Nut
NO.10 x 10 Screw
Ø5 Lock Washer
Ø5 Flat Washer
ST4.2 x 10 Tapping Screw
Knob
6
16
16
16
4
Before assembling the barbecue, read these instructions carefully.
Assemble the barbecue on a flat, clean surface. Grill is heavy. You
should have two people assemble the barbecue together.
7
8
9
10
11
12
13
1
Notes: Do not fully tighten all the nuts during this initial stage.
Cover, Knob
1
AA-Battery
1
Caution: Sheet metal can cause injury. Wear gloves when installing
Wrench
1
the grill. Use care when assembling.
1/4” x 38 mm Screw (x8)
1/4” x 13 mm Screw ( x12)
ST4.2 x 10 Self-tapped Screw (x4)
No.10 x 10 Screw (x16)
1/4”-20UNC Nut (x6)
Ø5 Flat Washer (x16)
Ø7 Lock Washer (x20)
Ø5 Lock Washer (x16)
Ø7 Washer (x20)
1 4
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[CEN 025] G50205 BBQ Manual E 11/4/05 6:54 PM Page 15
Fig. 1
CO
1
CO
CN
Attach two front casters (CO) and two rear locking casters (CN) to
the bottom shelf (CL) using the wrench #13 provided.
CL
CN
Fig. 2
2
Assemble the left and right cart side panel (CA & CB) to the bottom
shelf (CL) as shown using hardware #2 (X6) (from the top) and #3,
#4 and #5 (X6) (from the bottom).
CB
CA
2
CL
3
4
5
Fig. 3
3
CK
Assemble the upper rail (CK) to the cart assemble using hardware
#6, #7, and #8 (x4) (from the inside of cart).
6
7
8
1 5
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[CEN 025] G50205 BBQ Manual E 11/4/05 6:54 PM Page 16
A
B
Sides
4
Sides
Place the top lid and burner box assembly (A+B) onto the cart
assembly as shown.
Rear
Rear
Using hardware #6, #7 and #8 (x6) attach to cart assembly as shown.
Fig. 4
Fig. 5
BJ
5
Open lid and position the 3 flame tamers (BM) above the 3 main
burners ( BH & BI). Place the 2 cooking grate (BJ) into the burner
box above the flame tamers (BM).
BM
BI
BH
Fig. 6
6
Attach the warming rack (BL) to the inside of the burner box as
shown. Make sure to insert the front 3 bars into the 3 holes of the
back burner brace (BO). Place the two legs of the warming rack clip
onto the edge of burner box weldment (BA).
BL
BO
BA
1 6
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[CEN 025] G50205 BBQ Manual E 11/4/05 6:54 PM Page 17
Fig. 7
CK
7
Insert the left and right grease tray bar (CE & CF) into the holes of
upper rail (CK) as shown. Insert the tank heat shield (CD) into the
upper rail (CK) next to the 2 grease tray bars as shown. Assemble the
upper rear panel (BU) to the burner box and cart assembly using hard-
ware #1, #3, and #4 (x4).
+
CE
CF
1
4
3
Fix the upper rear panel (BU) to both grease tray rails (CE & CF) and
heatshield (CD) using hardware #9 (x4) as shown.
CD
BU
9
Fig. 8
DH
8
Remove the screws and washers from towel bar (DH). Assemble the
towel bars (DH) to the side shelf (DF) by using the hardware removed.
DF
2
3
4
DA
BB
Assemble the side burner shelf (DA) to the burner box assembly by
using hardware #2, #3, and #4 (x3) to fit the 3 holes at the back
part of the left upper panel (BB) as shown.
BC
Use #6, #7, and #8 (x2) to attach the side burner shelf (DA) to 2
front holes of the left upper panel (BB).
Assemble the side shelf (DF) to the upper right panel (BC) by using
the same hardware.
6
7
8
Fig. 9
DD
9
Push the side burner valve stem (part of BD) and mount it by using
screws and washers included on the valve bracket, threading
through the side burner control panel. Affix the bezel (BR) onto the
value stem using hardware provided.
DB
Push the knob (BS) onto the valve stem with the arrow on the knob
BS
pointing upwards.
BR
Insert the side burner (DB) into the frame and attach #6, #7 and #8 it to
the side burner bra ket using hardware #6, #7, and #8 (x2) as shown.
Gently slide the burner tube over the orifice of the valve. Then
place the side burner cooking grate (DD) as shown.
1 7
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[CEN 025] G50205 BBQ Manual E 11/4/05 6:54 PM Page 18
Fig. 10
10
Remove the screws and washers from the door handles (CG) and
assemble the handles to the left and right door (CI & CH) by using
the same hardware provided on the door handles. Insert the grease
tray (CJ) into the upper rail (CK) as shown.
CK
CG
CG
CJ
CH
CI
Fig. 11
11
Assemble the cart back panel (CC) to the back side of the cart by
using hardware #1, #3, and #4 (x4).
CC
4
3
1
Fig. 12
BF
12
DG
Unscrew the igniter cap and place AA battery #12 which is provid-
ed into igniter (BF) with positive end (+) facing outward.
Screw the igniter cap onto igniter as shown.
DG
Position the front condiment basket (DG) to the side shelf (DF) by
fitting the holes of the cabinet to the bracket on the side shelf.
12
1 8
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[CEN 025] G50205 BBQ Manual E 11/4/05 6:54 PM Page 19
Fig. 13
13
Attach the side burner igniter wire as shown.
Fig. 14
14
For propane model ONLY (#85-1102)
Open front doors (CH & CI) and secure 20lb propane tank onto the
bottom shelf (CL) of the cart as shown, attach the regulator valve
to 20lb propane tank.
WARNING
Do not store the extra tank into the cart.
1 9
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[CEN 025] G50205 BBQ Manual E 11/4/05 6:54 PM Page 20
I N F O R M A T I O N O N
This model has a 12’ hose with a male coupling plug that will allow you to attach your
barbecue to your residential gas line.
N A T U R A L G A S M O D E L
WE STRONGLY RECOMMEND CONTACTING A CERTIFIED GAS-TECHNICIAN TO
INSTALL YOUR NATURAL GAS UNIT.
Connecting to Gas Line
1. Pull back the outer sleeve located on the residential gas line (see illustration).
2. Insert the barbecue’s male coupling plug into the residential gas line’s coupling.
3. Push the male coupling plug in as far as possible, the outer sleeve will spring forward
locking the two together (see illustration).
Disconnecting From Gas Line
•
Pull back the outer sleeve located on the residential gas line and pull the barbecue’s
male coupling plug out.
Warning: Failure to follow all safety procedures could result in fire and explosion causing
property damage, serious personal injury or even death.
Consult the rating label on the back of the barbecue to confirm that it is set up to burn nat-
ural gas. If the retracting sleeve on the residential gas line does not fit the barbecue’s male
coupling plug, the retracting sleeve can be replaced. All gas supply plumbing must be car-
ried out by a qualified service agency. Modifications must be carried out in accordance with
provincial authorities, and in accordance with CAN/CGA 1-B149.1 & 2 installation code
requirements. A shut-off valve must be installed on the main line. Use a 3/8 or 1/2” gas line
rated at least 75,000 BTUs.
Before lighting for the first time, lighting for the first time each season, and after making
any adjustments, do the following:
•
Make sure all burner control knobs are in the “OFF” position.
•
Always connect the barbecue’s gas line to the residential gas line before opening
the shut-off valve.
•
Perform a “Leak Test”. This test must be performed outdoors, away from heat,
open flames and flammable liquids. Do not smoke while doing the test. Use only
a mixture of liquid soap and water. Use a spray bottle or brush to apply the
soapy solution to all the connection points. Check carefully for bubbles forming,
which is a sign of leaking gas. If you have a leaky connection, turn the gas off,
tighten the connections, turn the gas back on and retest. Do not use the barbecue
if any leaks cannot be stopped. If you can’t stop a leak, turn the gas off and get
assistance from a qualified service technician. Never use a match or open flame.
Attach the Natural Gas Hose (included with
your barbecue) to the grill. Tighten the female nut of
the hose onto the side burner valve using a wrench.
Natural Gas Supply Connection
Always disconnect the Grill and close its individual manual shutoff valve, when conducting
pressure tests of the gas supply piping system at pressures which exceed 1/2 psi (3.5kPa).
•
Always isolate the Grill from the gas supply piping system by closing its individual
manual shutoff valve when conducting pressure tests of the gas supply piping system
at pressures which are equal to or less than 1/2 psi (3.5kPa).
2 0
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[CEN 025] G50205 BBQ Manual E 11/4/05 6:54 PM Page 21
D I S T R I B U T O R
Trileaf Distribution Trifeuil
Toronto, Canada
M4S 2B8
2 1
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[CEN 025] G50205 BBQ Manual E 11/4/05 6:54 PM Page 22
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