BIG JOHN A2TS User manual

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Owner’s Manual
for Assembly, Operating & Maintenance of
Model A2TS Built-In Gas Grill
DANGER
IF YOU SMELL GAS:
1. SHUT OFF GAS TO APPLIANCE
2. EXTINGUISH OPEN FLAMES
3. OPEN LID (IF APPLICABLE)
4. IF ODOR CONTINUES, KEEP AWAY FROM THE
APPLIANCE AND IMMEDIATELY CALL YOUR
GAS SUPPLIER OR FIRE DEPARTMENT.
LEAKING GAS MAY CAUSE FIRE, EXPLOSION,
PERSONAL INJURY, DAMAGE TO PROPERTY, AND
DEATH.
YOU MUST READ THIS OWNER’S MANUAL
BEFORE OPERATING YOUR GAS GRILL.
WARNING: Follow all leak-check
procedures listed in this manual carefully
prior to operation of this unit. Do this
even if the grill was assembled by a
professional.
THIS GAS GRILL IS DESIGNED FOR OUTDOOR USE ONLY.
526 EAST ROLLING RIDGE DRIVE, BELLEFONTE, PA 16823
P: 814-359-2755 F: 814-359-2621 [e-mail]
WARNING: Do not ignite this grill without
reading the LIGHTING INSTRUCTIONS
first.
WARNING: DO NOT store or use
gasoline or other flammable liquids/
vapors in the vicinity of this grill.
An LP Cylinder not connected for use
should not be stored in the vicinity of this
unit.
www.bigjohngrills.com

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1. PROPANE SAFETY - GENERAL Page 3
2. PROPANE SAFETY - CYLINDER Page 4
3. GENERAL INFORMATION Page 5
4. ASSEMBLY INSTRUCTIONS Page 6
5. SET-UP INSTRUCTIONS Page 7
6. OPERATING INSTRUCTIONS Page 8
7. CLEANING & CARE INSTRUCTIONS Page 9
8. PARTS LIST Page 10-11
9. ACCESSORY LIST Page 12
10. TROUBLESHOOTING GUIDE Page 13
11. WARRANTY Page 14
12. WARNINGS Page 15
TABLE OF CONTENTS

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 Liquid propane (LP) gas is a petroleum product as are gasoline and natural gas. In normal tempera-
tures and pressures, LP gas is a gas. When moderate pressure is applied, inside a cylinder, LP gas
becomes a liquid. As the pressure is released the liquid readily vaporizes and boils off as a gas.
 LP gas has no odor, but rather an odor additive so you can smell it.
 Propane gas is denser than air, if a propane tank purges to relieve pressure build-up, the propane
will collect in low lying areas. These areas can be easily ignited and are highly flammable. Use cau-
tion when dealing with a propane tank that may have recently self-purged.
 DO NOT paint propane tanks any color other than white. Any alteration to tank color will result in
tank purging, fire, personal injury, or death.
 Big John Grills & Rotisseries uses high quality Worthington Cylinders in 30 lb. and 40 lb. sizes.
These tanks are protected with a rust-resistant white powder coat finish.
 Always keep the cylinder valve closed when not in use.
 Cylinders are designed to function with the valve completely open or completely closed, there is no
in-between. Never open the valve just a “crack” or “half way”.
 Always position the propane cylinder so that the connection between the valve and the regulator will
not cause any sharp bends in the hose.
 NEVER store or use propane cylinders indoors.
 Make sure the POL or QCC Connector is free from scratches or nicks which can cause gas leaks.
 DO NOT store or use gasoline or other flammable liquids or vapors in the vicinity of a gas appliance.
 DO NOT store extra liquid propane cylinders within the vicinity of a gas appliance.
 DO NOT store a liquid propane cylinder in/on any part of an appliance not intended for such use.
Improper storage of a cylinder could lead an explosion, fire, personal injury, or death.
 DO NOT store or lean items against unit surface or fuel cylinders while operating.
 Shut off unit and all gas sources if the odor of unburned gas is detected. Make no attempt to use the
unit until gas leaks are fixed and/or the odor is accounted for.
 Do NOT use a damaged, dented, or rusty LP cylinder or a cylinder with a damaged valve - replace
with a new one immediately.
 Replacement LP tanks must match the regulator connection supplied with this grill and be a mini-
mum of 30 lb. capacity.
PROPANE SAFETY - GENERAL
LIQUID PROPANE TANK REQUIREMENTS
 For tanks not purchased from Big John Grills & Rotisseries: check to be sure cylinders have been
tested within the past 5 years and have a D.O.T. certification. Your LP gas supplier can do this for
you.
 All LP tank supply systems must have a collar to protect the cylinder valve.
 All tanks used on Big John Grills equipment must be a minimum of 30 lb. size.
 Tanks larger than 100 lbs. in size may require a POL for connection. Please call a Big John Cus-
tomer Service Representative if you are using a 100 lb. propane tank.

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DISCONNECTING AND TRANSPORTING PROPANE CYLINDERS FOR REFILLING
 Turn off all control knobs and close the main cylinder valve. Disconnect regulator with QCC.
 Place cylinder valve plug snugly in the main cylinder valve outlet. Only use the cylinder valve plug
that is provided with the cylinder. Other types of caps or plugs may result in leakage of propane.
 Treat “empty” LP cylinders with the same care as full ones. Even when the tank is empty, there is
still some gas pressure left in the cylinder.
 Always transport and store propane cylinders in a secure, upright position. Never store these pro-
pane tanks on their side, handle them roughly, or drop them.
 Never keep propane cylinders (full or empty) in a hot vehicle. Heat can cause the relief valve to
purge propane creating a very dangerous situation.
 To fill, take the LP cylinder to a propane gas dealer WARNING: We strongly recommend that your
LP cylinder be filled by an authorized propane dealer, by a qualified attendant, who fills the
tank by weight. IMPROPER FILLING IS DANGEROUS.
 Air must be purged from a new LP cylinder before the initial filling. Your LP dealer will do this.
STORING PROPANE CYLINDERS
 Turn off all control knobs and close the main cylinder valve.
 Place cylinder valve plug or cap snugly in main cylinder valve outlet.
 Always store propane cylinders in a secure, cool/dry place in the upright position.
 Never store propane cylinders in a vehicle of any kind and or anywhere the temperatures can reach
125° F.
PROPANE SAFETY - CYLINDER

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 Big John products are designed for OUTDOOR USE ONLY! Only operate this equipment in a well-
ventilated area. Do not use in garage, building, or other enclosed area. Operation of this equipment
indoors or in a poorly ventilated area may cause an explosion, fire, personal injury, or death.
 Grill must be installed in masonry, cinder block, or metal construction at least 24” from any wood sur-
face or other combustible materials. If building in to a wooden structure, ensure fire-barrier is in-
stalled (ie: metal panels with air gap or fire board).
 Call a plumber or commercial equipment service company when installing equipment. Hoses, regu-
lators, and installation must meet your local zoning code.
 Do not retrofit any equipment or accessories to the unit that are not part of the original equipment
provided by Big John Grills & Rotisseries. Replacement parts must be obtained from the manufac-
turer. Any attempt to change or modify this unit could result in an explosion, fire, personal injury to
yourself or someone else, or death and will void your warranty.
 Do not touch or allow any contact with the sides, back, or top of grill after lighting. The unit is
EXTREMELY HOT! Allow the grill to cool completely before touching any metal surface.
 Do not operate grill within 12” of a combustible or non-combustible surface. Provide adequate clear-
ance and ventilation at all times.
 WARNING! Use of this grill in high wind conditions may result in poor burner operation (low flame,
blowing out, flaring up, etc.). Consider wind direction when planning your outdoor kitchen.
 DO not perform any maintenance until grill is completely cooled down.
 This grill is a lava rock char broiler grill and therefore, factory supplied lava rock must be placed
around burners for grill to operate properly. DO NOT experiment with other materials. Failure to use
lava rock will result in grill malfunction and could result in personal injury or property damage.
GENERAL INFORMATION
Thank you for purchasing a Big John Commercial Built-In Gas Grill! We take pride in producing and
selling equipment made right here in America and are pleased that you recognized the quality and dura-
bility of our products. Your new grill is a commercial grade, outdoor piece of cooking equipment. With
this unit, you will be able to cook a variety of foods quickly and easily. The lava rock and searing heat
provides the great outdoor grilling flavor that cannot be matched by radiant style grills. Due to exception-
al quality and reliability, Big John grills are preferred by professional chefs and home owner’s to com-
plete outdoor kitchens at golf courses, country clubs, restaurants, resorts, personal homes and many
more. Please read the information provided below before using your grill for the first time.

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This unit ships 90% assembled and we make sure the instructions for the rest are easy to follow and
perform. Please follow the instructions below to ensure your grill is properly assembled for safe opera-
tion. Please remember this is a commercial piece of equipment and therefore the materials used to
build it are of the best quality. Because of this, the grill weight is considerable and will require 2 people
to un-package, assemble, and set-up the unit.
1. Unbox unit and remove all packing materials, tape, protective laser paper (can be white, gray, or
clear in color), and plastic coverings
2. Follow hood assembly instructions if applicable
3. Have plumber or commercial equipment service company on hand to install.
ASSEMBLY INSTRUCTIONS

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SET-UP INSTRUCTIONS
1. Ensure unit is properly installed in structure and gas connections have been tested and approved by
the professional installing the unit.
2. Once properly installed, remove cooking grates and empty one bag of lava rock in each section - di-
rectly on top of the burner tubes and burner insert pan. You want 1 even layer of rocks covering the
burner tubes.
3. Replace cooking grates
4. Ensure all control valves are in the CLOSED position (parallel to the work shelf with all knob ends
turned to the left).
5. We recommend curing your grates by applying a coating of vegetable oil to each grate prior to light-
ing your grill. Heating the grates for approximately 20 minutes prior to using the grill for the 1st time
will cure the oil to the grates and get the lava rock ready.
6. Turn on gas source and allow system to pressurize - takes about 1 minute.
7. TO LIGHT THE GRILL: Hold a lit long handled butane lighter gun or fireplace match down
through the cooking grates next to a burner and open the control valve (turn it so black knob is point-
ing at you). The burner will ignite instantly with a *POOF* sound. Remove lighter and open 2nd con-
trol valve - it will light instantly from the 1st. Repeat for each section of the grill until all burners are
lit.
8. TO TURN OFF GRILL: Simply turn all of the control knobs to the CLOSED position (parallel to
the work shelf with all knob ends turned to the left) and turn off gas source.
ON OFF

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OPERATING INSTRUCTIONS
1. DO NOT ATTEMPT TO LIGHT UNIT WITHOUT REMOVING THE WEATHER COVER OR OPEN-
ING THE STAINLESS STEEL HOOD. Gas can accumulate and cause RAPID IGNITION. Always
be sure unit is lit before closing the hood.
2. Ensure all control valves are in the CLOSED position (parallel to the work shelf with all knob ends
turned to the left).
3. Check to make sure gas source is securely connected
4. Generously coat grates with vegetable oil or oil-based cooking spray.
5. Turn on gas source and allow system to pressurize - takes about 1 minute.
6. TO LIGHT THE GRILL: Hold a lit long-handled butane lighter gun or fireplace match down through
the cooking grate next to a burner and open the control valve (black knob is pointing at you). The
burner will ignite instantly with a *POOF* sound. Remove lighter and open 2nd control valve - it will
light instantly from the 1st. Repeat for each section of the grill you plan to use.
7. Once burners are lit, adjust the control knobs to set desired temperature. Grill will reach ~800° in
approximately 5-8 minutes if running at full blast.
8. TO TURN OFF GRILL: Simply turn all of the control knobs to the CLOSED position (parallel to
the work shelf with all knob ends turned to the left) and turn off gas source. NEVER turn grill off by
closing gas source first.
9. Wait approximately 10-15 minutes before attempting to clean or coat grates with vegetable oil. You
want to give the lava rock enough time to cool down otherwise flare-ups may occur.

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CLEANING & CARE
SPIDER & INSECT ALERT
All outdoor appliances should be inspected thoroughly for spiders and insects if unit is sitting for a period
of time between uses. Propane and natural gas contain an odorant that insects and spiders are attract-
ed to. This leads them to build webs and nests in burner tubes and around control valves. Nests can
form very quickly and are prevalent in areas with wet and humid conditions. We recommend the regular
cleaning and inspection of the burners and control valves as a form of normal maintenance.
1. Warning Signs of a nest or web:
a. The smell of gas
b. Burners are hard to light or will not light at all
2. How to clean the burner tubes:
a. Turn off gas and completely disconnect grill from gas source. (let cool completely if previously
lit)
b. Remove burner and visually inspect inside tube looking for a cotton-like substance that could
be a web or nest.
c. If a mud-like substance is found, this is a sign of wasps and should be cleaned immediately
d. Use a pipe cleaner to remove any signs of web, nest, or other debris
e. Wipe off outside and each hole along burner to ensure nothing is clogging holes
f. Rinse with water if necessary
g. Dry burner thoroughly before replacing into grill.
3. How to clean the control valve orifice:
a. Turn off gas and completely disconnect grill from gas source.
b. Use small wire, needle or pipe cleaner to gently wipe away any debris from orifice.
Remember, open flame cooking can cause significant splatter that can bake onto surfaces . Unlike oven
or top burner cooking, the meat is not in a pot or pan and grease laden smoke will reach all surfaces.
More cleaning is necessary to keep stainless steel components, like the front work shelf, bright and
new. Stainless Steel can be cleaned with cleanser, nylon scouring pads, oven cleaner, or special stain-
less steel cleaner found in hardware stores.
TO CLEAN COOKING GRATES:
1. Turn off the grill and wait approximately 10-15 minutes before attempting to clean. Grates will still be
warm to touch so wear protective gloves if necessary.
2. STAINLESS STEEL GRATES: Clean grates with non-metallic pad, like Scotch-Brite or a brass
bristle brush, once grates have cooled. DO NOT USE A WIRE BRUSH ON STAINLESS STEEL
GRATES. It will leave metal particles behind that rust. Rub grate in a back and forth motion, do not
use circular or go against the grain. If necessary, remove grates from grill, use oven cleaner, and let
sit for several hours. Then clean in hot soapy water. However, you want to leave a layer of black
carbon build-up on the grate which acts as a non-stick surface.
3. CAST IRON GRATES: Generously coat Cast Iron grates with vegetable oil or oil -based cooking
spray to protect from moisture for storage to prevent rusting between uses. You may use a BRASS
or WIRE GRILL BRUSH to clean Cast Iron Grates, if needed, prior to coating with vegetable oil for
storage.

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PARTS LIST
Item # Description
302201 Cast Iron Cooking Grate
302205 Stainless Steel Cooking Grate
302240 6 lb. Bag of Lava Rock
302236A Stainless Steel Burner Tube
302250 Control Valve Assembly with Black Knob
302253 Black Knob Only
302254LP Liquid Propane (LP) Orifice Only
302254NG Natural Gas (NG) Orifice Only
302241 Stainless Steel Burner Insert Pan - End
302242 Stainless Steel Burner Insert Pan - Center
302232 Stainless Steel Burner Insert Pan Cap
302221 Stainless Steel Drip Tray (17.5”L x 14.75”W x 0.375”H)
301045 Set of 4 Drip Tray Locks
If you are in need of additional parts not found on this list, please call
Big John Grills Customer Service at 800-326-9575 or 814-359-2755.

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ACCESSORIES
Item # Description
301091A FA-2 Stainless Steel Fits-All Hood
301138 2” Temperature Gauge for Stainless Steel Hood
301113 SG-3; 16” x 40” Steel Griddle with Grease Trap (Elevated Above Cooking Grates)
301110 SG-2; 15” x 30” Steel Griddle with 2 Handles (Sits Directly on Cooking Grates)
301106 SG-1; 15” x 16” Steel Griddle with 1 Stay-Cool Handle (Sits Directly on Cooking Grates)
302205V Stainless Steel Vegetable Grate

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TROUBLESHOOTING GUIDE
At any point in time, if you are experiencing problems with your grill call your local Gas Service or Appli-
ance Service and have them inspect and clean your equipment.

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WARRANTY INFORMATION
Big John Corporation provides a warranty, to the original purchaser, for all Big John finished units for a
period of 1 year from the date of sale. Any unit, or part thereof returned, freight prepaid, to our Sales &
Logistics facility, will be repaired or replaced to our commercial standard, free of charge, and returned to
the purchaser. Labor and transportation costs are NOT covered by this warranty. Misuse, neglect, or
alteration of the product is not covered by this warranty. This warranty is established automatically upon
receipt of the goods. No warranty card or registration procedures are required.
Outgoing warranty shipments must be F.O.B. factory (Bellefonte, PA). All items requested for return
must be received within 30 days of the return authorization being granted to the customer or no warran-
ty credit will be considered.

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WARNINGS
FAILURE TO FOLLOW THE DANGERS, WARNINGS, CAUTIONS, AND INSTRUCTIONS OUTLINED IN THIS
MANUAL MAY RESULT IN SERIOUS BODILY INJURY OR DEATH, OR CAUSE DAMAGE TO PROPERTY BY
FIRE OR EXPLOSION.
 Do not use this grill unless all parts are in place. This unit
must be assembled properly according to the assembly &
set-up instructions listed in this manual. Failure to do so is
dangerous.
 Always check your grill for gas leaks and burner obstructions
before use. Ask your gas service professional for instructions
on how to do this.
 Do not store or use gasoline, other flammable liquids, or va-
pors in the vicinity of this product.
 Do not store extra liquid propane cylinders within the vicinity
of this product.
 Ensure there are no sharp bends in the hose that would inhib-
it gas flow.
 Do not operate any equipment, including this grill, if there is a
gas leak present.
 Do not use a flame to check for gas leaks.
 Combustible materials should never be within 24 inches of
this grill in any direction.
 Do not put anything flammable in the area under the grill.
 No Big John Grills & Rotisseries equipment should used by
children.
 Accessible parts of the grill may be very hot. Keep children
away when in use.
 Big John equipment should never be left unattended or
moved while in operation.
 You should exercise reasonable care when operating your
grill and remember it will be hot during cooking and cleaning.
 Should the burners go out while in operation, turn off all gas
valves and turn off gas source. Let stand for 5-10 minutes
before attempting to relight using the lighting instructions
found in this manual.
 Only grill grade lava rock should be used in this grill. Do not
use wood, charcoal, ceramic briquettes, landscaping lava
rock, or other materials. This grill will not function properly if
grill grade lava rock is not used.
 Never lean over an open grill or place hands or fingers on the
front work shelf or grill grates.
 Should an excessive flare-up occur, turn off all burners and
propane tank and wait until fire is out. Put hood down if appli-
cable to help smother flames.
 Clean your Big John grill thoroughly on a regular basis.
 Keep any electrical cords or fuel supply hose away from
heated surfaces at all times, especially when in use.
 Use heat-resistant barbecue gloves or mitts when operating
grill.
 Do not enlarge valve orifices or burner holes when cleaning.
 Do not attempt to disconnect any gas fittings while your grill
is in operation.
 Do not store or lean items against grill surface or fuel cylin-
ders while operating.
 Liquid propane is NOT natural gas. The attempted use of
natural gas in a liquid propane unit or liquid propane gas in
a natural gas unit is dangerous and will void your warranty.
If you wish to change your unit from LP to NG or vice versa,
please call a Big John Customer Service Agent to obtain
required parts.
 Natural gas and propane connections must meet your local
zoning codes. Contact a gas professional to purchase a
hose and regulator.
 Do not attempt to disconnect the gas regulator or hose
assembly while unit is in operation.
 Do not paint propane tanks any color other than white. Any
alteration to tank color may result in tank purging, fire, per-
sonal injury, or death.
 NEVER store or use propane cylinders indoors.
 Always keep a propane cylinder in a secure, upright position
while transporting or storing. Do not lay tanks on their side.
 Never keep propane cylinders (full or empty) in a hot
vehicle. Heat could cause the relief valve to purge propane
creating a very dangerous situation.
 Always keep the cylinder valve closed when not in use.
 Do not store a liquid propane cylinder in/on any part of the
appliance not intended for such use. Improper storage of a
cylinder could lead an explosion, fire, personal injury, or
death.
 Propane gas is denser than air and will collect in low areas.
Use caution when dealing with any such fuels.
 Do not use a dented or rusted liquid propane cylinder as it
may be hazardous and should be checked by your propane
dealer.
 Do not use a propane cylinder with a damaged valve.
 Although your propane cylinder may appear empty, there
may still be gas present. The cylinder should be stored and
transported accordingly.
 If you see, smell, or hear the hiss of gas escaping from the
liquid propane cylinder:
1. Move away from the cylinder
2. Do not attempt to correct the problem yourself.
3. Call your fire department.