Camp Chef BBQ SEAR BOX User manual

WARNING & INSTRUCTION BOOKLET
MODELS: PGSEAR
BBQ SEAR BOX

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1. Do NOT leave this appliance unattended while
in use. The user must remain in the immediate
area of the product and have a clear view of the
product at all times during operation.
2. Keep children and pets away from burner at all
times.
3. The use of alcohol, prescription or non-
prescription drugs may impair your ability
to properly assemble or safely operate this
appliance.
4. For OUTDOOR use only. Do NOT use in a
building, garage or any other enclosed area. Do
NOT use in or on recreational vehicles or boats.
NEVER use this appliance as a heater.
5. Do not operate appliance under ANY overhead
construction. Keep a minimum clearance of
3 feet (1 m) from the sides, front and back
of appliance to ANY construction. Keep the
area clear of all combustible material and
flammable liquids, including wood, dry plants
and grass, brush, paper, and canvas.
6. Use ONLY on a level, stable non-combustible
surface like bricks, concrete or dirt. Do NOT use
this appliance on any surface that will burn or
melt like wood, asphalt, vinyl, or plastic.
7. Keep the fuel supply hose away from any heated
surfaces.
8. To prevent accidental fires, before using the
appliance ensure that the hose is not damaged
and all joints and connections are not leaking
by turning on the cylinder valve, leave the
burner valve closed, and apply a soapy solution
to the joints and connections. If a continuous
hissing sound is heard, or if the soapy solution
bubbles, there is a leak. Do not use the
appliance if there is a leak. Replace the faulty
parts.
9. Extinguish all open flames before connecting
the gas supply to the appliance and before
checking for leaks.
10. Do NOT move the appliance when in use. Allow
unit to cool to 115°F (45°C) before moving or
storing.
11. This appliance will be hot during and after
use. Use insulated oven mitts or gloves for
protection from hot surfaces or splatter from
cooking liquids.
12. In case there is a fire, call the local fire
department or dial 911. Stay clear from
flames. Do not attempt to extinguish an oil or
grease fire with water.
13. This product is not intended for commercial
use.
14. Always allow the appliance to cool before
covering with the patio cover.
15. Never use charcoal or wood briquets in a gas
grill. Flavoring chips must be contained in a
metal smoking box to contain ash and prevent
fires.
16. After cooking, allow grill and grease tray to
cool off completely before removing.
17. Use gloves or oven mitts to hold grease tray
when moving to avoid spilling hot grease.
• Use appliance only with LP (propane) gas and
the regulator/valve assembly supplied with the
appliance.
• Installation must conform with local codes, or
in their absence with National Fuel Gas Code,
NFPA 54/ANSI Z223.1, or Natural gas and proper
installation code CSA B149.1 or propane and
storage handling code B149.2 Handling and
storage of LP cylinders must conform to LP Gas
Code NFPA/ANSI 58. Appliance is not for use in
or on recreational vehicle and/or boats.
• Do not modify this appliance. Modifications will
result in a safety hazard. Questions regarding
certification in other areas may be addressed to
1.800.650.2433.
• Apartment Dwellers: Check with management
to learn the requirements and fire codes for
using an LP Gas appliance at an apartment. If
allowed, use outside on the ground floor with
a 10 foot clearance from walls or rails. Do
NOT use appliance on or under any apartment,
condominium balcony or deck.
• Before opening LP tank valve, check the
coupling nut for tightness. When appliance is
not in use, turn off control knob and LP tank
valve on supply cylinder.
• Never use LP tank if visibly rusted, damaged, or
out of date.
• If you notice grease or other hot material
dripping from appliance onto valve, hose
or regulator, turn off gas supply at once.
Determine the cause, correct, clean and inspect
valve, hose and regulator before continuing.
WARNING
If you smell gas:
1. Shut off gas to the appliance
at the tank.
2. Extinguish any open flame.
3. Open lid.
4. If odor continues, keep away from the
appliance and immediately call your
fire department.
WARNING
1. DO NOT store or use gasoline or other
flammable liquids or vapors in the
vicinity of this or any
other appliance.
2. An LP cylinder not connected for use
shall not be stored in the vicinity of
this or any other appliance.
DANGER
• DO NOT store a spare LP gas cylinder
under or near this appliance.
• Never fill the cylinder beyond
80% full.
• A fire causing death or serious
injury may occur if the above is
not followed exactly.
Failure to follow these instructions
could result in fire, explosion or burn
hazard, which could cause property
damage, personal injury or death.
WARNING
• To installer or person assembling this
appliance: Leave this manual with
this appliance for future reference.
• To consumer: Keep this manual with
this appliance for future reference.
This instruction manual contains
important information necessary for the
proper assembly and safe use of this
product. Read and follow all warnings
and instructions before assembling and
using this appliance. Do not discard
this instruction manual
WARNING
This product contains chemicals,
including lead in the brass of certain
component parts, that are known to
the State of California to cause cancer,
and birth defects or other reproductive
harm. Wash hands after handling.
When used, this product emits fuel
combustion chemicals that are known
to the State of California to cause
cancer, and birth defects or other
reproductive harm.

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a vehicle, which may become overheated by the
sun.
• Do not store LP tanks in an area where children
play.
• Storage of an appliance indoors is permissible
only if the cylinder is disconnected and removed
from the appliance.
LP Tank
The LP tank used with your appliance must meet
the following requirements:
• Purchase LP tanks only with these required
measurements: 12” (30.5cm) (diameter) x 18”
(45.7cm) (tall) with 20 lb. (9 kg.) capacity
maximum.
• Be constructed and marked in accordance
with specifications for LP tank of the U.S.
Department of Transportation (DOT) or the
National Standard of Canada, CAN/CSA-
B339, Cylinders, Spheres and Tubes for the
Transportation of Dangerous Goods.
• The propane cylinder used with this appliance
must include a collar to protect the cylinder
valve.
LP tank valve must have
• Type 1 outlet compatible with regulator or
appliance.
• 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.
LP tank must be arranged for vapor withdrawal.
LP (Liquefied Petroleum Gas)
• LP gas is non-toxic, 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.
LP Tank Filling
• Use only licensed and experienced dealers.
to check for gas leaks.
Use a clean paintbrush and 50/50 soap and water
solution. Use mild soap and water. Do not use
household cleaning agents. Damage to gas train
components can result. Brush soapy solution onto
all weld seams and entire valve area.
WARNING
If “growing” bubbles appear, do not use
or move the LP tank. Contact an LP gas
supplier or your fire department.
Installing The Lp Gas Cylinder Onto The Grill
1. Check that the cylinder valve is closed by
turning the knob clockwise.
2. Hang the cylinder from the tank hook.
TANK HOO
K
3. Orient the cylinder such that the valve opening
faces the left side of the grill, and so that the
hose is not kinked or damaged.
4. Attach or detach regulator to the LP gas
cylinder only when cylinder is at rest in the
tank holder.
5. Remove the protective cap from LP tank valve.
Perform a leak test.
• The regulator may make a humming or whistling
noise during operation. This will not affect the
safety or use of the appliance.
• Clean and inspect the hose before each use of
the appliance. If there is evidence of abrasion,
wear, cuts or leaks, the hose must be replaced
prior to the appliance being put into operation.
See product sheet for hose & regulator
information.
• Do not block holes in bottom or sides of
appliance.
• Never operate appliance with LP tanks out
of correct position specified in Assembly
Instructions.
• Always close LP tank valve and remove coupling
nut before moving LP tank form specified
operating position.
• NEVER store a spare LP tank under or near
appliance or in enclosed areas. NEVER fill the
cylinder beyond 80% full. An overfilled spare LP
tank is hazardous due to possible gas released
from the safety relief valve. Failure to follow
these instructions exactly could cause a fire
resulting in death or serious injury.
• If you see, smell, or hear escaping gas,
immediately get away from the LP tank/
appliance and call your fire department.
• All spare LP tanks must have safety caps
installed on the LP tank outlet.
LP Tank Removal, Transport and Storage
• Turn OFF all control knobs and LP tank valve.
Turn coupling nut counterclockwise by hand only
– do not use tools to disconnect. Install safety
cap onto LP tank valve. Always use cap and
strap supplied with valve. Failure to use safety
cap as directed may result in serious personal
injury and/or property damage.
• A disconnected LP tank in storage or being
transported must have a safety cap installed
(as shown).
Do not store an LP tank
in enclosed spaces such
as a carport garage,
porch, covered patio or
other building. Never
leave an LP tank inside
• LP dealer must purge tanks before filling.
• Dealer should NEVER fill LP tank more than
80% of LP tank volume. Volume of propane in
tanks will vary by temperature.
• 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
• Many retailers that sell appliances offer you the
option of replacing your empty LP tanks through
an exchange service. Use only those reputable
exchange companies that inspect, precision fill,
test and certify their cylinders. Exchange your
tank only for an OPD safety feature-equipped
tank as described in the “LP Tank” section of
this manual.
• Always keep new and exchanged LP tanks in
upright position during use, transit or storage.
• Leak test new and exchanged LP tanks BEFORE
connecting to appliance.
LP Tank Leak Test
WARNING
Appliance must be leak checked
outdoors in well-ventilated area, away
from ignition sources such as gas fired
or electrical appliances. During leak
test, keep appliance away from open
flames or sparks.
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
Safety Cap
OPD Hand Wheel

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Always use cap and strap supplied with valve.
Do not use a POL transport
plug (plastic part with
external threads). It will
defeat the safety feature of
the valve.
6. Hold regulator, insert
nipple (B) into LP tank
valve. Hand tighten coupling nut, holding
regulator in a straight line (C) with LP tank
valve so as not to cross thread the connection.
(C) Hold coupling nut and
regulator as shown for proper
connection to LP tank valve
(B) Nipple has to be centered
into the LP tank valve
7. Turn the coupling nut clockwise to tighten to
a full solid stop. The regulator will seal on the
back-check feature in 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 regulator and repeat steps 6 and 7. If
you are still unable to complete the connection, do
not use this regulator!
• Do not insert any foreign objects into the valve
outlet. You may damage the valve and cause a
leak. Leaking propane may result in explosion,
fire, severe personal injury, or death.
• Never attempt to attach this appliance to the
self-contained LP gas system of a camper or
trailer or motor home.
WARNING
Appliance must be leak checked
outdoors in well-ventilated area, away
from ignition sources such as gas fired
or electrical appliances. During leak
test, keep appliance away from open
flames or sparks.
Leak Testing
1. Turn all control knob(s) to OFF.
2. Be sure regulator is tightly connected to LP
tank.
3. Slowly 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 the leak
before proceeding.
4. Brush 50/50 soap and water solution onto
indicated connections shown.
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 number,
model number and name of items needed to the
Service Center at 1.800.650.2433.
6. Always close LP tank valve after performing
tank leak test by turning hand wheel clockwise.
WARNING
• Do not use appliance until
leak checked.
• If you cannot stop a gas leak,
immediately close LP tank valve and
call LP gas supplier or your
fire department!
Hose Check
• Before each use, check to see if hoses are cut or
worn. Replace damaged hose assembly before
using appliance. Use only valve/hose/regulator
specified by manufacturer. See product sheet
for hose & regulator information.
Warning: Never operate the appliance without the
grill grease cup installed under the appliance.
Lighting Instructions
Follow the instructions exactly.
1. Check that all burner control knobs and the
cylinder valve are turned to the “OFF” position.
2. Turn on the fuel supply by rotating the cylinder
valve knob counter-clockwise to full open.
3. DO NOT stand with head, body, or arms over the
grill when lighting.
Lighting The Main Burner
1. Make sure the control knob is in the “OFF”
position.
2. Push and turn the control knob to the “HIGH”
position.
3. If ignition does NOT occur in 5 seconds, turn
control knob to “OFF”, wait 5 minutes to allow
gas to dissipate and repeat lighting procedure.
If burner does not ignite, wait 5 minutes, see
“Match Lighting the Main Burners” section.
4. To turn off, turn the control knob clockwise until
it locks in the “OFF” position. This does not turn
off the gas flow from the cylinder.
Note: If burner does not light or flame is too low,
you may have spider or other insect blockage in
burner. See “Burner Assembly/Maintenance” under
Proper Care and Maintenance.
Match Lighting The Main Burners
1. Turn the burner control knob to “OFF”.
2. Use a long nose lighter and place through
lighting hole in the front of the grill to
approximately 1/2” (1 to 2 cm) from the burner.
Match Ignition Hole
3. Turn on the control knob to the “HIGH” position.
The burner should light within 5 seconds.
4. If the burner does not light, turn the control
knob to “OFF” and wait 5 minutes for gas to
dissipate and repeat lighting procedure.
5. If the burner does not light within the first
few attempts of match lighting, there is a
problem with the gas supply. Turn off the gas
at the burner and cylinder. DO NOT attempt to
operate the grill until the problem is found and
corrected. See “Trouble Shooting” section of
this manual.
Turning LP Cooker Off
• Turn knob to OFF position.
• Turn LP tank OFF by turning hand-wheel
clockwise to a full stop.
Burner Flame Check
• Light burner; rotate knob from HIGH to LOW. You
should see a smaller flame in LOW position than
seen on HIGH. Always check flame prior to each
use. A blue flame with little or no yellow flame
provides the best heat.
Operating The Grill
Never use Charcoal or Lighter Fluid inside your
Gas Grill. Read and follow all warnings and
instructions contained in the preceding sections of
this manual.
Breaking In Your Grill
• In manufacturing and preserving the
components of your grill, oil residue may be
present on the burner and cooking surfaces of
your grill.
• Before cooking on your grill for the first time you
should preheat it for 10 minutes on “HIGH” to
burn off these residual oils.
Preheating The Grill
• Prior to use, it is recommended that you preheat
your grill. This ensures that the grilling surfaces

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or holes are found replace burner. IMPORTANT:
Burner opening must slide over valve nozzle.
9. Orient the burner CORRECTLY by positioning the
burner opening onto the valve and installing
the screw to secure the burner in place.
10. Replace screw on the burner and follow the
“Gas Leak Testing” section of this manual.
Relight burners to verify proper operation.
11. Replace heat distribution plates and cooking
grills.
Proper Care & Maintenance
• To protect your grill from excessive rust, the unit
must be kept clean and covered at all times
when not in use.
• Wash cooking grills and heat distribution plates
with hot, soapy water, rinse well and dry. Lightly
coat cooking grill with vegetable oil or vegetable
oil spray.
• Clean inside and outside of grill by wiping
off with a damp cloth. Apply a light coat of
vegetable oil or vegetable oil spray to the
interior surface to prevent rusting.
• The stainless steel exterior surface of your grill,
can be cleaned with stainless steel cleaner.
• Never apply paint to the interior surface. Rust
spots on the interior surface can be buffed,
cleaned, then lightly coated with vegetable oil or
vegetable oil spray to minimize rusting.
Cleaning and Maintenance
Correct care and maintenance will keep your
appliance operating smoothly. Clean regularly as
determined by the amount of use. NOTE: Clean
the entire appliance each year and tighten all
hardware on a regular basis (1-2 times a year or
more depending on usage). Cleaning should be
done where detergents won’t harm patio, lawn, or
the like.
Cooking Grates
• When cool, wash your cast iron thoroughly with
are at the desired temperatures to sear the food
sugars when cooking. After lighting your grill,
set the main burner control knobs to the “HIGH”
position for 5 to 10 minutes.
Controlling Flare-Ups
• Flare-ups are a part of cooking meats on a gas
grill. This adds to the unique flavor of cooking
on a gas grill. Excessive flare-ups can over-cook
your food and cause a dangerous situation for
you and your grill. Excessive flare-ups result
from the build-up of grease in the bottom of
your grill. If this should occur, DO NOT pour
water onto the flames. This can cause the
grease to splatter and could result in serious
burns or bodily harm.
To Minimize Flare-Ups
• Trim excess fat from meats prior to cooking.
• Cook meats with high fat contents (chicken or
pork) on Low settings or indirectly.
• Ensure that your grill is on level ground and the
grease is allowed to evacuate the grill through
the drain hole in the bottom and into grease
cup.
Cleaning The Burner
NOTE: Spiders and small insects can spin webs
and build nests inside the burner. This especially
occurs in late summer and fall before frost when
spiders are most active. These nests can obstruct
gas flow and cause a fire in and around the
burner and orifice. Such a fire can cause operator
injury and serious damage to the appliance. To
help prevent a blockage and ensure full heat
output, clean and inspect burner tube often (once
or twice a month). NOTE: Water or air pressure will
not normally clear a spider web.
WARNING
All cleaning and maintenance should
only be done when the appliance is cool
and with the fuel supply turned off at
the LP cylinder. DO NOT clean any part
in a self-cleaning oven. The extreme
heat will damage the finish.
Burner Assembly/Maintenance
• Although your burner is constructed of stainless
steel, it may corrode as a result of the extreme
heat and acids from cooking foods. Regularly
inspect the burner for cracks, abnormal holes,
and other signs of corrosion damage. If found,
replace the burner.
• DO NOT obstruct the flow of combustion and
ventilation air. Burner tubes can become
blocked by spiders and other insects building
their nests. Blocked burner tubes can prevent
gas flow to the burners and could result in
a burner tube fire or fire beneath the grill.
To clean the Burner Assembly follow these
instructions to clean and/or replace parts of
burner assembly or if you have trouble igniting
the grill.
1. Turn gas off at control knobs and LP cylinder
tank valve.
2. Remove cooking grills and heat distribution
plates.
3. Remove screw from the burner “foot” using a
screwdriver.
4. Carefully lift the burner up and away from valve
opening.
5. Use a narrow bottle brush or a stiff wire bent
into a small hook to run through the burner
tube and flame port several times.
Debris
Note: Wear eye protection when performing
procedure 6.
6. Use compressed air to blow into burner tube
and out the flame ports. Check each port to
make sure air comes out each hole.
7. Wire brush entire outer surface of burner to
remove food residue and dirt.
8. Check burner for damage, if any large cracks
a non-citrus based soap and water. Be sure
to rinse and dry completely. (Note: Soap can
remove the seasoning of your cast iron if you
don’t restore it after cleaning.)
Heat Distribution Plates
• Periodically, it may be necessary to inspect and
clean the heat distribution plate to prevent
excess grease build-up. When the grill is cold,
remove the cooking grills. Inspect the heat
distribution plates and replace if broken or
damaged. Do not allow heat distribution plates
to become damaged to the extent that they may
fall through onto the burners. Replace the heat
distribution plates and cooking grills and light
the burners. Operate the grill on “HIGH” for 10
minutes to remove the excess grease.
Suggested Cleaning Materials
• Mild dish washing liquid detergent
• Wire brush
• Nylon cleaning pad
• Hot water
• Paper clip
• Soft brass bristled brush
Component Cleaning
• BURNER: Wire brush loose corrosion from burner
exterior. Clean clogged gas port holes with
an opened paper clip. Replace corroded or
damaged burners that would emit excess gas.
• After the appliance has cooled, wipe areas
where paint and finish have burned off to
minimize rusting.

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PGSEAR PARTS LIST
1115-PGSEAR
LID
PGSEAR-1
LID HANDLE
PGSEAR-2
M6 BOLT (2)
BB30L HINGE (2)
BB30L-5
CAST IRON GRILL (1)
PGSEAR-3
FLAVOR SCREEN (1)
PGSEAR-4
HEAT DEFLECTOR (1)
PGSEAR-5
BURNER (1)
PGSEAR-6
IGNITOR ELECTRODE (1)
PGSEAR-7
VALVE (1)
PGSEAR-15
KNOB (1)
PGSEAR-11
MANIFOLD (1)
PGSEAR-12
T
ANK BKT (1)
PGSEAR-14
LP REGULATOR (1)
HRL
GREASE TRAY (1)
PGSEAR-13
MANIFOLD COVER (1)
PGSEAR-8
MANIFOLD BKT (2)
PGSEAR-9
#8-32 SCREW (7)
M4 SCREW (2)
#8-32 KEPSNUT (4)
#8-32 SCREW (4)
M6 LOCK WASHER (2)
M6 BOLT (6)
PARTS LIST 1. Remove Qty (2) bolts from drum as shown.
Propane Tank Bracket
2. Install the propane tank bracket as shown
using existing hardware.
3. Remove cast iron grate, flavor screen, and heat
deflector from the sear and set aside
4. Remove side shelf from grill.
5. Install sear as shown using the supplied
hardware.
SEAR
LEVELING SCREW
6. Level the sear using the leveling screw. (Note:
Make sure the lid does not interfere with the
rivets on the side of the grill.)
7. Install heat deflector as shown.
HEA
T DEFLECTOR
8. Install flavor screen as shown with finger hole
at the back.
FLAVOR SCREEN
FINGER HOLE
9. Install cast iron grate as shown.
CAST IRON GRATE
10. Install handle as shown using the supplied
hardware.
11. Install knob and tighten the set screw in the
bottom with the allen wrench that is included.
HANDLE
KNOB
M6 LOCK WASHER (2)
M6 BOLT (2)

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12. Install grease tray.
GREASE TRAY
HOSE & REGULATOR
13. Install hose and regulator. Fittings must be
tightened using a wrench on both the hose
and fitting on the appliance.
WARNING
Leak test must be performed before
lighting the grill. Refer to leak test
instructions for proper testing.
LIMITED WARRANTY
Camp Chef No-Hassle Warranty
Here at Camp Chef we stand by our products and take pride
in our customer service. Because of this, your new Camp
Chef product comes with a No-Hassle Warranty. What does
that mean? It means that if we did something wrong, we
will make it right. We guarantee our products to be free from
defect in all materials and workmanship (excluding paint
and finish). We will replace defective parts so you can get
back to enjoying your product as soon as possible.
Required Maintenance:
Clean your product after each use to maintain its finish and
prolong its lifespan. Wipe away all grease and ashes. Keep
metal products free of moisture, salts, acids and harsh
fluctuations in temperature. Unfortunately, product paint
and other finishes are not covered by this warranty. The
exterior finish of the product will wear down over time.
Coverage Details:
Warranty does not cover normal wear of parts or damage
caused by misuse, abuse, overheating and alteration. No
alterations are covered in this warranty. Camp Chef is
not responsible for any loss due to neglectful operation.
Furthermore, this warranty does not cover damages caused
by natural disasters such as earthquakes, hurricanes,
tornadoes, floods, lightning, fires, etc.
Upon the expiration of this warranty, all such liability will
terminate. No other warranties are expressed or implied.
Please keep all original sales receipts. Proof of purchase is
required to obtain warranty services. Any parts or products
returned without written authorization will be discarded
without notice.
To obtain warranty services submit a warranty request at
http://www.campchef.com/warranty-information, email
[email protected], or call 1.800.650.2433.
Our Product Specialists are happy to help.
Warranty applies to the contiguous U.S. states only.
WARRANTY COVERAGE PERIODS
Pellet Grills & Stoves 1 year from purchase date
Fire Pits 1 year from purchase date
Water Heaters 1 year from purchase date
Movie Screens 1 year from purchase date
All other items & accessories 90 days from purchase date
www.CampChef.com • 1.800.650.2433 • Camp Chef is a registered trademark of Logan Outdoor Products
©2017 • 3985 N 75 W, Hyde Park, UT 84318, USA • Made in China 0117_PGSEAR_Instructions