Char-Griller Duo 5050 User manual

OM5050F.4 ™ & © Char-Griller / A&J Mfg.
OWNER’S MANUAL
Duo™
Model # 5050
Keep your receipt with this manual for Warranty.
CUSTOMER SERVICE
1-912-638-4724
[email protected]
Contents of this manual are Trademarked and Copyrighted by Char-Griller | A&J Manu-
facturing. Using the information contained in this manual without consent of Char-Griller
and/or A&J Manufacturing is strictly prohibited.
Patented

OM5050F.4 ™ & © Char-Griller / A&J Mfg. 2
!
WARNING
For Outdoor Use Only
(outside any enclosure)
DANGER:
DO NOT use gas grill for indoor cooking
or heating. TOXIC fumes can accumu-
late and cause asphyxiation. Do not use
in or on boats or recreational vehicles.
PROP 65 WARNING:
WARNING: This product is equipped to operate
on propane gas which contains benzene, a
chemical known to the State of California to
cause cancer, birth defects, or other reproduc-
tive harm. This product and combustion by-
products produced when using this product
contain chemicals known to the State of Califor-
nia to cause cancer, birth defects, or other re-
productive harm.
SAVE THESE INSTRUCTIONS FOR FU-
TURE REFERENCE. IF YOU ARE ASSEM-
BLING THIS UNIT FOR SOMEONE ELSE,
GIVE THIS MANUAL TO HIM OR HER TO
SAVE FOR FUTURE REFERENCE.
FOR CUSTOMER SERVICE, CALL 912-
638-4724
WARNING:
Improper installation, adjustment, altera-
tion, service or maintenance could cause
injury or property damage. Read the instal-
lation, operation and maintenance instruc-
tions thoroughly before assembling or ser-
vicing this equipment.
Failure to follow these instructions could
result in fire or explosion that could cause
property damage, personal injury or death.
A propane gas cylinder is required for
operation. This gas grill is not intended
for commercial use.
!
Danger
If you smell gas:
1. Shut off gas to the appliance.
2. Extinguish any open flame.
3. Open Lid.
4. If odor continues, keep away from the appliance and immediately
call your gas supplier or your fire department.
Warning
Do not store or use gasoline or other flammable liquids or va-
pors in the vicinity of this or any other appliance.
An LP cylinder not connected for use shall not be stored in the
vicinity of this or any other appliance.
!

OM5050F.4 ™ & © Char-Griller / A&J Mfg. 3
For Your Safety
Stop! Call us first! Do Not return product to store. This grill has
been made to high quality standards. If you have any questions
not addressed in this manual or if you need parts please call our
customer service department at 1-912-638-4724 (USA), Mon-
day-Friday 8:30am-5pm (EST).
Have your grills serial number (located on the back of the grill
body or on the leg) when calling.
P.O. Box 30864
Sea Island, GA
31561
912-638-4724
www.CharGriller.com

OM5050F.4 ™ & © Char-Griller / A&J Mfg. 4
Important Safety Information .…………………page 5 - 6
Illustrated Parts List ……………………………..…page 7 – 8
Tools, Assembly Tips and Hardware List ….page 9
Assembly Instructions …………………………….page 11 – 24
Operating Grill
Connecting Gas Cylinder…………………………..page 26
Checking for Leaks………………………………..…page 27
Lighting Grill…...………………………………….....page 28 - 30
Cleaning and Care……………………………………page 31 - 32
Troubleshooting……………………………………..page 33 - 34
Grill Preparation………………………………………..page 35
Recipes…………………………………………..…...…page 36 - 40
Accessories…………………………………………….page 42 - 43
Table of Contents

OM5050F.4 ™ & © Char-Griller / A&J Mfg. 5
WARNING
FOR YOUR SAFETY
1.DO NOT store or use gasoline or any other flammable vapors and liquids within 25 feet
(8m) of this or any other appliance.
2. When cooking with oil/grease, do not allow the oil/grease to exceed 350°F (177°C).
Do not store or use extra cooking oil in the vicinity of this or any other appliance.
3. An LP Cylinder not connected for use should be stored a minimum of 10 feet (3m)
away from this or any other appliance. Never fill the cylinder beyond 80 percent
full. If the above information not followed exactly, a fire causing death or serious
injury may occur.
4. If you smell gas:
- Shut Off gas to the grill.
- Extinguish any open flame.
- Open Lid
For Your Safety
Stop! Call us first! Do Not return product to store. This grill has been made to high
quality standards. If you have any questions not addressed in this manual or if you
need parts please call our customer service department at 1-912-638-4724
(USA), Monday-Friday 8:30 am-5 pm (EST).
NOTE: The use and installation of this product must conform to local codes. In absence
of local codes, use the National Fuel Gas Code, ANSI Z223.1/NFPA54.
IMPORTANT NOTICE: read all instructions prior to assembly and use.
Read and understand all warnings and precautions prior to operating your grill.
CAUTION
1. This grill is for use with propane gas only (propane gas cylinder not included).
2. Never attempt to attach this grill to the self-contained propane system of a camper
trailer, motor home or house.
3. Never use charcoal or lighter fluid with the gas grill.
4. Do not use gasoline, kerosene or alcohol for lighting. The LP-gas supply cylinder must
be constructed and marked in accordance with the specifications for propane gas
cylinders of the U.S. Department of Transportation (DOT) CFR 49. This grill is not
intended to be used in or installed on recreation vehicles and/or boats.
5. Do not attempt to move the grill while it is lit.
6. Do not use the grill unless it is completely assembled and all parts are securely fas-
tened and tightened.
7. Keep all combustible items and surfaces at least 36 inches (91.4cm) away from grill
at all times.
8. DO NOT use this grill or any gas product near unprotected combustible constructions.
9. Do not use in an explosive atmosphere. Keep grill area clear and free from combus-
tible materials, gasoline and other flammable vapors and liquids.

OM5050F.4 ™ & © Char-Griller / A&J Mfg. 6
10. Do not touch metal parts of grill until it has completely cooled (about 45 minutes) to
avoid burns, unless you are wearing protective gear (BBQ mittens, pot holders, etc.)
11. Do not alter this grill in any manner
12. Clean and inspect the hose before each use. If there is evidence of abrasion, wear,
cuts, or leaks, the hose must be replaced prior to operating the appliance. The re-
placement hose assembly will be that which is specified by the manufacturer.
13. Move gas hoses as far away as possible from hot surfaces and dripping hot grease.
14. Never Keep a filled container in a hot car or car trunk. Heat will cause the gas pres-
sure to increase, which may open the relief valve and allow gas to escape.
15. Keep the grill’s valve compartment, burners and circulating air passages clean. In-
spect the grill before each use.
WARNING
1. This grill is for outside use only, and should not be used in a building, garage or any
other enclosed area.
2. The use of alcohol, prescription or non-prescription drugs may impair the operator’s
ability to properly assemble or safely operate the grill.
3. Always open grill lid slowly and carefully as heat and steam trapped within the grill
can burn you severely.
4. Always place your grill on a hard, level surface far away from combustibles. An as-
phalt or blacktop surface may not be acceptable for this purpose.
5. Do not leave a lit grill unattended. Keep children and pets away form the grill at all
times.
6. Do not place this grill on any type of tabletop surface.
7. Do not use the grill in high winds.
8. Disconnect the propane tank (LP tank) by first turning off valve on top of propane
tank, turn off burner valves, then disconnect regulator from valve on propane tank
by turning plastic connector counter clockwise. Unscrew wing-bolt in bottom shelf to
release the tank for removal.
DANGER
Liquid propane (LP) gas is flammable and hazardous if handled improperly. Know its
characteristics before using any propane product.
1. Propane Characteristics; Flammable, explosive under pressure, heavier that air and
settles in pools and low areas
2. In its natural state, propane has no odor. For your safety, an odorant has been add-
ed.
3. Contact with propane can cause freeze burns to skin.
4. This grill is shipped from the factory for propane gas use only.
5. Never use a propane cylinder with a damaged body, valve, collar or footing.
6. Dented or rusted propane cylinders may be hazardous and should be checked by
your propane gas supplier.

OM5050F.4 ™ & © Char-Griller / A&J Mfg. 7
1 2
3 4
5
6
7
8 9
10
11
1213
14
15
16
17
18
18
19
20
21
22
23
24
24
25
26
27
28 29
30
31
32
33
34
35
36

OM5050F.4 ™ & © Char-Griller / A&J Mfg. 8
ITEM QTY PART NAME PART NUMBER
1 1 GAS GRILL HOOD 30-0009
2 1 CHARCOAL GRILL HOOD 30-0013
3 1 GAS GRILL BODY 30-0010
4 1 CHARCOAL GRILL BODY 30-0014
5 2 THERMOMETER 55-0088
6 2 HOOD HANDLE 55-0009
7 2 WARMING RACK 20-0001
8 2 BURNER (short wire) 80-0007
9 1 BURNER (long wire) 80-0006
10 1 BASE 20-0037
11 3 FLARE-UP SHIELD 10-0001
12 2 LONG LEG 10-0031
13 2 SHORT LEG 10-0032
14 2 BEZEL 10-0358
15 2 LEG CROSS BAR 10-0033
16 6 COOKING GRATE 10-0325
17 2 WHEEL 55-0006
18 2 LEG BRACE 10-0034
19 1 AXLE 10-0327
20 1 WIRE SHELF 20-0038
21 1 CONDIMENT BASKET 20-0039
22 1 SIDE BURNER/ CONTROL PANEL 80-0009
23 3 UTENSIL HOOK 50-0002
24 2 GREASE TRAY 10-0028
25 1 CATCH PAN, REMOVABLE 20-0163
26 1 DAMPER CIRCLE 10-0036
27 1 POT STAND 20-0005
28 2 FIRE GRATE HANGERS, 8.5 20-0024
29 1 ASH PAN 20-0157
30 2 HUB CAP 55-0057
31 1 SIDE HANDLE 20-0040
32 2 GAS STACK 20-0034
33 1 CHARCOAL STACK 10-0184
34 1 GRATE LIFTER 10-0045
35 1 STOPPER BRACKET 10-0360
36 2 SLIDER BRACKET 10-0359

OM5050F.4 ™ & © Char-Griller / A&J Mfg. 9
¼-20x 1 ½” BOLT………....8 PCS
¼-20x 2 ¼” BOLT……….....8 PCS
¼-20x ½” BOLT….............. 33 PCS
2/5” FLAT WASHER………....2 PCS
¼” FLAT WASHER…………….18 PCS
¼-20 HEX NUT……………......27 PCS
¼” LOCK WASHER…………...35 PCS
HINGE PINS…………..............2 PCS
LARGE HAIR COTTER PIN…..2 PCS
SMALL HAIR COTTER PIN…...3 PCS
CENTER HINGE PIN……………..1 PC
SCREW……………………….....….3 PCS
#10-24 x 0.40” BOLT…...…....6 PCS
Assembly: Requires 2 people. Get another person to help. Tools Needed: Pliers, Phillips Head
Screwdriver and a 7/16” Nut Driver.
NOTE: Do Not tighten any bolts unless instructed to do so. Tightening too soon may prohibit
parts from fitting together. All Hex Nuts should be on the inside of the grill unless stated other-
wise. Unpack all contents in a well cleared and padded area. Estimated Assembly Time: 45
minutes STOP! Do Not Return to Store. If you are missing parts or need assistance please
email us at [email protected] or call 912-638-4724. Do not attempt assembly if you are
missing parts.
Hardware: 551030

OM5050F.4 ™ & © Char-Griller / A&J Mfg. 10
Page intentionally left blank for notes

OM5050F.4 ™ & © Char-Griller / A&J Mfg. 11
Step 1: Assemble the Leg Cross Bar, Short Leg, Long Leg, and Leg Braces then secure them
with four 2 1/4” Hex Bolts, four Flat Washers, four Lock Washers, and four Hex Nuts. Orient the
Leg so that the holes on the Legs and Leg Cross Bar are pointing in the direction of the Leg
Braces Side, see Below. NOTE: The orientation of the Legs are critical for later steps so pay
careful attention to how they go together.
Leg Brace
Leg Brace
Hex Bolts
Leg Cross Bar
Short Leg Long Leg
Hex Nuts
Flat Washers
Lock Washers Hex Bolts
Step 2: Lay down the assembly on the floor with the Leg Braces pointing up then install the
other set of Leg Cross Bar, Short Leg, Long Leg, and Wire Shelf using four 2 1/4” Hex Bolts,
four Flat Washers, four Lock Washers, and four Hex Nuts. First insert the Wire Shelf extend
bars at the end of the Wire Shelf into the upper hole on the Long Legs then insert a bolt
through the Leg Brace, Long Leg, Flat Washer, Lock Washer, and loosely tighten with a Hex Nut.
Then Place the other Leg Cross Bar, Short Leg in place (making sure that the holes on the Leg
Cross Bar and Short Leg are pointing in the direction of the Leg Brace) and secure them with
Hex Bolts and Hex Nuts. NOTE: The orientation of the legs are critical for later steps so pay
careful attention to how they go together.
Leg Cap
Leg Cross Bars
Short Leg
Long Leg
Wire Shelf
Hex Bolt
Hex Nuts
Flat Washer Lock Washer

OM5050F.4 ™ & © Char-Griller / A&J Mfg. 12
Holes on Leg Cross Bars
Top View of Assembly
Step 3: Place Bottom Shelf between the four legs and secure it to the legs with four Lock
Washers and four 1/2” Hex Bolts. The Hex Bolt should goes on the top hole on the Bottom
Shelf Base. Then slightly bend the “U” Shape wire on the Wire Shelf and insert it into the slots
on the Bottom Shelf.
Correct Orientation
Hex Bolts
Lock Washers
Hex Bolts
Wire Shelf
Bottom Shelf

OM5050F.4 ™ & © Char-Griller / A&J Mfg. 13
Step 4: Install one Flat Washer, Cotter Pin, and Hub Cap onto the Axle then slide the Axle
through the Wheels, Legs, and Bottom Shelf as shown below. Finish by attaching 2nd Washer,
Cotter Pin and Hub Cap.
Wheels
Hub Cap
Cotter Pin
Flat Washer
Bottom Shelf
Hub Cap
Flat Washer
Axle
Cotter Pin
Step 5: Attach two Slider Brackets and one Stopper Bracket onto the bottom of the Gas Grill
Body with six #10-24 x 0.40” Bolts. (NOTE: Oriented The Slider and Stopper Brackets as shown
below. This is critical for installing the Catch Pan on later step). The Bolts should go in from
inside the Grill Body.
Slider Brackets Stopper Bracket
Pan Head Bolts

OM5050F.4 ™ & © Char-Griller / A&J Mfg. 14
Step 6: Attach the Grill Bodies to the previous assembly cart using four Lock Washers, four
Flat Washers, and four 1/2” Hex Bolts per Grill Body from the inside of the Grill Bodies. The
Gas Grill Body should be on the Wheel side see below. NOTE: The orientation of the Grill Body
should be as shown Below.
Charcoal Grill Body
Gas Grill Body
Hex Bolts
Lock Washers
Lock Washers
Hex Bolts
Flat
Washers
Flat Washers

OM5050F.4 ™ & © Char-Griller / A&J Mfg. 15
Step 7: Install the Catch Pan onto the bottom of the Gas Grill Body by sliding the Catch Pan
underneath the Grill Body bottom. Making sure that the Brackets on the Catch Pan rest on top
of Slider Brackets. Slid the Catch Pan all the way till you can hang the Catch Pan side bracket
onto the Stopper Bracket.
Catch Pan
Stopper Bracket
Slider Bracket
Gas Grill Body
Step 8: Install Side Burner Body/Control Panel Assembly onto the Gas Grill Body. Lay down
the Side Burner Body Assembly that connect with the Control Panel on the floor and attach the
Control Pane to the front of the Grill Body with four 1/2” Hex Bolts and four Lock Washers (two
Hex Bolts and two Lock Washers on each side). Then attach the Side Burner Body Assembly on
the side of the Gas Grill Body.
Hex Bolts
Lock Washers
Hex Bolts
Side Burner Body
Gas Grill Body
Control Panel

OM5050F.4 ™ & © Char-Griller / A&J Mfg. 16
Step 9: Install the Burners into the Gas Grill Body by inserting the IGNITER WIRES and Burn-
ers through the open holes at the front of the Grill Body from inside of the Grill Body, see figure
9A. (NOTE: IGNITER MUST BE ON BOTTOM SIDE OF BURNER). The BURNER with the longer wire
goes on the right side of the GRILL BODY. Making sure that the Valve goes inside each burner,
see figure 9B. Then secure the Burners to the Grill Body with the screws provided, see figure
9C.
Figure 9A
Figure 9B Figure 9C
Valve
Burner
Screw
Burner
Burner
Igniter with Wire

OM5050F.4 ™ & © Char-Griller / A&J Mfg. 17
Step 10: Connect the Igniter Wires to the receptors on the Electronic Igniter underneath the
Control Panel. Any Wire can goes into any of the three receptors on the Electronic Igniter.
Electronic Igniter
Igniter Wires
Control Panel
Step 11: Install the Condiment Basket to the Charcoal Grill Body using four Lock Washers
and four 1/2” Hex Bolts. The Bolts should go from inside the Charcoal Grill Body
Condiment Basket
Hex Bolts
Charcoal Grill Body
Lock Washers

OM5050F.4 ™ & © Char-Griller / A&J Mfg. 18
Step 12: Install the Damper Circle to the side of the Charcoal Grill Body using one 1/2” Bolt,
two Flat Washers, one Lock Washer, and on Hex Nut see below.
Hex Nut
Lock Washer
Flat Washers
Damper Circle
Hex Bolt
Step 13: Attach the Side Handle to the side of the Charcoal Grill Body using two 1/2” Hex
Bolts, and two Lock Washers.
Side Handle
Hex Bolts
Lock Washers
Charcoal Grill Body
Gas Grill Body

OM5050F.4 ™ & © Char-Griller / A&J Mfg. 19
Step 14: Attach the Hood Handles to the Gas Grill Hood and Charcoal Grill Hood with two
Lock Washers and two Wing Nuts per handle. Then attach the Thermometer and Bezels to the
Grill Hoods. The Thermometer goes through the Bezel then the Grill Hood and secure with a
Wing Nuts.
Thermometer
Bezel
Wing Nuts
Grill Hood
Handle
Lock Washers
Step 15: Attach the Gas Chimney to the Gas Grill Hood and the Charcoal Chimney to the
Charcoal Grill Hood by inserting the Chimney through the opening on the Grill Hoods then se-
curing them with two 1/2” Hex Bolts and two Hex Nuts per Chimney. NOTE: Gas Grill Hood has
two Chimney openings and Charcoal Grill Hood has ONLY one opening.
Hex Bolts
Gas Chimney
Gas Grill Hood
Charcoal Grill Hood
Charcoal Chimney
Hex Nuts
Hex Bolts

OM5050F.4 ™ & © Char-Griller / A&J Mfg. 20
Step 16: Attach the Grill Hoods to the Grill Bodies using Shoulder Bolts, Clevis Hinge, and
Hinge Pins. First Place the Gas Grill Hood on the Gas Grill Body in the closed position and screw
the left side hinge with a Shoulder Bolt. Place the Charcoal Grill Hood in the closed position and
screw the right side hinge with a Shoulder Bolt. Then have your helper carefully open the Char-
coal Grill Hood while you insert the Clevis Hinge through the Charcoal Grill Body and Hood
Hinge. After the Charcoal Grill Hood is in place get your helper to carefully open the Gas Grill
Hood while you continue to push the Clevis Hinge through the Gas Grill Hood Hinge and Body.
Complete the installation by insert the Hinge Pins through the holes on the Shoulder Bolts and
Clevis Hinge.
Clevis Hinge
Shoulder Bolt
Shoulder Bolt
Charcoal Grill Hood
Gas Grill Hood
Cotter Pins