PERMASTEEL PG-40400S0L User manual

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PARTIAL STAINLESS STEEL GAS BBQ GRILL
USER'S MANUAL
MODEL NUMBER: PG-40400S0L
CUSTOMER SERVICE:(888)-287-0735
FOROUTDOORUSEONLY

Model Number: PG-40400SOL
PermaSteel Partial Stainless Steel BBQ Grill
We warrant to the original consumer purchaser ("Purchaser") of the PermaSteel Partial Stainless
Steel BBQ Grill ("Product") that each Product shall be free from defects in workmanship and
materials for a period of the years listed below from the date of original purchase. Our obligation
under this warranty shall be limited to repair or replacement of, or adequate compensation for, the
Product, at the option of us, during the warranty period. Our liability shall not extend beyond repair
or replacement, or the cost equivalent thereto.
This warranty excludes normal wear and tear of the Product and its parts or components, and any
damage arising from any of the following: negligent use or misuse of the Product, use contrary to
this User's Manual, or alteration by any one other than us. The warranty period of the years listed
below shall not be extended or renewed by the repair or replacement of, or compensation for, the
Product.
If your Product is defective or otherwise requires service or parts, please first call PermaSteel
Customer Service toll-free at (888)-287-0735, between 8:00 a.m. and 5:00 p.m., PST. Please tell
us which model you purchased, the date of purchase, and the problem with your Product. We will
use our very best efforts to honor this warranty, and repair, replace or compensate you for your
Product through your original place of purchase. A copy of your original purchase receipt must
accompany your service request.
Component
Burners:
Stainless Steel Flame Tamer:
Cast Iron Cooking Grids:
Valves, Igniters and related parts
Frame, Housing, Cart, Control Panel,
Partial Stainless Steel Parts:
Warranty Period:
1 Year
1 Year
1 Year
1 Year
1 Year
LIMITATION OF REMEDIES AND LIABILITY
We shall not be liable for any incidental or consequential damages for breach of any express or
implied warranty on its Product. Except to the extent prohibited by applicable law, any implied
warranty or merchantability or fitness for a particular purpose on this Product shall be limited to the
duration of the above warranty. Neither us nor anyone else who has been involved in the creation,
production, or delivery of the Product shall be liable for damages of any type, including but not
limited to any lost profits, lost savings, loss of anticipated benefits, or other incidental or
consequential damages which may arise out of the purchase, use, or inability to use the Product,
whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, even if
you have been advised of the possibility of such damage or any other claim by any other party.
Our liability for any breach of warranty shall be limited to repair or replacement of the defective part
or parts as described above. Some states do not allow the exclusion or limitation of incidental or
consequential damages, so the above limitation or exclusion may not apply to you. The above
warranty gives you specific legal rights, and you may have other rights which vary from state to
state.

BEFORE YOU BEGIN
MESSAGE TO OUR USERS
SAFETY SYMBOLS
INSTALLATION & SAFETY PRECAUTIONS
PROPANE & GAS WARNING
PAGE 1
PAGE 1
PAGE 2
PAGE 2
ASSEMBLY
PARTS
STEP I
STEP II
STEP III
SAFETY NOTICE
POST ASSEMBLY
GAS CONNECTION
LEAK TESTING
FINAL INSTALLATION CHECK LIST
GRILL LIGHTING INSTRUCTION
OPERATING INSTRUCTION
CARE & MAINTENANCE
TROUBLE SHOOTING
FOOD SAFETY
GRILL STORAGE
PAGE 3
PAGE 5
PAGE 6
PAGE 7
PAGE 8
PAGE 9
PAGE 12
PAGE 13
PAGE 14
PAGE 15
PAGE 18
PAGE 19
PAGE 20
PAGE 20

Thank you for your purchase of our Partial Stainless Steel BBQ Gas Grill. We sincerely
wish you will enjoy using our fine products.
• Please read this User's Manual in its entirety before using the grill.
• Please contact our customer service at (888)-287-0735 if you have any questions.
• Please read this User's Manual carefully. Failure to follow the provided instruction
can result in seriously bodily injury and/or property damage.
• Some parts of this grill may have sharp edges. Please wear suitable protective gloves.
IMPORTANT: This grill is intended for outdoor use only and is not intended to be
installed in or on recreational vehicles or boats.
NOTE TO INSTALLER: Leave this User's Manual with the customer after delivery
and/or installation.
NOTE TO CONSUMER: Leave this User's Manual in a convenient place for future
reference.
The symbols listed here are being used throughout this User's Manual. Please pay
special attention to them. The meaning of each of the symbols is listed here:
• DANGER- this symbol indicates an imminently hazardous situation which
will result in death or serious bodily injury if not properly followed.
•WARNING- this symbol indicates a warning of potential serious
bodily injury if the instructions are not strictly followed. Please be sure to read and
follow all these messages carefully.
,&
• _I, CAUTION- this symbol indicates a potentially hazardous situation which
may result in minor or moderate bodily injury if the instructions are not properly
followed.

WARNING
READ THIS SECTION FIRST BEFORE INSTALLING THE GRILL
This grill is designed to use LP gas only. Please use the grill with the regulator
supplied by PermaSteel.
The installation of this appliance must conform with local codes or, in the absence
of local codes, with either the National Fuel Gas Code, ANSI Z223. 1, or
CAN/CGA B149.1, Natural Gas Installation Code or CAN/CGA-B149.2, Propane
Installation Code.
The LP-gas supply cylinder is to be constructed and marked in accordance with the
specifications for LP-gas cylinders 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.
If an external electrical source is utilized, the outdoor cooking gas appliance, when
installed, must be electrically grounded in accordance with local codes or, in the
absence of local codes, with the National Electrical Code, ANSI/NFPA 70-1990,
or the Canadian Electrical Code, CSA C22.1. Keep the power cord of the motor
away from the hot surfaces of the grill while in use. Remove and store the motor in
a dry place when not in use.
This grill is safety certified for use in the United States and Canada only. Never
modify to use in other places. Modification may cause serious bodily injury or
property damage. PermaSteel is not responsible for any modifications, and all
warranties will be void.
WARNING
FOR YOUR SAFETY, PLEASE READ THIS SECTION FIRST
• If you smell gas:
• Shut off gas to the grill.
• Extinguish any open flames immediately.
• Open the grill lid.
• If the odor persists, please call your gas supplier or your fire department
immediately.
• Do not store or use gasoline or other flammable items in the vicinity of this grill.
• Any LP cylinder that is not connected for use should not be stored in the vicinity
of this grill.
2

REF#
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DESCRIPTION
Double-layer Lid
Temp. Gauge
_id handle
Name Plate
_id handle Seats
_id Rotary Pins
#Varm ing Rack
Sooking Grids
Flame Tamers
Burners
Grease Tray
Motor Bracket
Firebox
Valve Bracket
Main Burner Valves
Regulator
Side Burner Hose
Main Burner Manifold
Sontrol Panel
Knob Seats
Knobs
Side Burner Lid Handle
Side Burner Lid
Side Burner Lid Hinge
Sooking Grid, Side Burner
Side Burner Brass Ring
Gross BarA, Side Shelf
Q'TY
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DESCRIPTION Q'TY
Cross Bar B, Side Shelf 2
Right Side Shelf 1
Side Burner Valve 1
Side Burner Manifold 1
Side Burner 1
Bracket A, Side Burner 1
Side Burner Ignition Electrode 1
Side Burner Base 1
Lighting Rod 1
Right Door 1
Door Handles 2
Left Door 1
Tank Holder Rubber Strap 1
Right Side Panel 1
Casters with Brake 2
Casters without Brake 2
Bottom Panel 1
Left Side Panel 1
Door Magnet 1
Door Hinges 2
Hole Bushing 1
Tank Holder 1
Left Side Shelf 1
Back Panel 1
Rear Panel 1
Door Bracket 1
Heat Insulate Panel 1
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Notice: This part list is for your reference only, some parts will be different,
please subject to the actual appliance in carton.
4

PLEASE READ AND FOLLOW THE INSTRUCTIONS CAREFULLY
STEP BY STEP
Tools Required:
• #2 Philips head screwdriver (not provided)
• Hexagon/Allen wrench (provided).
• The following hardware bag is attached in left of warming rack packing foam.
Item Description Specification Quantity
Truss head screw
1 (With Split lock And 1/4-20xl/2" 8 pcs
Gasket)
2Hexagon/wrench 1 pc
STEP I:
•Take out side shelves from carton, remove all the packing material.
•Use four 1/4-20xl/2" screws to attach left side shelf from outside of the
firebox.
•Repeat the above step to install the left side shelf to firebox.
5

STEP I1:
1. Take out side burner hose with attached side burner valve from inside grill cabinet,
through square opening of right side panel.
2. Remove the packing materials. Use the provided hexagon wrench (Allen) to
loosen (don't remove) the setscrew on the control knob, and pull out the knob.
3. Remove the two M4"6 screws from front of side burner valve.
4. Remove the two screws on side burner bracket A, which attach side burner,
remove side burner, to allow side valve to be mounted.
5. From underneath side shelf, place side burner valve steam to go through opening
on front of side burner control panel. Attach and secure side gas valve to control
panel using the M4"6 screws.
6. Slightly insert Side Burner onto tip of gas valve make sure it's centered. Replace
and tighten the two screws on bracket A.
7. Attach igniter wire with red sleeve to valve electrode.
8. Place and press control knob onto valve steam, and tighten the setscrew of knob.
VERY IMPORTANT: the knob must be removed first, otherwise the side
burner can't be installed in next step.
3
2
4
6

5
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STEP II1:
• Place the warming rack to warming rack brackets.
• Attach the motor bracl_et in the left of firebox.
7

Safety Notice:
When you move or change the regulator, make sure the regulator hose in the
fixed ring, as the figure show below.
8

ONLY USE THE REGULATOR AND HOSE ASSEMBLY PROVIDED
WITH THIS GRILL. REPLACEMENT PRESSURE REGULATORS AND
HOSE ASSEMBLIES MUST BE THOSE SUPPLIED BY THE
MANUFACTURER
This is a LP (Liquefied Petroleum Gas) configured grill. Do not attempt to use a natural
gas supply unless the grill has been reconfigured for natural gas use.
The installation of this appliance must conform with local codes or, in the absence of
local codes, with either the National Fuel Gas Code, ANSI Z223. 1, or CAN/CGA-B149.2
Propane Installation Code.
•LP TANK REQUIREMENTS - THE LP TANK USED WITH YOUR GRILL MUST
MEET THE FOLLOWING
1) Measurement: 12"(30.5cm) (Diameter) X 18" (45.7cm) (Tall).
2) Maximum Capacity: 201bs(9Kg).
3) Constructed and marked in accordance with the specification for LP-gas
cylinders 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. See LP tank collar for marking.
4) Is arranged for vapor withdrawal.
5) Includes a collar to protect the tank valve.
6) Has no dents or rust. A dented or rusty LP tank may be hazardous,and
should be checked by your supplier.
7) Provides a shut-off valve terminating in an LP gas tank valve outlet specified, as
applicable for connection type QCC1 in the standard for compressed gas tank
valve outlet and inlet connection ANSI/CGA-V-1.
•LP TANK VALVE USED MUST MEET THE FOLLOWING
1) Have type I outlet compatible with regulator provided.
2) Have safety relief valve.
3) UL listed Overfill Protection Device (OPD). This OPD safety feature is
identified by a unique triangular hand wheel. Only use tanks equipped with this
type of valve. (See figure shown on the next page)
• FOR YOUR SAFETY
Ensure that the black plastic grommets of the regulator provided are in place and
that the hose does not come into contact with the heat shield or the grill head.
9

•CONNECT THE REGULATOR TO THE LP TANK
VERY IMPORTANT:
- THE REGULATOR SHALL NOT BE IN A LOCATION THAT WILL ATTAIN A
TEMPERATURE ABOVE 140"F (60°C) .
- THE REGULATOR SHALL INCORPORATE A PRESSURE RELIEF VALVE
OR OVERPRESSURE DEVICE.
- THE INLET OF THE PRESSURE REGULATOR SHALL BE FITTED TO
CONNECT TO THE TYPE I CONNECTION OF THE TANK VALVE PER
ANSIZ21.81.
1) Make sure tank valve is in its full off position (turn clockwise to stop).
2) Check tank valve to assure it has proper external male threads (type I
connection per ANSIZ21.81).
3) Make sure all burner knobs are in their off position.
4) Remove the protective cap from LP tank valve. Always use cap and strap
supplied with valve.
5) Inspect valve connection port and regulator assembly. Look for any damage or
debris. Remove any debris. Inspect hose for damage. Never attempt to use
damaged or plugged equipment. Contact your local LP gas dealer for repair.
6) When connecting regulator assembly to the valve, hand tighten nut clockwise
to a positive stop. Do not use a wrench to tighten. Use of a wrench may
damage quick coupling nut and result in a hazardous condition. (See figure
shown below)
OPD HANDWHEEL
7) Open tank valve fully (counterclockwise). Use a soapy water solution to check
all connections for leaks before attempting to light grill. If a leak is found, turn
tank valve off and do not use grill until a local LP gas dealer can make repairs.
10

WARNING
Never insert any foreign objects into the valve outlet. It may damage the valve
and cause leak, leaking gas may result in fire, explosion, heavy body injury, or
even death.
Do not connect this grill to the self-contained LP gas system of a motor home or
camper trailer.
Do not use this grill until leak tested.
STOP and call the fire department if any leaks are detected.
If you cannot stop a gas leak, close the LP tank valve IMMEDIATELY, call LP gas
supplier or the fire department.
DANGER
NEVER store a spare LP tank under or near grill or in an enclosed area.
NEVER fill the tank beyond 80% full. An overfilled spare LP tank is dangerous
because surplus gas may leak from safety relief valve. The safety relief valve on
a LP tank could activate to release gas and cause a fire.
The spare LP tank must have safety caps installed on the LP tank outlet.
If any gas leaks are found on the spare LP tank, immediately step away from the
grill, and call the fire department.
VERY IMPORTANT:
DISCONNECT THE TANK WHEN THIS GRILL IS NOT IN USE.
To disconnect LP gas tank:
1) Turn all the knobs off.
2) Turn the tank valve off fully (turn clockwise to stop).
3) Detach the regulator assembly from tank valve by turning the quick coupling
nut counterclockwise.
4) Install the protective cap back onto the LP tank valve.
11

GENERAL
Although all gas connections on the grill are leak tested at the factory prior to shipment,
a complete gas tightness check must be performed at the installation site due to
possible mishandling in shipment, or excessive pressure unknowingly being applied to
the unit. Periodically check the whole system for leaks, or immediately check if the
smell of gas is detected.
BEFORE TESTING
1) Make sure that all packing material is removed from the grill including the
tie-down straps.
2) Do not smoke while leak testing.
3) Never leak test with an open flame.
4) Make a soap solution with one part liquid detergent and another part water.
Prepare a spray bottle, brush, or rag to apply the solution to the connections. For
the initial leak test, make sure the LP cylinder is full.
5) Grill must be leak tested outdoors in a well-ventilated area, away from ignition
sources such as gas fired or electrical appliances, and flammable materials.
6) Keep grill away from open flames and/or sparks while testing.
TO TEST
1) Make sure all control knobs are in the "OFF" position.
2) Make sure the regulator is connected to the LP tank tightly.
3) Completely open LP tank valve by turning counter clockwise. If you hear a "POP"
sound, turn gas off IMMEDIATELY, as it indicates a heavy leak at the connection.
Call your gas dealer or fire department.
4) Check every connection from the LP tank up to and including the connection to
the manifold pipe assembly (the pipe that goes to the burner) by brushing or
spraying the soapy solution on the connections.
5) If soap bubbles appear, there is a leak. Turn off LP tank valve IMMEDIATELY
and retighten connections, Open LP tank valve again, and recheck.
6) If leaks cannot be stopped, DO NOT ATTEMPT TO REPAIR. Call our service
center at (888)-287-0735 for help.
7) Always close the LP tank valve after leak testing by turning clockwise.
Only those parts recommended by the manufacturer should be used on the grill.
Substitution will void the warranty. Do not use the grill until all connections have
been checked and do not leak.
12

SAFETY TIPS:
1) ALWAYS CHECK FOR LEAKS AFTER EVERY LP TANK CHANGE.
2) ALWAYS CHECK FOR LEAKS BEFORE EACH USE.
3) USE LONG BBQ TOOL TO AVOID BURNS.
4) CHECK ALL GAS SUPPLY FITTINGS FOR LEAKS BEFORE EACH USE. IT
IS HANDY TO KEEP A SPRAY BOTTLE OF SOAPY WATER NEAR THE
SHUT-OFF VALVE OF THE GAS SUPPLY LINE. SPRAY ALL THE FITTINGS.
BUBBLES INDICATE LEAKS.
5) DISCONNECTED LP CYLINDERS MUST HAVE THREADED VALVE PLUGS
TIGHTLY INSTALLED, AND MUST NOT BE STORED IN A BUILDING,
GARAGE, OR ANY OTHER ENCLOSED AREAS.
6) TURN OFF ALL CONTROL KNOBS AND LP TANK VALVE WHEN THE
GRILL IS NOT IN USE.
7) IF THE APPLIANCE IS STORED INDOORS, THE LP TANK MUST BE
DISCONNECTED AND REMOVED FROM THE GRILL.
8) LP TANKS MUST BE STORED OUTDOORS IN A WELL-VENTILATED AREA.
DISCONNECTED LP TANKS IN STORAGE OR BEING TRANSPORTED
MUST HAVE A SAFETY CAP.
9) NEVER LEAVE A LP TANK IN A RECREATIONAL VEHICLE OR BOAT
WHICH MAY BECOME OVERHEATED BY THE SUN.
10) DO NOT STORE LP TANK IN OR NEAR AN AREA WHERE CHILDREN
PLAY.
11) FOR ANY OTHER PROBLEMS, SEE "TROUBLESHOOTING" OR CONTACT
OUR SERVICE CENTER AT (888)-287-0735.
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At least 36" clearance maintained from combustible constructions to the sides
and back of this grill.
There is no unprotected combustible construction material over the grill.
All internal packaging has been removed.
Burners are sitting properly on valve orifices.
Knobs turn freely.
The regulator & hose connected to grill are provided by the manufacturer. (Pre-
set for 11.0" water column).
Unit tested and free of leaks.
User informed of gas supply shut off valve location.
13

VERY IMPORTANT: ALWAYS INSPECT THE HOSE PRIOR TO EACH USE.
•BEFORE LIGHTING:
Inspect the gas supply hose before turning the gas "ON". If there is evidence
of cuts, wear, or abrasion, it must be replaced before use. The replacement hose
assembly must be that specified by the manufacturer.
VERY IMPORTANT: TO LIGHT MAIN AND SIDE BURNERS OF THE GRILL:
1) Read instructions before lighting.
2) Turn all knobs to "OFF" then open the LP tank valve. Always keep your face
and body as far from the grill as possible when lighting.
3) Open lid during lighting.
4) Push and turn any control knob slowly to "HI" position. The built-in igniter will
click and spark simultaneously to light the pilot and burner in sequence.Turn
the control knob to "OFF" IMMEDIATELY if the burner does not light within 5
seconds. Wait 5 minutes for gas to dispel, then repeat the lighting procedure.
5) Follow match lighting instructions if burner can't be lit after repeating 3-4 times.
TO LIGHT THE MAIN AND SIDE BURNERS BY MATCH: (AS THE
FOLLOWING FIGURE SHOWS)
If the burner will not light after several attempts then the burner can be match lit.
Tools: Lighting rod (hanging behind the right door)
LO
14

Usage:
1)
2)
3)
Read instructions before lighting.
Open the lid during lighting.
Simply place a lighted match between the coils on the end of the lighting
rod and hold next to the burner to ignite.
4) Push and turn the knob to "HI" position, make sure the burner lights
and stays lit.
5) Repeat steps 3-4 to light other burners.
6) Keep a spray bottle of soapy water near the gas supply valve and
check the connections before each use. Do not light the grill if odor
of gas is present, and call our service center at (888)-287-0735.
FLAME CHARACTERISTICS:
1) Check for proper burner flame characteristics. Each burner is adjusted prior to
shipment; however, variations in the local gas supply may take subtle necessary
adjustments.
2) Burner flames should be blue and stable with small yellow tips, with no excessive
noise, or lifting. If any of these conditions exist call our customer service line. If
the flame is yellow, it indicates insufficient air. If the flame is noisy and tends to
lift away from the burner, it indicates too much air.
3) Small yellow tips are ok.
CAUTION
Clean the grill often. A grease fire that may damage the grill may occur if the grill
has not been cleaned frequently.
NEVER leave the grill unattended while using.
Do not use water to extinguish the grease fire, it may cause bodily injury. Turn
knobs off and LP tank off in case grease fire occurs.
Grease fire can't be put out by closing the lid. Turn off knobs and LP tank
IMMEDIATELY if any grease fire occurs.
15

WARNING
For your safety:
• Keep grill area clear and free from any flammable material.
• NEVER let children operate the grill or play near the grill.
• This grill is for outdoor use ONLY. NEVER use in an enclosed area such as a
carport, porch, covered patio, garage, or under a surface that can catch fire.
• Do not block the ventilation holes in the four sides of the grill cart, it may affect the
combustion performance of the burner due to insufficient air.
• Use the grill at least 36" away from any wall or surface. 120" away from objects that
may spark and ignite gas i.e. live electrical appliances, pilot lights of water heaters.
• Do not use this grill on or under wood balconies.
• This grill is designed to use only LP gas, DO NOT use lava rock, briquettes, or
charcoal on it.
• NEVER light the burner with the lid closed. Non-ignited gas accumulated inside a
closed grill may cause explosions.
• Check the burner flames periodically.
• Turn off the gas supply when the grill is not in use.
• Always turn off the LP tank completely and detach from the grill before moving.
TOTAL GAS CONSUMPTION:
Total gas consumption (per hour) of PG-40400SOL grill with all burners on "HI":
Main burners 40,000 Btu/hr
Side burner 12,000 Btu/hr
Total 52,000 Btu/hr
GENERAL USE OF THE GRILL:
The grill burners encompass the entire cooking area and are side ported to
minimize blockage from falling grease and debris. Above the burners are
stainless steel radiated flame tamers. The igniter knobs are located on the valve
panel. Follow the lighting instructions printed on the control panel.
USING THE GRILL:
Grilling requires high heat for searing and proper browning. Most foods are cooked
at the "HI" heat setting for the entire cooking time. However, when grilling large
pieces of meat or poultry, it may be necessary to turn the heat to a lower setting
after the initial browning. This cooks the food through without burning the outside.
Foods cooked for a long time or basted with a sugary marinade may need a lower
heat setting near the end of the cooking time.
16

1) Make sure the grill has been leak tested and is properly located.
2) Remove any packing material.
3) Light the grill burners using the instructions in this manual.
4) Turn the control knob to "HI" and preheat the grill for 15 minutes.
Cautions: Never leave the grill unattended when the grill is on.
5) The grill lid should be closed during the appliance preheat period.
6) Place the food on the grill and cook to the desired doneness. Adjust heat
setting, if necessary. The control knob may be set to any position between
"HI" and "LO".
7) The grill is designed to grill efficiently without the use of lava rocks or
briquettes of any kind. Heat is radiated by the stainless steel flame tamers
under the cooking grids.
8) The hot grill sears the food, sealing in the juices. The longer the preheat, the
faster the meat browns.
WARNING
ELECTRICAL GROUNDING INSTRUCTIONS
This grill is equipped with a three-prong (grounding) plug, and should be plugged
directly into a properly grounded three-prong receptacle. Do not cut or remove the
grounding prong. Keep any electrical supply cords and the fuel supply hose away
from any heated surfaces. Remove and store the motor in a dry place when not use.
USING OPTIONAL ROTISSERIE KIT (AVAILABLE SEPARATELY):
1) Take off the rotisserie kit from the grill.
2) Slide off the left fork, and load the meat or poultry onto the rod.
3) Restore the left fork, putting two forks into the meat or poultry as far as possible.
Make sure the meat or poultry is located in the middle of the rod. Screw the
wing nuts of the fork as tight as possible.
4) Wrap the food with butchers string (never use nylon or plastic string) to secure
any loose portions, if necessary.
5) Restore the rotisserie kit into the motor.
ROTISSERIE TIPS:
1) If larger cuts of meat are being grilled, the rod may flex. This is normal.
2) Remove the cooking grids for larger cuts of meat if the meat scrapes on the
cooking grids during rotation.
17