Pit Boss PTG2SS Instruction Manual

Portable gas grill
instructions and use
CAUTION! Carefully read instructions before
using to reduce the risk of fire, explosion
or burn hazard. Failure to follow these
intructions could cause property damage,
personal injury or death.
barbecue À GAZ
PORTATIF
instructions et UTILISATION
ATTENTION! Lire attentivement les
instructions afin de réduire le risque
d'incendie.
Model / Modèle : PTG2SS
Important: Read Carefully. Retain For Future Reference
Important : Prenez connaissance de ce document et conservez-le pour
référence ultérieure
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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.
Failure to follow these instructions could result in fire or explosion which
could cause property damage, personal injury or death.
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• This instruction manual contains important information necessary for
the proper assembly and safe use of this appliance. Failure to follow
these instructions could result in death or serious injury from explosion
or fire.
• Readandfollowallwarningsandinstructionscarefullybeforeassembling
or using this appliance.
• Follow all warnings and instructions when using this appliance.
• Keep this manual for future reference. SAVE THESE INSTRUCTIONS.
Tools Required for Assembly:
Phillips Screwdriver

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This appliance can produce carbon monoxide, an odorless toxic gas. Using it in
an enclosed space can kill you. Never use this appliance in an enclosed space,
such as a camper, tent, car, boat or home. This appliance is not intended for
and should never be used as a heater.
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To reduce the risk of serious injury or death from fire or explosion:
• Never leave grill unattended
• Never use alcohol, prescription or non-prescription drugs while assembling or
safely operating this appliance.
• Keep children and pets away at all times.
• Do not connect to the LP Gas supply until assembly is complete.
• Do not store or use gasoline or other flammable vapors and liquids 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.
• Always have a type BC or ABC fire extinguisher readily available.
•
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To reduce the risk of a laceration hazard, wear protective gloves when handling
parts that have sharp edges.

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A COMPLETE GUIDE TO COOKING WITH YOUR PORTABLE GAS GRILL
Packing List ................................................................................................................... 4
Preparation for Assembly .......................................................................................... 5
Grill Assembly Instructions ....................................................................................... 5
Hood Handle Assembly ................................................................................................ 5
Regulator-Valve Housing Assembly .......................................................................... 6
Igniter Housing Assembly ............................................................................................ 6
Drip Tray Access .............................................................................................................. 7
Table Top Use .................................................................................................................. 7
Using Gas ...................................................................................................................... 8
LP Gas Cylinder ................................................................................................................ 8
LP Regulator .................................................................................................................... 9
Connecting LP Gas Cylinder ........................................................................................ 10
Disconnecting LP Gas Cylinder ................................................................................... 10
Before Using Your LP Gas Grill ............................................................................... 11
Installation Codes .......................................................................................................... 11
Selecting a Location ...................................................................................................... 11
Performing a Leak Test ................................................................................................. 12
How to Perform a Leak Test ........................................................................................ 12
Lighting the Grill ........................................................................................................ 13
Lighting Grill Using the Pulse-Spark Ignitor ........................................................... 13
Manually Lighting the Grill ......................................................................................... 15
Check the Flame ............................................................................................................ 15
Cooking on the Gas Grill ......................................................................................... 16
Grill Cooking (Direct Method) .................................................................................... 17
Warming Rack ................................................................................................................ 18
End of Cooking Session ................................................................................................ 18
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Storage and Transportation ........................................................................................ 19
Care and Maintenance ............................................................................................ 20
Cleaning the Grill .......................................................................................................... 20
How to Clean the Burners ........................................................................................... 20
Emergencies .............................................................................................................. 22
Trouble Shooting ....................................................................................................... 23
Replacement Parts ................................................................................................... 25
Parts Illustration ........................................................................................................... 25
Parts List ......................................................................................................................... 26
Limited Warranty .................................................................................................... 27
Retain your receipt
If you need a replacement part under warranty, a proof of purchase will be
necessary.
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Grill Body
Regulator Housing Assembly
Igniter Housing Assembly
Handle and Bezels
Warming Rack (inside)
Cooking Grid (inside)
Flavor Activator (inside)
Owner's Manual and Warranty Card
Detailed Parts List and Illustrations may be found on pages 24 and 25
When ordering parts, it is VERY important to have the complete Model
Number to receive the correct replacement parts for your grill. The grill model
number and serial number are printed on the label located on the inside
surface of the rear leg.

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Remove grill and all packaging materials from the carton and place on a clean level
surface. Some parts are packed inside the grill body. Remove, unpack and inspect
these parts as well.
NOTE: Before using your grill, read the instructions and your manual.
For easier set-up and assembly, follow instructions of each step in the order they are
written as you look at the diagrams. If accessories mentioned in certain assembly
steps do not come with your model, skip that step and proceed to the next step that
applies to your model.
If you have any questions or need help, contact Customer Service at 1-877-303-
3134. Be sure to have the grill model number and serial number printed on the label
located on the inside surface of the rear leg. If you need replacement parts, look in
the Parts List section to find the exact parts you need. If you need a replacement
part under warranty, a proof of purchase will be necessary. You will be asked to
forward your proof of purchase. It is important to retain your receipt.
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1 HOOD HANDLE ASSEMBLY
Place a Handle Bezel between each end of the handle and the grill hood then insert a
¼-20 x .50" bolt through the inside of the hood into each end of the handle. Tighten
the bolts.
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2 REGULATOR-VALVE HOUSING ASSEMBLY
Insert the end of the regulator valve nozzle into the open end of the burner tube
(venturi). Align the holes in the Regulator Housing with the threaded holes in the
grill firebowl and insert two 5/32 x .31" bolts through the holes in the housing into
the threaded holes in the firebox. Tighten the bolts securely.
3 IGNITER HOUSING ASSEMBLY
• A - Thread the Electrode Wire through the hole in the Igniter Housing and
attach the end onto the pin at the bottom end of the Piezo Igniter.
• B - Align the holes in the Igniter Housing with the threaded holes in the firebowl
end. Insert Four 5/32 x .31" bolts through the housing into the threaded holes.
When installing the fourth bolt, first insert it through the ring at the end of the
Match holder chain and then through the Housing and into the firebowl end.
Tighten the bolts securely.
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WARNING - To reduce the risk of serious injury or death from fire or explosion:
• Be sure the grill has cooled completely before removing the drip tray.
• Be sure to empty and re-install the drip tray after each use.
CAUTION - To reduce the risk of laceration hazard, wear protective gloves when
handling parts that have sharp edges.
4 DRIP TRAY ACCESS
The Drip Tray is accessed for cleaning by rotating the spring tab and sliding the tray
out from under the grill.
Note: Shown without igniter
Housing for clarity
5 TABLE TOP USE
Unfold the legs, as shown and place grill on a level surface.
When legs are unfolded completely they will snap into the open position. Dimples
in the legs help them remain in position. To close, simply apply enough pressure to
overcome the friction fit.
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LP GAS CYLINDER
DANGER - If you see, smell, or hear the hiss of LP gas escaping from the cylinder:
1. Do not attempt to light appliance.
2. Extinguish any open flame.
3. Disconnect from fuel supply.
Carbon Monoxide Hazard
• This appliance can produce carbon monoxide which has no odor. Using it in an
enclosed space can kill you.
• Never use this appliance indoors, on recreational vehicles, or boats.
WARNING - To reduce the risk of serious injury or death from fire or explosion:
• Use only propane gas with this LP gas grill.
• Do not attempt to convert this LP unit to natural gas.
• Always use a gas appliance outdoors in an open area with good ventilation
to avoid breathing toxic fumes from combustion or leaking gas. As with all
conventional fuels, the burning process consumes oxygen and produces toxic
gases, including carbon monoxide. In addition, the combustion products of
such fuels, including liquefied petroleum (LP), contain chemicals known to the
state of California and other authorities to cause cancer, birth defects, and
other reproductive harm.
• Read and follow all warnings on LP Gas Cynlinder.
• Do not operate the LP gas grill without the LP gas cylinder oriented as instructed
in "Connecting LP Gas Cylinder" on page 7.
• Never connect or disconnect LP Gas Cylinder or fittings while grill is in use or
is hot.
• Do not use an LP Gas Cylinder if it has a damaged valve or shows signs of
dents, gouges, bulges, fire damage, corrosion, leakage, excessive rust, or other
forms of visual external damage; it may be hazardous and should be checked
immediately by a liquid propane supplier.
• Do not store a spare LP Gas Cylinder under or near the LP gas grill.
• When grill is not in use, turn off all grill Control Knobs and disconnect LP Gas
Cylinder.

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• Never fold or transport grill while LP Cylinder is attached.
• Never refill a 1 lb. cylinder.
The LP Gas Cylinder, for use with this LP gas grill, must meet the following
requirements:
1. 1 lb. capacity.
2. Contructed and marked in accordance with 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 Transportation of
Dangerous Goods; and Commission, as applicable (See collar for marking).
3. Marked "PROPANE."
4. Provided with a cylinder connection device that is compatible with the grill's
connection.
LP REGULATOR
WARNING - To reduce the risk of serious injury or death from fire or explosion:
• Clean and inspect the gas regulator before each use of the outdoor cooking gas
appliance. Replace the gas regulator prior to being used if there is evidence of
excessive abrasion or wear.
• Use only the gas regulator assembly that has been supplied with this gas grill.
Do not use a regulator from another manufacturer. A replacement gas regulator
must be specified by this grill's manufacturer before using.
• Always check for gas leaks when you connect and disconnect the regulator
to the LP Gas Cylinder, especially after a period of storage (for example, over
winter).
Any use or alteration of this unit inconsistant with these instructions could
be hazardous and will void your warranty.
NOTE: If the regulator assembly is not working properly and you need a replacement,
contact: Customer Service at 1-877-303-3135. Be sure to have the grill model
number and serial number printed on the label located on the inside surface of the
rear leg.
If you need a replacement part under warranty, a proof of purchase will be
necessary. You will be asked to forward your proof of purchase. It is important to
retain your receipt.
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CONNECTING LP GAS CYLINDER
1. Purchase 1lb. LP Gas Cylinder at your local retailer.
2. Turn the regulator knob to the "Off" position.
3. Remove protective cap from regulator opening. Remove plastic cap from top of
propane cylinder. Save cylinder cap for replacement on cylinder if gas remains
in cylinder after use.
4. Insert the 1 lb. LP Gas Cylinder into the threaded hole in the underside of the
regulator. Turn the cylinder clockwise until firmly seated. Hand tighten only.
(Fig. 1)
5. For optimum performance, allow cylinder to hang vertically off the edge of the
table when there is no danger of being bumped or disturbed.
NOTE: NEVER FOLD UP OR TRANSPORT GRILL WITH CYLINDER ATTACHED.
DISCONNECTING LP GAS CYLINDER
1. Turn regulator knob to the "Off" position.
2. Remove the cylinder by turning counterclockwise.
3. Replace the protective cap over the regulator opening. Replace the plastic cap
on the top on the top of propane cylinder for storage if not empty.
4. Store cylinder outdoors and away from grill.

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INSTALLATION CODES
WARNING: To reduce the risk of serious bodily injury or death from fire or explosion:
• This installation must conform with local codes or, in the absence or local codes,
with either the National Fuel Gas Code, ANSI 223.1/NFPA 54 Natural Gas and
Propane Installation Code, CSA B149.1, or Propane Storage and Handling Code,
B149.2 or the Standard for Recreational Vehicles, ANSI A 119.2/NFPA 1192 and CSA
Z240 RV Series, recreational Vehicle Code, as applicable.
• If an external electrical source is utilized, the outdoor cooking appliance, when
installed, must be electrically grounded in accordance with local codes or, in the
absence of local codes, with the National Electrical Codes, ANSI/NFPA 70, or the
Canadian Electrical Code CSA C22.1.
• Keep any electrical supply cord and the fuel supply hose away from any heated
surfaces.
SELECTING A LOCATION
WARNING: To reduce the risk of serious bodily injury or death from fire or explosion:
• Use this outdoor cooking appliance only outdoors and never in a building,
garage, breezeway, carport, porch or in any enclosed area. Locate outdoor
cooking appliance in an area with good ventilation on a level stable surface
clear of combustible and flammable material.
• Locate your LP gas grill at least 10 feet away from your house or any building.
• Maintain minimum clearances of 10" from back and sides of grill to any
combustible construction.
• Do not locate this appliance under overhead, unprotected combustible
construction.
• This outdoor cooking appliance is not intended to be used in/on boats or
installed in/on recreational vehicles.
• Never use gas grill as a space heater.
WARNING: Do not use this appliance under extended awnings. Failure to
comply could result in a fire or personal injury.
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PERFORMING A LEAK TEST
WARNING: To reduce the risk of serious bodily injury or death from fire or explosion:
• Perform a leak test before lighting your grill for the first time.
• Perform a leak test if any gas component is changed.
• Perform a leak test after travel, especially over rough or bumpy roads.
• Perform a leak test a minimum of once a season.
• Perform a leak test after a prolonged period of storage or non-use.
• Perform leak tests in a well ventilated area.
• Never use an open flame to test for gas leaks.
• Never smoke near the grill during a leak test.
• Do not perform a leak test on a grill while it is hot or in use.
• Do not use the gas grill if you detect a gas leak that cannot be corrected by
using the leak test procedures.
Before using your gas grill, perform a leak test on the Regulator Connection and LP
Gas Cylinders described in the next section.
HOW TO PERFORM A LEAK TEST - "First Time Use"
Supplies Needed for a Leak Test:
• Clean paint brush, water, dish washing liquid, empty clean bowl or can for
solution.
1. Make sure the regulator knob is turned to the "Off" position and verify that the
LP Gas Cylinder is tightened securely to the regulator.
2. Mix one part of water with one part of dish washing liquid.
3. Brush mix on Regulator, Propane Cylinder and connection as indicated by the
heavy arrows in the figure below. If "growing" bubbles appear, there is a gas
leak.
• If the leak appears at the regulator/cylinder connection, repeat cylinder
installation procedure, but do not over-tighten. (Note: Only hand tighten)
Repeat Leak Test..

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• If the leak is coming from the Gas Cylinder or if the leak cannot be stopped,
remove the cylinder and DO NOT USE THE GRILL. Call Customer Service at 1-877-
303-3134. Be sure to have the grill model number and serial number printed on
the label, located on the inside of the rear leg. If you need a replacement part
under warranty, a proof of purchase will be necessary.
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WARNING: To reduce the risk of serious bodily injury or death from fire or explosion:
• Open Hood before lighting the grill to release trapped gas.
• During failed lighting attempts, or if the burner goes out during operation, turn
Control Knob "Off" to dissipate any accumulated gas. Wait five minutes before
repeating lighting procedure.
LIGHTING GRILL USING THE PULSE-SPARK IGNITOR
1. Open the Hood.
2. Push the Regulator Knob in and turn 270 degrees (or 3/4) counterclockwise
to the High position (Fig. 2). Note the triangular indicator mark on the silver
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regulator housing.
3. Push the igniter button in repeatedlly until the burner is lit. Listen for the click
indicating spark ignition, and look to make sure the burner is lit.
If the burner goes out during operation, turn regulator knob to the "Off" position.
Open hood and wait five minutes before attempting to relight the grill to allow any
accumulated gas to dissipate.
If burner fails to light after three to four attempts, turn regulator knob to the "Off"
position and allow any accumulated gas to dissipate. Check for igniter spark by
pushing igniter button and looking at the igniter tip. If no spark, adjust gap between
electrode tip and burner to 3/16" (Fig. 3). If still no spark, see Troubleshooting
Section.
Wait five minutes; then repeat the lighting procedures.
The burner can also be lit manually, see Manual Lighting of the Grill on the next
page.
Should you notice that your burner is getting hard to light or the flame is not as
hot as it once was, refer to the "How to Clean your Burner" section to remove any
possible obstructions.

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MANUALLY LIGHTING THE GRILL
1. Open the Hood. IMPORTANT: Make sure regulator knob is turned "Off".
2. While holding a lit match near the burner (Fig. 4), push the regulator knob in
and turn 270 degrees (or 3/4 turn) counterclockwise to the High position (Fig. 2).
If burner goes out during operation, turn regulator knob to the "Off" position.
Open hood and wait five minutes before attempting to relight the grill to allow any
accumulated gas to dissipate.
CHECK THE FLAME
WARNING: To reduce the risk of serious bodily injury or death from fire or explosion
or a fire:
• Regularly inspect and clean Burner/Venturi Tube for insects or insect nests,
especially after periods of storage. Spiders or small insects can build nests,
webs, and lay eggs in th grill's Venturi Tube, obstructing the flow of gas to the
burner (Fig. 6). The backed-up gas can ignite and cause a fire. This is known as
a "flashback".
• Be sure Burner is re-installed properly before using grill.
The burner has been preset by the manufacturer for optimal flame performance. A
blue flame, possibly with a small yellow tip, is the result of the optimal air and gas
mixture (Fig. 5).
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Check the flame before each cooking session and throughout the grilling season.
Check the flame, especially after long periods of storing the grill. Note that the
minimum flame height should be 1/4". If the flame is significantly yellow in color, the
appropriate amount of LP gas in the air/LP gas mixture is not correct. This could be
due to a blocked burner from grease drippings or from insects building a nest inside
the burner or burner opening. Should you notice that your burner is getting hard
to light or the flame is not as hot as it once was, refer to the "How to Clean your
Burner" section to remove possible obstuctions.
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WARNING: To reduce the risk of serious bodily injury or death from fire, explosion
or burn hazard:
• Never use charcoal or lighter fluid in your gas grill. Keep this outdoor cooking
appliance clear and free from combustible materials, gasoline, and other
flammable vapors and liquids.
• Keep any electrical supply cord and regulator hose away from any heated
surfaces.
• Make sure there are no gas leaks or obstructions to the flow of combustion and
ventilation air before each use.
• Always open the hood before lighting the LP gas grill.
• Do not attempt to extinguish a grease fire wth water or other liquids. Have a
BC or ABC fire extinguisher readily available. Never douse or spray the grill or
cooking surfaces with water when hot. Burns from grease or water splatters
could occur.
• If your gas grill catches on fire:
- If the fire is in the grill portion and you can safely reach the regulator knob,

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then turn it to the "Off" position.
- If the fire involves the LP gas Cylinder, leave it alone, evacuate the area, and
call the Fire Department.
- If there is any type of fire that threatens either personal safety or endangers
property, call the Fire Department.
• Do not use the gril without the drip tray in place. Check the drip tray for build-
up. Empty excess grease before each use to reduce the risk of a grease fire in
the drip tray.
• Do not place containers of oil or grease on or near the grill.
• Do not operate a gas grill if you have knowledge or suspect a gas leak.
• Do not leave grill unattended.
• Do not wear loose clothing (hanging shirt tails, clothing with frills, etc.) around
a gas grill while in use or hot.
• Do not lean your body over the gas grill when lighting it or while it is in use or
hot.
• Do not touch hot surfaces. Use heat-resistant gloves, long-handled tongs, or
cooking mitts at all times, since the grill will become very hot. Open the hood
carefully when cooking to avoid burns from the hot air and steam trapped
inside.
• Do not allow children to operate or play near a gas grill. Keep children, animals
and bystanders out of the grill area.
• Do not move an LP gas grill when in use or hot.
• When grill is not in use, turn off all grill regulator knobs, and disconnect the LP
gas cylinder.
• Do not cover more than half (50%) of the cooking area if using griddle plates.
Full coverage of cooking area will cause overheating below the plates.
• Do not leave any utensils or cookware on a hot cooking surface.
• To reduce risk of burn injury from flame rollout or hot air/steam trapped inside
grill, open hood carefully.
GRILL COOKING (DIRECT METHOD)
Direct Cooking on the Grids: Food is cooked directly over the heat source. The
burner heats up the flavor activator under the cooking grid, which in turn heats
the food on the grill. The natural food juices from cooking fall onto the hot flavor
activator below and vaporize. Rising smoke bastes the food, giving it that unique

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barbecued flavor.
Use the direct cooking method for foods that take less than 25 minutes to cook:
steaks, chops, kabobs, sausages, and more. These foods should be turned once
halfway through the grilling time.
To sear meats, place them over direct high heat for 2 to 5 minutes per side. Smaller
pieces require less searing time. Hamburgers, steaks, chops, chicken breasts, and
larger cuts of meat all benefit from searing. Usually after searing you finish cooking
the food at a lower temperature.
For direct cooking, preheat the grill for 10 minutes with the burner on "High." Place
food on the cooking grid, and then adjust the burner to the temperature required.
Close the hood and lift it only to turn food or to test for doneness at the end of the
recommended cooking time.
Controlling Flare-ups: Flare-ups are part of cooking meats on a grill. This adds to
the unique flavor of barbequed food. However, excessive flare-ups can overcook
your food and create dangerous situation for you and your grill. Excessive flare-ups
may result from large amounts of fat on the food being cooked or the build up of
grease in the grill. If excessive flare-ups occur, DO NOT pour water on the flames.
This can cause grease to splatter and could result in serious burns or bodily harm.
If a grease fire occurs, turn off the burner until the grease burns out. To prevent or
minimize flare-ups, trim all excess fat or skin from meats before grilling and keep
the grill and drip tray cleaned of excess grease.
WARMING RACK
The warming rack is a convenient way to cook food more slowly and further from
the heat or to warm items such as bread or rolls. When opening the hood, be alert
for dripping fat from the warming rack that could drip onto the back of the grill.
Always check that your warming rack is properly fitted before use. Using heat
resistant gloves, carefuly wipe away any dripping grease.
END OF COOKING SESSION
WARNING: To reduce risk of serious injury or death from fire or burn hazard:
• Allow grill and grease in the drip tray to completely cool before emptying,
cleaning, moving, or storing grill.
• Empty the drip tray after each cooking session so grease does not accumulate.

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1. After each cooking session, close the hood and turn the burner to the "high"
position and burn for five minutes. This will burn off some cooking residue, thus
making cleaning easier.
2. When you have finished using your grill, turn the regulator knob clockwise to
the "Off" positon.
3. Remove the propane cylinder and replace the protective cap over the regulator
opening. Replace the plastic cap on the top of propane cylinder for storage if
not empty.
4. Store cylinder outdoors and away from grill.
5. Wait until the grill is cool to the touch before closing the hood, cleaning, storing
or transporting.
6. Clean your LP gas grill between uses and after extended storage periods. To
maintain the condition and extend the life of your grill, the unit should be
covered when stored.
STORAGE AND TRANSPORTATION
DANGER: Do not put grill in storage or travel mode immediately after use. Allow
grill to cool to touch before moving or storing. Failure to do so could result in fire
resulting in property damage, personal injury or death.
1. Disconnect LP gas cylinder from the grill and store outside, in a dry, well-
ventilated area, away from any sources of heat or ignition. Re-cap LP gas
cylinder valve with the safety cap.
2. Cover the regulator opening with the plastic cap supplied with the grill.
3. If storing grill or before an extended period of non-use, remove burner and
wrap with aluminum foil to reduce the risk of insects entering the burner holes.
Cooking grid abd flavor activator may be wrapped in foil as well.
4. Store grill indoors only if the LP gas cylinder is disconnected from the gas grill
and stored outside.
5. Before next use, remove aluminum foil and reinstall burner, flavor activator, and
cooking grid.
6. Before using the grill after periods of storage or non-use (i.e. over winter),
check your LP gas grill for gas leaks, deterioration, proper assembly, and burner
obstructions.
7. Periodically check and tighten all nuts, bolts, and screws on grill.
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