Big John PG-52 Installation Manual
Owner’s Manual
for Assembly, Operating & Maintenance of
Model PG-52 Table Top Gas Griddle
www.bigjohngrills.com
YOU MUST READ THIS OWNER’S MANUAL
BEFORE OPERATING YOUR GAS GRIDDLE.
DANGER
IF YOU SMELL GAS:
1. SHUT OFF GAS TO APPLIANCE
2. EXTINGUISH OPEN FLAMES
3. IF ODOR CONTINUES, KEEP AWAY FROM THE
APPLIANCE AND IMMEDIATELY CALL YOUR
GAS SUPPLIER OR FIRE DEPARTMENT.
LEAKING GAS MAY CAUSE FIRE, EXPLOSION,
PERSONAL INJURY, DAMAGE TO PROPERTY, AND
DEATH.
WARNING: Follow all leak-check
procedures listed in this manual carefully
prior to operation of this unit. Do this
even if the griddle was assembled by a
professional.
WARNING: Do not ignite this griddle
without reading the LIGHTING INSTRUCTIONS first.
WARNING: DO NOT store or use
gasoline or other flammable liquids/
vapors in the vicinity of this griddle.
An LP Cylinder not connected for use
should not be stored in the vicinity of this
unit.
THIS GAS GRIDDLE IS DESIGNED FOR OUTDOOR USE ONLY.
526 EAST ROLLING RIDGE DRIVE, BELLEFONTE, PA 16823
P: 814-359-2755 F: 814-359-2621 sales@bigjohngrills.com
1
TABLE OF CONTENTS
1. PROPANE SAFETY - GENERAL Page 3
2. PROPANE SAFETY - CYLINDER Page 4 & 5
3. PROPANE SAFETY - QCC Page 6
4. GENERAL INFORMATION Page 7
5. ASSEMBLY INSTRUCTIONS Page 8
6. SET-UP INSTRUCTIONS Page 9
7. OPERATING INSTRUCTIONS Page 10
8. CLEANING & CARE INSTRUCTIONS Page 11
9. PARTS LIST Page 12
10. ACCESSORY LIST Page 13
11. TROUBLESHOOTING GUIDE Page 14
12. WARRANTY Page 15
13. WARNINGS Page 16
2
PROPANE SAFETY - GENERAL
Liquid propane (LP) gas is a petroleum product as are gasoline and natural gas. In normal tempera-
tures and pressures, LP gas is a gas. When moderate pressure is applied, inside a cylinder, LP gas
becomes a liquid. As the pressure is released the liquid readily vaporizes and boils off as a gas.
LP gas has no odor, but rather an odor additive so you can smell it.
Propane gas is denser than air, if a propane tank purges to relieve pressure build-up, the propane
will collect in low lying areas. These areas can be easily ignited and are highly flammable. Use caution when dealing with a propane tank that may have recently self-purged.
DO NOT paint propane tanks any color other than white. Any alteration to tank color will result in
tank purging, fire, personal injury, or death.
Big John Grills & Rotisseries uses high quality Worthington Cylinders in 30 lb. and 40 lb. sizes.
These tanks are protected with a rust-resistant white powder coat finish.
Always keep the cylinder valve closed when not in use.
Cylinders are designed to function with the valve completely open or completely closed, there is no
in-between. Never open the valve just a “crack” or “half way”.
Always position the propane cylinder so that the connection between the valve and the regulator will
not cause any sharp bends in the hose.
NEVER store or use propane cylinders indoors.
Make sure the POL or QCC Connector is free from scratches or nicks which can cause gas leaks.
DO NOT store or use gasoline or other flammable liquids or vapors in the vicinity of a gas appliance.
DO NOT store extra liquid propane cylinders within the vicinity of a gas appliance.
DO NOT store a liquid propane cylinder in/on any part of an appliance not intended for such use.
Improper storage of a cylinder could lead an explosion, fire, personal injury, or death.
DO NOT store or lean items against unit surface or fuel cylinders while operating.
Shut off unit and all gas sources if the odor of unburned gas is detected. Make no attempt to use the
unit until gas leaks are fixed and/or the odor is accounted for.
Do NOT use a damaged, dented, or rusty LP cylinder or a cylinder with a damaged valve - replace
with a new one immediately.
Replacement LP tanks must match the regulator connection supplied with this grill and be a mini-
mum of 30 lb. capacity.
LIQUID PROPANE TANK REQUIREMENTS
For tanks not purchased from Big John Grills & Rotisseries: check to be sure cylinders have been
tested within the past 5 years and have a D.O.T. certification. Your LP gas supplier can do this for
you.
All LP tank supply systems must have a collar to protect the cylinder valve.
All tanks used on Big John Grills equipment must be a minimum of 30 lb. size.
Tanks larger than 100 lbs. in size may require a POL for connection. Please call a Big John Cus-
tomer Service Representative if you are using a 100 lb. propane tank.
3
PROPANE SAFETY - CYLINDER
DISCONNECTING AND TRANSPORTING PROPANE CYLINDERS FOR REFILLING
Turn off all control knobs and close the main cylinder valve. Disconnect regulator with QCC.
Place cylinder valve plug snugly in the main cylinder valve outlet. Only use the cylinder valve plug
that is provided with the cylinder. Other types of caps or plugs may result in leakage of propane.
Treat “empty” LP cylinders with the same care as full ones. Even when the tank is empty, there is
still some gas pressure left in the cylinder.
Always transport and store propane cylinders in a secure, upright position. Never store these pro-
pane tanks on their side, handle them roughly, or drop them.
Never keep propane cylinders (full or empty) in a hot vehicle. Heat can cause the relief valve to
purge propane creating a very dangerous situation.
To fill, take the LP cylinder to a propane gas dealer WARNING: We strongly recommend that your
LP cylinder be filled by an authorized propane dealer, by a qualified attendant, who fills the
tank by weight. IMPROPER FILLING IS DANGEROUS.
Air must be purged from a new LP cylinder before the initial filling. Your LP dealer will do this.
STORING PROPANE CYLINDERS
Turn off all control knobs and close the main cylinder valve.
Place cylinder valve plug or cap snugly in main cylinder valve outlet.
Always store propane cylinders in a secure, cool/dry place in the upright position.
Never store propane cylinders in a vehicle of any kind and or anywhere the temperatures can reach
125° F.
4
PROPANE SAFETY - CYLINDER
CONNECTING A FILLED 30 LB. CYLINDER
Remove the main cylinder plug.
Make sure that all gas valves on the grill are in the “OFF” position.
Thread the QCC Connector or POL Connection snugly into main cylinder.
ALWAYS check for leaks. Apply soapy water with a brush or spray bottle to areas where the QCC
(or POL) screw into tank, where the QCC (or POL) attach to regulator, where the hose screws into
the regulator, and where the hose screws into the appliance.
Open the cylinder valve and watch for bubbles.
If bubbles appear, tighten the connections further. If this does not remedy the problem, call your
propane dealer.
If the system is free of leaks, light the burners and proceed to cook.
In the event of a QCC failure, your grill will not light or stay lit, see page 14 for troubleshooting.
If you suspect any problems, have your grill and tank serviced by a qualified professional.
Spray Soapy Water on All Propane
Connections between Cylinder Valve
and Unit to Test for Leaks
Cylinder Valve to
QCC Connection
Hose to Regulator
Connection
Hose to Unit
Connection
Lime Green QCC
to Regulator
Connection
5
PROPANE SAFETY - QCC
HOW A QCC VALVE WORKS
There is a safety check valve inside our bright green QCC-1 fitting. Once the regulator is connected to the
propane tank and the main cylinder is “OPEN”, a minimal amount of gas is allowed to flow through the
check valve. If there are no downstream leaks, the pressure on both sides of the check valve will equalize
and the spring loaded stopper will open allowing maximum gas to flow. This only takes a few seconds to
complete and then you can start the lighting procedure.
IF THE QCC INDICATES FAILURE
If there is a downstream leak, or if you have started with a control valve “OPEN”, the pressure will not
equalize on both sides of the QCC check valve and it will fail. The only gas flow you will have is a small
amount that is designed to flow around the check-valve, the equivalent of 5,000 BTU’s. This may allow
you to light part of a burner, but not much more. When you open a control valve to light another burner,
you will not get any additional flame and may experience a blow out where none of the burners will light.
In case of a QCC failure, follow procedure below:
TO TROUBLESHOOT THE PROBLEM
CHECK: 1. Check that all of the control valves are in the “CLOSED” position.
2. Check that you are using at least a 30# propane tank
3. Check that you have lava rock in the grill
4. Check that the QCC is lime green - black or dark green will cause lighting problems.
If everything is correct, reset the system.
SOLUTION: To reset: Close all of the control val ves on the grill & close propane tank valve.
Then start the lighting procedure from the beginning. If the problem persists, Check for
If you experience a QCC Failure, first check your system for leaks:
Leaks:
1. Turn off all control valves and turn off propane tank
2. Extinguish any remaining open flames
3. Let gas dissipate until odor is no longer detected
4. Make sure all control valves are closed and gas tank valve is off
5. In a spray bottle, mix together dish soap and water
6. Spray the following with soapy water mixture
a. Tank Valve to QCC (part that screws into tank from regulator)
b. QCC to Regulator
c. Regulator to Hose
d. Entire hose
e. Hose to Grill
f. Each Control Valve where it Connects to Manifold
g. Manifold end cap (opposite side from hose connection)
7. Turn on propane tank
8. Inspect each connection and length of hose for any bubbles being produced
9. If bubbles are detected (bubbles indicate gas is escaping), turn off propane tank
and call Big John Grills to order replacement parts. Do not go to your local hardware store.
10. If no bubbles are detected, check to see if propane tank is empty.
11. If tank is not empty, please call Big John Grills for further assistance
If you need assistance at any time please call
Big John’s Customer Service at 1-800-326-9575 or 814-359-2755
6
Loading...