Camp Chef BBQ SEAR BOX, PGSEAR Warning & Instruction Booklet

WARNING & INSTRUCTION BOOKLET

MODELS: PGSEAR

BBQ SEAR BOX

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 nonprescription 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.

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/CSAB339, 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

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

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.

(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

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

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.

PGSEAR PARTS LIST

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

ANK BKT (1) PGSEAR-14

LP REGULATOR (1)

HRL

GREASE TRAY (1)

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)

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 warranty@campchef.com, 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

Camp Chef BBQ SEAR BOX, PGSEAR Warning & Instruction Booklet

Specifications and Main Features

Frequently Asked Questions

User Manual