Members Mark Regal04ang, Regal04alp, Regal04clp Owner's Manual

Owner's Manual

Liquid Propane Gas Grill

MODEL REGAL04ALP

Natural Gas Grill

MODEL REGAL04ANG

MODEL REGAL04ALP SHOWN

Grill Information Center: If you have questions about assembly or grill operation, or if there are damaged or

missing parts when you unpack this unit from the shipping box, call us 8am - 4:30 pm CST, Monday through Friday at: 1-800-770-9769

WARNING:

Read this Owner's Manual carefully and be sure your gas grill is properly assembled, installed and maintained. Follow all leak check procedures carefully in this manual prior to grill operation. Do this even if the grill was club assembled. Failure to follow these instructions could result in serious bodily injury and/or property damage. 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 Owner's Manual with

the consumer after delivery and/or installation.

Note to Consumer: Leave this Owner's Manual in

a convenient place for future reference.

Important Note: This grill is manufactured to

exact specifications. Model REGAL04ALP is certified for use with LP gas and Model REGAL04ANG is certified for use with Natural Gas. You can not

convert this grill from one fuel type to the other.

For your safety, conversion kits are not available. Any attempt to convert your grill will void your warranty.

Manufacturer:

Grand Hall Enterprise Co., Ltd.

9th Fl., No.298, Rueiguang Rd., Neihu, Taipei, Taiwan (114)

P80109002G - Date: 04/22/2004

Table of Contents

Read These Safety Instructions

Warranty.....................................................2

Safety Instructions.....................................2

Natural Gas Safety Instructions...............4

Pre-Assembly Instructions..............................5

Hardware, Parts Diagram and Lists........6

Rotisserie, Parts Diagram and Lists.....10

Assembly Instructions.............................11

Lighting Instructions................................15

Rotisserie Instructions.............................17

Back Burner, Rotisserie Instructions....19

Cleaning and Maintenance Instructions....20

Frequently Asked Questions..................22

Cooking Instructions..............................A-1

Cooking Guide......................................A-2

Member's Mark Grill Warranty

Full 1-Year Warranty on Grill

For one year from the date of purchase, the Manufacturer will repair or replace, at their option, any grill part (except for paint loss, rusting, AA batteries) that is defective in material or workmanship.

Limited Warranty on Selected Grill Parts

From the date of purchase for the designated time periods stated below, the Manufacturer will replace the following grill parts if they are defective in material or workmanship. You will be charged shipping and handling.

• Lifetime of the grill: Stainless steel parts

(except for discoloration due to normal use or

excessive heat, and scratches or dents caused by normal use and improper maintenance). Aluminum Castings (except for paint loss)

• 2 Years: Cast-iron Burners

• For Warranty Service: Call our Grill Information

Center 8am - 4:30pm CST, Monday through Friday at 1-800-770-9769

Warranty Restrictions:

• This warranty does not cover surface rust or natural oxidation.

• This warranty is void if grill is used for commercial or rental purposes.

• This warranty applies only when the grill is used in the United States.

• This warranty gives you specific legal rights, and

you may also have other rights which vary from state to state. See back cover for warranty details.

FOR YOUR SAFETY

If you smell gas:

1. Shut off gas to the appliance.

2. Extinguish any open flame.

3. Open lid.

4. If odor continues, immediately call your gas supplier or your fire department.

FOR YOUR SAFETY

Do not store or use gasoline or other flam-

1. mable vapors and liquids in the vicinity of this or any other appliance.

An LP gas tank not connected for use shall

2. not be stored in the vicinity of this or any other appliance.

WARNING

Combustion byproducts produced when using this product contain chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

WARNING

Failure to comply with these instructions could result in a fire or explosion that could cause serious bodily injury, death, or property damage.

WARNING

Your grill will get very hot. Never lean over

the cooking area while using your grill. Do not touch cooking surfaces, grill housing, grill lid or any other grill parts while the grill is in operation, or until the grill has cooled after use.

Failure to comply with these instructions may result in serious bodily injury.

WARNING

(a) Do not store a spare LPG-gas cylinder under or near this appliance. (b) Never fill the cylinder beyond 80 percent full and (c) If the information in "(a)" and "(b)" is not followed exactly, a fire causing death or serious injury may occur.

Grill Installation Codes

The installation must conform with local codes or in the absence of local codes, with either the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or CAN/CGA-B149.1, Natural Gas and Propane Installation Code.

Correct LP Gas Tank Use

LP gas grill models are designed for use with a standard 20 lb. Liquid Propane Gas (LP gas) tank, not included with grill box. Never connect your gas grill to an LP gas tank that exceeds this capacity. A tank of approximately 12 inches in diameter by 18-1/2 inches high is the maximum size LP gas tank to use. You must use an

"OPD" gas tank which offers a listed Overfill Prevention Device. This safety feature prevents

the tank from being overfilled which can cause malfunction of the LP gas tank, Regulator and/or grill.

The LP gas tank must be constructed and marked in accordance with specifications of the U.S. Dept. of Transportation (DOT). In Canada, the LP gas tank must meet the Canadian Transportation and Communications (CTC) specifications. Also be sure to read and follow all LP gas instructions on the following page.

The LP gas tank has a Shut Off Valve, terminating in an LP gas supply tank valve outlet, that is compatible with a Type 1 tank connection device. The LP gas tank must also have a safety relief device that has a direct communication with the vapor space of the tank.

The tank supply system must be arranged for vapor withdrawal.

The LP gas tank used must have a collar to protect the tank valve.

Proper Placement and Clearance of Grill Never use your gas grill in a garage, porch, shed,

breezeway or any other enclosed area. Your gas grill is to be used outdoors only, at least 24 inches from the back and side of any combustible surface. Do not locate this appliance under overhead unprotected combustible surfaces. Do not obstruct the flow of ventilation and combustion air around the gas grill housing. This outdoor gas grill is not intended to be installed in or on recreational vehicles and/or boats.

WARNING

Failure to comply with these instructions could result in a fire or explosion that could cause serious bodily injury, death, or property damage.

• Never connect an unregulated LP gas tank to

your gas grill. The gas Regulator assembly supplied with your gas grill is adjusted to have an outlet pressure of 11" water column

(WC) for connection to an LP tank.

• Only use the Regulator and Hose Assembly

supplied with your gas grill. Replacement Regulators and Hose Assemblies must be those specified by manufacturer.

• Have your LP gas tank filled by a reputable

propane gas dealer and visually inspected and

re-qualified at each filling.

• Never fill the gas tank beyond 80% full.

• Have your propane gas dealer check the

release valve after every filling to ensure that it

remains free of defects.

• Always keep LP gas tanks in upright position.

• Do not store (or use) gasoline or other flammable

vapors and liquids in the vicinity of this gas grill.

• An LP gas tank that is not connected for use must

NOT be stored on bottom shelf inside cabinet or in

the vicinity of this or any other gas grill.

• Do not subject the LP gas tank to excessive heat.

• Never store an LP gas tank indoors. If you

store your gas grill in the garage or other indoor location, always disconnect the LP gas tank first and store it safely outside.

• LP gas tanks must be stored outdoors in a

well-ventilated area and out of the reach of children. Disconnected LP gas tanks must not be stored in a building, garage or any other enclosed area.

• When your gas grill is not in use the gas

must be turned off at the LP gas tank.

• The Regulator and Hose assembly can be seen

after opening the doors (if applicable), and must be inspected before each use of the grill. If there is excessive abrasion or wear or if the hose is cut, it must be replaced prior to the grill being used again.

• Keep the gas Regulator Hose away from hot

grill surfaces and dripping grease. Avoid unnecessary twisting of hose. Visually inspect hose prior to each use for cuts, cracks, excessive wear or other damage. If the Hose

appears damaged do not use the gas grill, call our Grill Information Center for a replace ment, at 1-800-770-9769.

• Never light your gas grill with the Lid closed

or before checking to ensure the Burner Tubes

are fully seated over the Gas Valve Orifices.

• Never allow children to operate your grill. Do

not allow children to play near your grill.

WARNING

If you smell gas:

• Shut off gas supply to the gas grill.

• Turn the Control Knobs to OFF position.

• Extinguish any open flame such as candle,

cigarette, lighter, etc., that could cause gas to ignite.

• Open the Grill Lid.

• Get away from the LP gas tank.

• Do not try to fix the problem yourself.

• If odor continues or you have a fire you cannot

extinguish, call your fire department. Do not call near the LP gas tank because your telephone is an electrical device and could create a spark resulting in fire and/or explosion.

NOTE: The normal flow of gas through the Regulator and Hose Assembly can create a humming sound. A low volume of sound is perfectly normal and will not interfere with operation of the grill. If humming sound is loud and excessive you may need to purge air from the gas line or reset the Regulator excess gas flow device. This purging procedure should be done every time a new LP gas tank is connected to your grill. For help call the Grill Information Center.

Grill Information Center, 8:00am-4:30pm CST, Monday through Friday at: 1-800-770-9769

Natural Gas Safety Instructions

• Your Natural Gas Grill is designed to operate on

Natural Gas only, at a pressure of 7" water column (W.C.) (1/4 psig or 1.75 kpa), regulated at the residential meter. Check with your gas utility company for local gas pressure and with your local

municipality for building code requirements. If your residential gas line pressure has not been regulated to 7" W.C., contact your local gas utility company for professional assistance.

• The gas pressure Regulator supplied with this

appliance must be used. This Regulator is set for an outlet pressure of 4" W.C.

• It is recommended that a Shut Off Valve be installed

at the gas supply source outdoors. Install at a point

after the gas pipe exits the outside wall and before the

Quick Disconnect Hose, or install it at the point before the gas line piping enters the ground. See Figure 1.

• Pipe sealing compound or pipe thread tape resistant

to the action of Natural Gas must be used on all male

pipe threads when making the connection.

Figure 1 (For Natural Gas Model Only)

NATURAL GAS SUPPLY

LOCKING

GAS

SHUT OFF

VALVE

Additional Hardware Not Included

TO NATURAL GAS REGULATOR

MALE FITTING

LOCKING GAS SHUT OFF VALVE

QUICK DISCONNECT

Gas Line Piping

If the length of line required does not exceed 50 feet, use a 5/8" O.D. tube. One size larger should be used for lengths greater than 50 feet.

• Disconnect your gas grill from fuel source when

the gas supply is being tested at high pressures.

This gas grill and its individual Shut Off Valve must

be disconnected from the gas supply pipe system

during any pressure testing of that system at

pressure in excess of 1/2 psi (3.5kpa).

• Turn off your gas grill when the gas supply is

tested at low pressures. The grill must be isolated

from the gas supply pipe system by closing its individual Manual Shut Off Valve during any

pressure testing of the gas supply pipe system at

pressures equal to or less than 1/2 psi (3.5kpa).

• The Quick Disconnect connects to a 3/8 inch NPT

thread from gas source. The Quick Disconnect fitting is a hand operated device that automatically shuts off the the flow of gas from the source when it is disconnected.

• The Quick Disconnect fitting can be installed

horizontally, or pointing downward. DO NOT install

the fitting with the opening pointing upward

because the fitting could collect water and debris.

• The Dust Covers (plastic plugs) provided with the

Quick Disconnect help keep the open ends

clean while disconnected.

• The outdoor connector must be firmly attached to

a ridged permanent construction.

• The Quick Disconnect MUST BE installed above

ground.

Gas piping may be copper tubing, type K or L; polyethylene plastic tube, with a minimum wall thickness of .062 inch; or standard weight (schedule

40) steel or wrought iron pipe. Copper tubing must be tin-lined if the gas contains

more than 0.3 grams of hydrogen sulfide per 100 cubic feet of gas.

Plastic tubing is suitable only for outdoor, underground use.

Gas piping in contact with earth, or any other material which may corrode the piping, must be protected against corrosion in an approved manner.

Underground piping must have a minimum of 18" cover.

Test Connections

All connections and joints must be thoroughly tested for leaks in accordance with local codes and all listed procedures in the latest edition of ANSI Z223.1

DANGER!

Do not use an open flame to check for gas leaks. Be sure there are no sparks or open flames in the area while you check for gas leaks. This will result in a fire or explosion which can cause serious bodily injury or death, and damage to property.

• WARNING: Do not route the 12 foot Quick

Disconnect Hose under a deck. The hose must be

visible and inspected prior to each grill use.

Assembly Instructions For Your Safety

Before Using Your Grill

During unpacking, assembly and construction stages always wear work gloves and eye protection. As you unpack this gas grill from shipping box, use the parts list to ensure all necessary parts are included. Inspect all parts for damage as you proceed. Do not operate your grill if it appears damaged. If you have questions during the assembly process, call 8am - 4:30 CST, Monday through Friday, 1-800-770-9769

CAUTION: While it is possible for one person to unpack this gas grill, obtain assistance from another person when handing the large and heavy grill head.

CAUTION: BEWARE OF FLASH-BACK

CAUTION: Spiders and small insects occasion-

ally spin webs or make nests in the grill burner tubes during transit and warehousing. These webs can lead to a gas flow obstruction which could result in a fire in and around the Burner Tubes. This type of fire is known as a "FLASH-BACK" and can cause serious damage to your grill and create an unsafe operating condition for the user. Although an obstructed Burner Tube is not the only cause of "FLASH-BACK", it is the most common cause. To reduce the chance of "FLASH-BACK", you must clean the Burner Tubes before assembling your grill, and at least once a month in late summer or early fall when spiders are most active. Also perform this Burner Tube cleaning procedure if your grill has not been used for an extended period of time.

To reduce the chance of "FLASH-BACK" (see CAUTION at left) clean the Burner Tubes and Burners before fully assembling your grill. Remove the Cotter Pin from the rear underside of each Burner using a pair of long nose pliers. Carefully lift each Burner up and away from the Gas Valve Orifice, then refer to Figure 1 and perform one of these three cleaning methods:

Bend a stiff wire, (a lightweight coat hanger

works well) into a small hook as shown below. Run the hook through the Burner Tube and inside the Burner several times to remove any debris.

Use a Burner Cleaning Brush, or a bottle

brush with a flexible handle. Run the brush through the Burner Tube and inside the Burner several times, removing any debris.

Use an air hose to force air through each

Burner Tube. The forced air should pass debris or obstructions through the Burner and out the ports.

WARNING!

The location of the Burner Tube with respect to the Orifice is vital for safe operation. Check to ensure the Orifice is inside the Burner Tube before using your gas grill. See Figure 2. If the orifice is not inside the burner tube, lighting the Burner may cause explosion and/or fire.

Tools Required for Assembly

Phillips Head screw driver

•

Long nose pliers - used to remove the

•

Cotter Pin when cleaning the Burners

Open-end wrench (included with Hardware

•

Pack) used to tighten the Casters.

GAS COLLECTOR BOX

Figure 1

TO CLEAN BURNER TUBE, INSERT HOOK HERE

ORIFICE

SPARK ELECTRODE

BURNER TUBE

Figure 2

CONTROL KNOB

CROSS SECTION OF MANIFOLD

GAS COLLECTOR BOX

GAS VALVE

BURNER PORTBURNER

FOOT

COTTER PIN

SPARK ELECTRODE

ORIFICE

Contents for Hardware Pack/LPG(Part#P06002003A)

Contents for Hardware Pack (Part #P4182A)

The following table illustrates a breakdown of the Hardware Pack. It highlights what components are used in the various stages of assembly.

Component

Hex Head Screw with Flange 1/4"x1/2" Ref.# S169G04081

Self - Tapping Screw M4 x 10mm Ref.# S172M04101

Self - Tapping Screw M4 x 10mm

Qty. to use

Purpose of Component

Attaches Left Side Burner Frame and Right Side Shelf onto the Cart

Secures the Spice Tray Panel on the Grill Bowl

Secures the Side Burner Panel on the Grill Bowl

Ref.# S172M04101 Wrench

Tightens the Caster and Hex Head Screw

Ref.# P05515005A Battery/AA

Powers the Electric Ignitor

Ref.# P05301001A

Size and Quantity of each Hardware Piece:

Hex Head Screw with Flange 1/4" x 1/2" QTY. 8 Ref.# S169G04081

Contents for Hardware Pack/NG(Part#P06002004A)

Contents for Hardware Pack (Part #P4182A)

The following table illustrates a breakdown of the Hardware Pack. It highlights what components are used in the various stages of assembly.

Self-Tapping Screw M4 x 10 QTY. 2 Ref.# S172M04101

Wrench (scale: 1/4) QTY. 1 Ref: #P05515005A

Battery/AA (scale 1/2) QTY. 1 Ref.#P05301001A

Component

Hex Head Screw with Flange 1/4" x 1/2" Ref.# S169G04081

Self - Tapping Screw M4 x 10mm Ref.# S172M04101

Phillips Head Screw 3/16" x 3/8" Ref.# S112G03061

Wrench Ref.# P05515005A

Battery/AA Ref.# P05301001A

Size and Quantity of each Hardware Piece:

Hex Head Screw with Flange 1/4" x 1/2" QTY. 8 Ref.# S169G04081

Self-Tapping Screw M4 x 10 QTY. 2 Ref.# S172M04101

Phillips Head Screw 3/16" x 3/8" QTY. 2 Ref.# S112G03061

Qty. to use

Purpose of Component

Attaches Left Side Burner Frame and Right Side Shelf onto the Cart

Secures the Spice Tray Panel on the Grill Bowl

Secures the Side Burner Panel on the Grill Bowl

Secures the NG Regulator on the Leg

Tightens the Caster and Hex Head Screw

Powers the Electric Ignitor

Wrench (scale: 1/4) QTY. 1 Ref: #P05515005A

Battery/AA (scale 1/2) QTY. 1 Ref.#P05301001A

Parts Diagram

Remove all the components from Grill Cart and Bowl, and place them within easy reach for grill assembly.

61 48

47 (NG only)

Parts List

QTY.REF#PART#DESCRIPTION

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

40.

41.

42.

43.

44.

45.

46.

47.

Lid Lid Hinge Temperature Gauge Name Plate Lid Handle Cooking Grid Flame Tamer / Ceramic Flame Tamer / Rack Burner / Main Gas Collector Box W. Electrode Back Burner Wind Shield Back Burner Assembly Back Burner Orifice (LPG) (NG) Back Burner Electrode Back Burner Extension Tube Grease Tray Grease Tray Handle Grease Tray Heat Shield,Upper Burner Bracket Bowl Panel, Left Bowl Panel, Right Bowl Panel, Front Bowl Panel, Rear Grease Draining Plate Electric Wire Set Gas Valve/Manifold Assembly (LPG) (NG) Control Panel (LPG) (NG) Control Knob for Main Burner Control Knob for Back Burner Control Knob for Side Burner Control Knob Seat Control Knob Spring Electric Ignitor, 4-port Battery / AA Cart Rear Wind Shield Cart Rear Panel Side Shelf, Right Spice Tray Lighting Stick Caster, 3 in., without Brake Caster, 3 in., with Brake Caster Bracket Door, Left Door, Right Door Handle Door Bracket (LPG) (NG) Cart Bottom Shelf (LPG) (NG)

P0011814AA P05532001O P00601051A P00412031D P00205011B P01602029C P01804001A P01722001B P02001044E P02609002B P06905004B Y0310012

P06520003A P06523001A P02610005B P03701004A P02705025B P00203005H P06903011A P0220306CA P00705047G P00706047G P0073807DC P0072508DC P06902002C P02615007A

Y0060088 Y0060089

P02909056A P02909056F P03426031L P03426041L P03426051L P03415014A P05504021A P02502134C P05301001A P06906001C P07701005A P01107001B P05206001A P05507031E P05112003D P05112004D P03325001K P04302009A P04303009A P00201001C

P03302003C P03302009C

P01010001C P01010002C

1 2 1 1 1 3 6 1 3 3 1 1 1

1 1 1 1 1 1 1 1 1 1 2 1 1

3 1 1 5 5 1 1 1 1 1 1 1 2 2 2 1 1 2 1

48.

49.

50.

51.

52.

53.

54.

55.

56.

57.

58.

59.

60.

61.

62.

63.

64.

65.

66.

67.

68.

69.

Parts List

Cart Legs with Side Panel, Left (LPG) (NG) Cart Legs with Side Panel, Right Regulator with Hose / LPG Tank Pull-Out Tray Assembly Side Burner Frame Side Burner Body Side Burner Lid Side Burner Control Panel Side Burner Pot Support Side Burner w/ Brass Ring Side Burner Electrode Side Burner Connection Hose (LPG) (NG) Side Burner Gas Valve Assembly (LPG) (NG) Regulator Assembly / NG Side Burner Extension Hose (NG only) Burner Air shutter / Main (NG only) Hose, 12ft. / NG Door Stop Plate (NG only) Door Magnet Cart Spice Basket (LPG) (NG) Side Burner Air shutter (NG only) Grease Tray Heat Shield,Lower Hardware Pack (LPG) (NG) Owner's Manual Grill Cover Rotisserie Assembly

P00904001B P00904002B P00905001B P03601004A Y0340004 P01108001B P02301005B P01127029B P02904011S P00805010B P02002047D P02614007C

P03705009H P03705009I

Y0060091 Y0060092 Y0080007 P03705007A P05524105A P03703001A P05510089E P05523001K

P05204005B P05204005B P05524005C P06903012B

P06002003A P06002004A P80109002G P07002001A Y0250042

QTY.REF#PART#DESCRIPTION

1 1 1 1 1 1 1 1 1 1 1

1 1 3 1 1 4

1 2 1 1 1

1 1 1

Record your grill Model Number and Serial Number below for future reference. MODEL NUMBER:

CSA label located here

SERIAL NUMBER:

For the repair or replacement parts you need: Call our Grill Information Center, 8am - 4:30pm CST, Monday through Friday at 1-800-770-9769

To make sure you obtain the correct replacement part(s) for your gas grill please refer to the parts list on this page. The following information is required to ensure you receive the correct parts:

1. Model and Serial Number (see CSA label on grill)

2. Part Number

3. Description

4. Quantity of parts needed Please allow sufficient time to process and ship.

IMPORTANT: Keep this Owner's Manual for convenient referral and for part replacement. IMPORTANT: Use only factory authorized parts. The use of any part that is not factory authorized can

be dangerous. This will also void your warranty.

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Members Mark Regal04ang, Regal04alp, Regal04clp Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual