Napoleon Ultra Chef US405RSB-INFRARED, Ultra Chef UD405RSB-TUBE BURNER, Ultra Chef 405 User Manual

APPLY SERIAL NUMBER LABEL FROM CARTON

APPOSEZ LÉTIQUETTE DU NUMERO DE SERIE DU CARTON

Serial No. / NO de série XXXXXX000000
MODEL NO. / N

O

DE MODÈLE

UD405RSB-TUBE BURNER

MANUFACTURED BY / MANUFACTURE PAR: NAPOLEON APPLIANCE CORP.,

214 BAYVIEW DR., BARRIE, ONTARIO, CANADA L4N 4Y8 PHONE: [phone]

FAX: [phone] EMAIL: [e-mail] WEB SITE: www.napoleongrills.com

RETAIN THIS MANUAL FOR FUTURE REFERENCE.

GARDER CE LIVRE POUR RÉFÉRENCES FUTURES

US405RSB-INFRARED

N415-0172 / JAN 08/08

Do not try to light this appliance without reading "LIGHTING"

instructions section of this manual.

WARNING

Do not store or use gasoline or other flammable liquids or vapors in the vicinity of

this or any other appliance. An L.P. cylinder not connected for use must not be

stored in the vicinity of this or any other appliance. If the information in these

instructions is not followed exactly, a fire or explosion may result, causing

property damage, personal injury or death.

DANGER

IF YOU SMELL GAS:

• Shut off gas to the appliance.

• Extinguish any open flame.

• Open lid.

• If odor continues, keep away from the appliance and immediately call your gas
supplier or your fire department.

CAUTION

During unpacking and assembly it is recommended that you wear work gloves and safety glasses for your

protection. Although we make every effort to make the assembly process as problem free and safe as pos-

sible, it is characteristic of fabricated steel parts that the edges and corners may be sharp and can cause cuts

if handled incorrectly.

SAFE OPERATING PRACTICES

• This gas grill must not be installed in or on recreational
vehicles and/or boats.

• This gas grill must only be used outdoors in a well-venti­lated space and must not be used inside a building, garage
or any other enclosed area.

• Keep any electrical supply cord and fuel supply hose away
from any heated surfaces.

• Inspect the fuel supply hose before each use. If there is
evidence of excessive abrasion or wear or the hose is cut, it
must be replaced, prior to using the gas grill, with a replace­ment hose assembly specified by the manufacturer.

• When the propane cylinder is not disconnected from the ap­pliance, the gas grill and cylinder must be stored outdoors
in a well ventilated space.

• Do not locate in windy settings. High winds adversely affect
the cooking performance of the gas grill.

• Adults and especially children should be alerted to the haz­ards of high surface temperatures. Young children should be
supervised near the gas grill.

• Under no circumstances should this gas grill be modified.

• Gas must be turned off at the propane cylinder or at the natu­ral gas supply valve when the gas grill is not in use.

• When the gas grill is to be stored indoors, the connection
between the propane cylinder and the gas grill must be dis­connected and the cylinder removed and stored outdoors in
a well ventilated space out of reach of children. Disconnected
cylinders must not be stored in a building, garage or any
other enclosed area. Natural gas units must be disconnected
from the supply when being stored indoors.

• The top lid is to be closed during the gas grill preheat period.

• Do not use the condiment tray to store lighters, matches or
other flammable materials.

• This gas grill is designed for outdoor use only.

2

NAPOLEON gas grills are manufactured under the strict Standard of the world recognized

ISO 9001-2000 Quality Assurance Certificate.

NAPOLEON products are designed with superior components and materials, and are assembled by trained

craftsmen who take great pride in their work. The burner and valve assembly are leak tested and test-fired at a

quality test station, and thoroughly inspected by a qualified technician before packaging and shipping to ensure

that you, the customer, receive the quality product you expect from NAPOLEON.

NAPOLEON GAS GRILL ULTRACHEF LIMITED LIFETIME WARRANTY

NAPOLEON warrants the following materials and workmanship in your new NAPOLEON gas grill against
defects for as long as you own the gas grill. This covers: aluminum castings (excluding paint), stainless steel
side shelves, wheels, knobs, stainless steel burners, stainless steel lid inserts, and lid handles. Subject to the
following conditions. During the first five years NAPOLEON will provide replacement parts at our option free of
charge. From the sixth year to lifetime NAPOLEON will provide replacement parts at 50% of the current retail
price.

Components such as stainless steel sear plates,ceramic infra red burner (excluding screens), cooking grids,
igniters (excluding batteries), temperature gauges and brass valves are covered and NAPOLEON will provide
parts free of charge during the first two years of the limited warranty.

Components such as regulators, casters, warming racks, hoses and connectors, fasteners and accessories
are covered and NAPOLEON will provide parts free of charge during the first year of the limited warranty.

NAPOLEON shall not be liable for any transportation charges, labour costs or export duties.

"NAPOLEON warrants its products against manufacturing defects to the original purchaser only, provided that the purchase was made through an authorized

NAPOLEON dealer and is subject to the following conditions and limitations:"

This factory warranty is non-transferable and may not be extended what-so-ever by any of our representatives.
The gas grill must be installed by a licenced, authorized service technician or contractor. Installation must be done in accordance with the installation instructions

included with the product and all local and national building and fire codes.

This limited warranty does not cover damages caused by misuse, lack of maintenance, grease fires, hostile environments, accident, alterations, abuse or neglect

and parts installed from other manufacturers will nullify this warranty.

This limited warranty further does not cover any scratches, dents, painted finishes, corrosion or discolouring by heat, abrasive and chemical cleaners, nor chipping

on porcelain enamel parts, nor any components used in the installation of the gas grill.

Should deterioration of parts occur to the degree of non-performance within the duration of the warranted coverage, a replacement part will be provided.
In the first year only, this warranty extends to the replacement of warranted parts which are defective in material or workmanship provided that the product has been

operated in accordance with the operation instructions and under normal conditions.

After the first year, with respect to this President's Limited Lifetime Warranty NAPOLEON may, at its discretion, fully discharge all obligations with respect to this

warranty by refunding to the original warranted purchaser the wholesale price of any warranted but defective part(s).

NAPOLEON will not be responsible for the installation, labour or any other costs or expenses related to the re-installation of a warranted part, and such

expenses are not covered by this warranty.

Notwithstanding any provision contained in this President's Limited Lifetime Warranty NAPOLEON's responsiblity under this warranty is defined as above and it

shall not in any event extend to any incidental, consequential, or indirect damages.

This warranty defines the obligation and liability of NAPOLEON with respect to the NAPOLEON gas grill and any other warranties expressed or implied with respect

to this product, its components or accessories are excluded.

NAPOLEON neither assumes, nor authorizes any third party to assume, on its behalf, any other liabilities with respect to the sale of this product. NAPOLEON will

not be responsible for: over firing, blow outs caused by environmental conditions such as strong winds, or inadequate ventilation.

Any damages to the gas grill due to weather damage, hail, rough handling, damaging chemicals or cleaners will not be the responsibility of NAPOLEON.
The bill of sale or copy will be required together with a serial number and a model number when making any warranty claims from NAPOLEON.
NAPOLEON reserves the right to have its representative inspect any product or part prior to honouring any warranty claim.
NAPOLEON shall not be liable for any transportation charges, labour costs, or export duties.

CONDITIONS AND LIMITATIONS

3

GENERAL INFORMATION

This gas barbecue is certified under Canadian and American national standards, CAN/CGA-1.6b-2002 and ANSI Z21.58b - 2002
respectively for outdoor gas grills and should be installed to conform with local codes. In absence of local codes, install to the current
National Fuel Gas Code CAN/CGA-B149.1 or ANSI Z223.1/NFPA 54, natural gas and propane installation code. When installed, the
unit must be electrically grounded in accordance with local codes or, in absence of local codes, with the current CSA C22.1 Canadian
electrical code in Canada or the National Electrical Code, ANSI/NFPA 70 in the United States.

Use only the pressure regulator and hose assembly provided with this barbecue. Replacement pressure regulators and
hose assemblies must be specified by the manufacturer. Do not store propane cylinder or spare cylinder on the shelf
beneath the barbecue. Never fill the cylinder beyond 80 percent full. If the preceding information is not followed exactly, a fire

causing death or serious injury may occur.

The regulator supplies a pressure of 11 inches water column to the gas grill and has a QCC1 type fitting. Cylinders to be used
with this unit must be supplied with a QCC1 cylinder valve. A QCC1 cylinder has a positive seating connection, which will not
allow gas flow until a positive seal has been achieved. It is also equipped with an excess flow device. In order to attain full

flow to the barbecue, the gas grill valves must be in the off position when the cylinder valve is turned on.

PROPANE CYLINDER SPECIFICATIONS: A dented or rusty cylinder may be hazardous and should be checked by your propane

supplier. Never use a cylinder with a damaged valve. Use only a propane supply cylinder constructed and marked in accordance with
the specifications for LP-gas cylinders of the Canadian Transport Commission (CTC) or the US Department of Transportation (DOT).
This appliance has been designed for use with a 20lb. (9.1 kg) size propane cylinder only (not supplied). The propane cylinder must
be provided with a shut-off valve terminating in a propane cylinder valve type QCC1, and a safety relief device having direct commu­nication with the vapour space of the cylinder. The cylinder supply system must be arranged for vapour withdrawal and the cylinder
shall include a collar to protect the cylinder valve. The cylinder shall incorporate a listed OPD (overfill protection device).

CALIFORNIA PROPOSITION 65: The burning of gas fuel creates by - products, some of which are on the list as substances

known by the State of California to cause cancer or reproductive harm. When cooking with gas, always ensure adequate
ventilation to the unit, to minimize exposure to such substances.

IMPORTANT DO'S AND DON'TS

DO'S DON'TS

Do not attempt to use a tank which is not equipped with a
QCC-1 type connection.

Do not use condiment tray to store lighters, matches or
any other combustibles.

Do not locate unit under unprotected combustible
construction.

Do not operate rear burner with main burners operating.

Do not leave grill unattended when operating.

Do not light burners with lid closed.

Do not move grill when hot or operating.

Do not use a pressure washer to clean any part of the unit.

Do not allow cold water (rain, sprinkler, hose, etc.) to
come in contact with hot ceramic burners. A large
temperature differential can cause cracking in the
ceramic tile.

Do not operate the grill in a screened in porch, gazebo
or any other enclosed area.

4

Read the entire instruction manual before operating the
gas grill.

Maintain proper clearance to combustibles (20" to rear
of unit, 6" to sides). Additional clearance is recom­mended (24") near vinyl siding or large panes of
glass.

Leak test the unit before initial use, annually and
whenever any gas components are replaced.

Follow lighting instructions carefully when operating
grill. Burner controls must be off when turning supply
cylinder valve on.

Ensure sear plates are positioned properly according to
sear plate installation instructions.

Clean grease tray and sear plates regularly to avoid
build-up which may lead to grease fires.

Remove warming rack before lighting rear burner. (The
extreme heat will damage the warming rack.)

Inspect infrared burner venturi tube for spider webs
and other obstructions periodically. Clean the tubes
completely if you find any such obstructions.

GAS HOOK-UP INSTRUCTIONS

CYLINDER CONNECTION: Ensure that the gas regulator hose is kink free. Remove the cap or plug from the cylinder fuel

valve. Insert the black QCC1 regulator nipple onto the QCC1 fuel valve. Hand tighten clockwise. Do not use tools. Leak test all joints
prior to using the barbecue. A leak test must be performed annually, and each time a cylinder is hooked up, or if a part of the gas

system is replaced.

PROPANE CYLINDER INSTALLATION: Set cylinder into the hole in the bottom shelf.

PROPANE GAS HOOK-UP: Press the nylon grommet into the side panel, and pass the hose from the side burner through

the grommet. Insert the quick connect hose end into the regulator outlet.

NATURAL GAS HOOK-UP: This natural gas grill is supplied with a 10ft supply hose (complete with a quick disconnect)

designed for natural gas and certified for outdoor use. The gas grill is designed to operate at an inlet pressure of 7 inches water
column. A regulator must be installed if the house pressure is greater than 7 inches water column. Piping and valves upstream
of the quick disconnect are not supplied. The quick disconnect must not be installed in an upward direction and a readily
accessible manual shut-off valve must be installed upstream of, and as close to, the quick disconnect as is feasible. The flared
end of the hose must be connected to the unit as illustrated in the Natural Gas Hose Attachment diagram. These connections must
be made by a licensed gas installer. Leak test all joints prior to using the gas grill.

Connect the 20" hose from the manifold, to the side burner as illustrated in the Natural Gas Hose Attachment diagram. Connect the
supply hose to the flare connection which faces down from the side burner. Tighten all connections using two wrenches. (Do not

use thread sealer/pipe dope.)

WARNING

• The installation must be performed by a licensed gas fitter, and all connections must be leak tested before operating the grill.

• Do not route hose underneath drip pan.

• Do not route hose between space in bottom shelf and back panel.

• Do not route hose over top of rear panel.

• Ensure all hose connections are tightened using two wrenches. Do not use teflon tape or pipe dope on any hose connection.

• Ensure the hose does not contact any high temperature surfaces, or it may melt and leak causing a fire.

• Leak test all the connections using a soap and water solution, as per the leak testing instructions found in this manual.

LEAK TESTING INSTRUCTIONS

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 leaks. Sparks or open flames will result in a fire or explosion, damage to property, serious bodily injury or death.

LEAK TESTING: This must be done before initial use, annually and whenever any gas components are replaced or serviced. Do

not smoke while performing this test, and remove all sources of ignition. See Leak Testing Diagram for areas to check.

1. Turn all burner controls to off. Turn supply valve on.

2. Brush a half and half solution of liquid soap and water onto all joints and connections of the regulator, hose, manifolds and

valves.

3. Bubbles will indicate a gas leak. Either tighten the loose joint or have the part replaced with one recommended by the customer

care department.

4. If the leak cannot be stopped, shut off the gas supply, disconnect it and have the barbecue inspected by your gas supplier or

dealer. Do not use the appliance until the leak has been corrected.

5. Turn off gas supply.

5

405 LIGHTING INSTRUCTIONS

Open lid.

Ensuring burner

controls are in the off

postion, turn on the

gas supply valve.

SIDE

BURNER

IGNITER

SIDE

BURNER

Rear Burner Lighting

Remove warming

rack and hanging

basket.

Light match and hold

to ports on left side of

rear burner.

Turn rear burner

control to high posi-

tion.

LIGHTING HOLE

Tube Burner Lighting

Turn left burner

control to high posi-

tion.

Press and hold

igniter button until lit,

or light by match.

If ignition is not

immediate, turn

burner control off.

Wait 5 minutes.

LEFT

IGNITER

BURNER

Main Infared Burner

Lighting

Turn infrared burner

control to high

position.

Press and hold

igniter button until lit,

or light by match.

If ignition is not

immediate, turn

burner control off.

Wait 5 minutes.

CENTER

BURNER

INFRARED

REAR

BURNER

BURNER

(US405)

Side Burner Lighting

Open burner cover.

Turn side burner

control to high

position.

Push igniter several

times or light by

match.

RIGHT

BURNER

(UD405)

If ignition is not

immediate, turn

burner control off.

Wait 5 minutes.

The propane cylinder is equipped with an excess flow device. Unless all
burners are turned off prior to turning the cylinder on, only small flames will
be achievable.

Do not use rear burner while operating main burner.

6

With left burner

operating on high, turn

center or right tube

burner to high

If ignition is not

immediate, turn

burner control off.

Wait 5 minutes.

INFRARED HEAT

Most people don’t realize that the heat source that we are most familiar with, namely the sun warms the earth using mainly infrared energy.
Infrared energy is a form of electro-magnetic energy that has a wavelength just greater than the red end of the visible light spectrum, but less
than that of radio waves. This energy was discovered in 1800 by Sir William Herschel who, dispersed sunlight into its component colours
using a prism. He showed that most of the heat in the beam fell into the spectral region just beyond the red end of the spectrum, where no
visible light existed. This is infrared energy. Most materials readily absorb infrared radiation in a wide range of wavelengths, causing an
increase in temperatures of the materials. This is the same phenomenon that causes us to feel warmth when we are exposed to sunlight.
The infrared rays from the sun travel through the vacuum of space, through the atmosphere and penetrate our skin. This causes increased
molecular activity in the skin, which creates internal friction and generates heat, allowing us to feel warmth.

Foods cooked over infrared heat sources are heated by the same principle. Charcoal is the traditional way of infrared cooking that we are
all familiar with. The glowing briquettes emit infrared energy to the food being cooked, with very little drying effect. Any juices or oils that
escape from the food drip down onto the charcoal and vaporize into smoke giving the food its delicious grilled taste. The Napoleon infrared
burner cooks in the same way. In each burner, 10000 ports each with its own tiny flame cause the surface of the ceramic to glow red. This
glow emits the same type of infrared heat to the food, without the hassle or mess of charcoal. It also provides a more consistent heated area
that is far easier to regulate than a charcoal fire. For instantaneous searing the burners can be set to high, yet they can also be turned down
for slower cooking. We all know how difficult that is on a charcoal fire. Traditional gas burners heat the food in a different way. The air
surrounding the burner is heated by the combustion process and then rises up to the food being cooked. This generates lower grill
temperatures that are ideal for more delicate cuisine such as seafood or vegetables. The bottom line is that Napoleon’s infrared burners
produce searing heat for juicier, tastier steaks, hamburgers and other meats. For cooking times and tips refer to the Infrared Grilling Chart.

COOKING INSTRUCTIONS

When lit for the first time, the gas grill will emit a slight odour. This is a normal temporary condition caused by the "burn-in" of internal
paints and lubricants used in the manufacturing process and will not occur again. Simply run the main burners on high for
approximately ½ hour.

INFRARED MAIN BURNER USE:

1. Follow the infrared burner ignition procedures and operate on high for 5 minutes with the lid closed or until the ceramic burners glow red.

2. Place food on grills and cook according to times listed in the Infrared Grilling Chart.

3. Depending upon your taste, continue cooking over infrared burners on high, medium or low, turning food frequently, or place food away from

infrared burners, close lid, and allow oven temperature to slowly finish cooking your food.

Caution: Due to the intense heat the infrared burners provide, food left unattended over burners will burn quickly. Keep the lid open when

cooking with the infrared burners on high. The intense heat ensures adequate searing temperatures even with the lid open. This also allows
observation of the food, so as to prevent burning.

MAIN BURNER USE: When searing foods, preheating is recommended by operating all main burners in the high position with the
lid closed for approximately 10 minutes. Food cooked for a short period of time (fish, vegetables) may be grilled with the lid open.
Cooking with the lid closed will ensure higher, more even temperatures that will reduce cooking time and cook meat more evenly.
Food that has a cooking time longer than 30 minutes, such as roasts, may be cooked indirectly (with the burner lit opposite to the
food placement). When cooking very lean meats, such as chicken breasts, or lean pork, the grids can be oiled before pre-heating
to reduce sticking. Cooking meat with a high degree of fat content, may create flare-ups. Either trim some fat or reduce tempera­tures to prevent this. Should a flare-up occur, move food away from flames, reduce heat. Leave the lid open.

REAR BURNER USE: Remove the warming rack prior to use. Cooking grids should also be removed if they interfere with the
rotisserie. This gas grill is equipped with a 14,000 BTU rear burner. The rear burner is designed to be used in conjunction with the
included rotisserie kit. See the rotisserie kit assembly instructions. To use the counterbalance, remove the rotisserie motor from the
gas grill. Place the spit with meat being cooked across the hangers inside the grill. The meat will naturally hang with the heavy side
down. Tighten the counterbalance arm and weight, so that the arm is facing up. Slide the counterweight in or out to balance the load,
and tighten in place. Re-install the motor and begin cooking. Place a dish underneath to collect drippings for basting and naturally
delicious gravy. Basting liquid may be added as required. To seal in juices, first operate rear burner on high until brown, then reduce
the heat to thoroughly cook foods. Keep the lid closed for best results. Your roasts and fowl will brown perfectly on the outside and
stay moist and tender on the inside. For example, a 3 pound chicken on the rotisserie will be done in approximately 1½ hours on
medium to high.

SIDE BURNER USE: The side burner can be used like any range top burner, for gravies, soups etc. The gas grill should be located
so that the side burner is protected from the wind, because the wind will adversely affect it's performance.

7

INFRARED GRILLING CHART

FOOD

Steak

1” Thick

Hamburger

1/2” Thick

Chicken

Pieces

Pork Chops

Spare Ribs

CONTROL SETTING COOKING TIME HELPFUL SUGGESTIONS

High setting 2 min. each side 4 min. - Rare

High setting 2 min. each side

then medium setting

High setting 2 min. each side

then medium setting

High setting 2 min. each side 4 min. - Rare

High setting 2 1/2 min. each

side

High setting 3 min. each side

High setting 2 min. each side

medium-low to low setting

Medium 6 min. per side

High setting for 5 minutes

low to finish

6 min. - Medium

8 min. - Well Done

5 min. - Medium

6 min. - Well Done

20-25 min.

20 min. per side

turn often

When selecting meat for grilling, ask for meat
with a marbled fat distribution. The fat acts as a
natural tenderizer while cooking and will keep
the meat moist and juicy.

Preparing hamburgers to order is made easier
by varying the thickness of your patties. To add
an exotic taste to your meat, try adding hickory­flavored woodchips into Napoleon’s woodchip
smoker.

The joint connecting the thigh and the leg from
the skinless side, should be sliced 3/4 of the
way though in order for the meat to lay flatter on
the grill. This will help it to cook faster and more
evenly. To add a trademark taste to your cooking,
try adding mesquite-flavoured woodchips in your
Napoleon woodchip smoker.

Trim off the excess fat before grilling. Choose
thicker chops to get more tender meat.

Choose ribs that are lean and meaty. Grill until
meat easily pulls away from the bone.

Lamb Chops

Hot Dogs

High setting for 5 minutes

medium to finish

Medium - Low 4-6 min.

15 min. per side

Trim off the excess fat before grilling. Choose
extra thick chops to get more tender meat.

Select the larger size wieners. Slit the skin
lengthwise before grilling.

CLEANING INSTRUCTIONS

Ensure that the burners are turned off prior to cleaning. Avoid unprotected contact with hot surfaces. Clean grill in an area
where cleaning solutions will not harm decks, lawns or patios. Do not use oven cleaner to clean any part of this gas grill. Do
not use a self cleaning oven to clean cooking grids or any other parts of the gas grill. Barbecue sauce and salt can be
corrosive and will cause rapid deterioration of the gas grill components unless cleaned regularly.

Note: Stainless steel tends to oxidize or stain in the presence of chlorides and sulfides, particularly in coastal areas and other
harsh environments, such as the warm, high humidity atmosphere around pools and hot tubs. These stains may be perceived
as rust, but can be easily removed and prevented. To ensure stain prevention, wash all stainless steel surfaces every 3-4
weeks with fresh water and stainless steel cleaner or as often as required.

GRIDS AND WARMING RACK - The grids and warming rack are best cleaned during the pre-heat period with a soft brass wire
brush. Steel wool can be used for stubborn stains. Stainless grids will discolour permanently from normal usage, due to the high
temperature of the cooking surface.

CLEANING INSIDE THE GAS GRILL - Remove cooking grids. Use a soft brass wire brush to clean loose debris from casting sides
and insides of the lid. Scrape sear plates with a putty knife or scraper, and use a wire brush to remove ash. Remove sear plates
and brush debris off of burners with a brass wire brush. Brush all debris from inside the gas grill into the drip pan. The pan
should be scraped out with a putty knife or scraper, and all the debris should be scraped into the disposable grease tray. This tray
should be replaced every two to four weeks, depending on gas grill usage. For supplies, see your NAPOLEON Gas Grill dealer.
Ensure that the sear plates are placed properly when they are reinstalled (Check assembly instructions for proper orientation).

CLEANING THE OUTSIDE OF THE GAS GRILL - Do not use abrasive cleaners to clean any painted, or stainless steel parts. Exterior
grill surfaces should be cleaned while warm to the touch, with warm soapy water. To clean stainless surfaces, use a stainless
steel cleaner or a non-abrasive cleaner. Always wipe in the direction of the grain. Do not use steel wool, as it will scratch the
finish. Stainless steel parts will discolour when heated, usually to a golden or brown colour. This discolouration is normal and
will not affect the performance of the grill.

INFRARED BURNERS - Because of the high intensity of the infrared burner, most drippings and food particles that fall onto the
burner surface are immediately incinerated. However, some debris and residue may remain. To remove this residue after
cooking, turn the grill on high with lid closed for 5-10 minutes. Do not clean the ceramic tile with a wire brush. If debris is
collecting on your burner, simply light the burner and operate on high for 5 minutes with the lid open, allowing debris to burn off.

8

MAINTENANCE INSTRUCTIONS

It is recommended that this gas grill be thoroughly inspected and serviced annually by a qualified service person.
Turn off the gas at the source and disconnect unit before servicing. Maintenance should only be done when the grill is

cool, to avoid the possibility of burns. A leak test must be performed annually, and whenever any component of the gas
train is replaced.
COMBUSTION AIR ADJUSTMENT - (This must be done by a qualified gas installer.) The air shutter is factory set and should not

have to be adjusted under normal conditions. However, some extreme field conditions may exist that require adjustment. When
the air shutter is adjusted correctly, the flames will be dark blue with light blue tips, and occasional yellow tips.

BURNER

LIGHT BLUE

YELLOW TIPPING

DARK BLUE

If the burner is getting too little air, the flames will be lazy yellow, and possibly produce soot. If the burner is getting too much air,
the flames will be lifting erratically from the burner and may cause difficulties when lighting.

1. To adjust the air shutter, remove cooking grids and sear plates and leave lid open. The back cover must be removed for back
burner air shutter adjustment.

2. Loosen air-shutter lock screw and open or close air shutter as required. The normal settings are:
Main Burner Propane 3/16" Back Burner Propane 3/8"

Natural 1/8" Natural 1/8"

3. Light burners and set to high. Visually inspect burner flames. When shutters are set, turn burners off, tighten locking screw,

and replace removed parts.

BURNER PORT

APPROXIMATELY

1/2"

WARNING

HOSE - Check for abrasion, melting, cuts and cracks. If any of these conditions exist, do not use gas grill. Have part replaced by

your gas grill dealer, or qualified gas installer.

BURNER - The burner is made from heavy wall 304 stainless steel, but due to the extreme
heat and corrosive environment, surface corrosion will occur. Use a brass wire brush to
remove surface corrosion. Clean any blocked ports using an opened paper clip. Do not
enlarge the burner ports. Spiders and insects are attracted to the smell of propane and
natural gas. The burner is equipped with an insect screen on the air shutter, which will reduce
the likelihood of insects building nests inside the burner, but does not entirely eliminate the
problem. The nest or web will cause the burner to burn with a soft yellow or orange flame or
cause a fire (flashback) at the air shutter underneath the control panel. To clean the inside of
the burner, it must be removed from the gas grill. Remove the 2 screws located above the
burner to the left and right of the centre of the burner. Lift back of burner upwards to remove.
Use a flexible venturi tube cleaning brush to clean out the inside of the burner. Shake any
loose debris out of the burner, through the gas inlet. Ensure that the insect screen is clean,
tight, and free of any lint or other debris. Check also that the valve orifices are clean. Do not
enlarge the orifices. Re-install the burner. Check that the valve enters the burner when
installing. Replace burner cover and mounting screws to complete installation.

WARNGUN

9

ALUMINUM CASTINGS - Clean castings periodically with warm soapy water. Aluminum will not rust, but due to high temperatures
and weathering, oxidation can occur on aluminum surfaces. This will appear as white spots on the castings. To refinish the
castings, clean them and sand lightly with fine sandpaper. Wipe surface to remove any residue, and paint with high temperature
barbecue paint. Protect surrounding areas from over-spray. Follow curing directions found on the can.

PROTECTION OF INFRARED BURNERS - The infrared burners of your grill are designed to provide a long service life. However,

there are steps you must take to prevent cracking of their ceramic surfaces, which will cause the burners to malfunction.
Following are the common causes of cracks and the steps you must take to avoid them. Damage caused by failure to follow
these steps is not covered by your grill warranty.

Impact with Hard Objects - Never allow hard objects to strike the ceramic. Take care when inserting or removing cooking

1.

grates and accessories into or from the grill. If these objects were to fall on the ceramic, it is likely to crack.

2.

Water or Other Liquids - Cold liquid contacting a hot surface in substantial amounts can cause the surface to break. Do
not throw water into the grill to douse a flame. Also if the ceramic or interior of a burner becomes wet while not in use, later
operation of the burner can create steam, which may produce enough pressure to crack the ceramic. In addition, repeated
soaking of the ceramic will cause it to swell and expand. This expansion will cause undue pressure on the ceramic and
therefore it may crack and crumble.

i) Never throw water into the grill to control flare-ups
ii) Do not attempt to operate the infrared burners in open air while raining.
iii) If you find standing water in your grill (because of exposure to rainfall, sprinklers etc.), inspect ceramic for
evidence of possible watersoaking. If ceramic appears to be wet, remove the burner from the grill. Turn upside

down to drain the excess water. Bring indoors and allow to dry thoroughly.

3. Impaired Ventilation of Hot Air From the Grill - In order for the burners to function properly, hot air must have a way to escape
the grill. If the hot air is not allowed to escape, the burners may become deprived of oxygen, causing them to back flash. If this
occurs repeatedly, the ceramic may crack. Do not cover more than 75% of the cooking surface with solid metal (ie. griddle or
large pan).

TROUBLESHOOTING

Problem Possible Causes Solution

Low heat / Low flame when
valve turned to high.

Excessive flare-ups/uneven
heat.

Burners burn with yellow
flame, accompanied by the
smell of gas.

For propane - improper lighting
procedure.

For natural gas - undersized
supply line.

For both gases - improper
preheating.

Sear plates installed incorrectly. Ensure sear plates are installed correctly. The archs

Improper pre-heating.

Excessive grease and ash build
up on sear plates and in drip pan.

Possible spider web or other
debris, or improper air shutter
adjustment.

Ensure lighting procedure is followed carefully. All gas grill
valves must be in the off position when the tank valve is
turned on. Turn tank on slowly to allow pressure to equalize.
See lighting instructions.

Pipe must be sized according to installation code.

Pre-heat grill with main burners on high for 10 to 15 minutes.

without slots should be located directly above the left and
right burners. When the sear plates are installed correctly,
six of the eight slots should be in valleys.

Pre-heat grill with main burners on high for 10 to 15
minutes.
Clean sear plates and drip pan regularly. Do not line base
with aluminum foil. Refer to cleaning instructions.

Thoroughly clean burner by removing. See general mainte­nance instructions. Open air shutter slightly according to
combustion air adjustment instructions.

(This must be done by a qualified gas installer.)

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Problem Possible Causes Solution

Flames lift away from
burner, accompanied by the
smell of gas, and possibly
difficulties in lighting.

Burner will not light with the
igniter, but will light with a
match.

Humming regulator.

Burners will not crosslight
each other.

"Paint" appears to be
peeling inside lid or hood.

Improper air shutter adjustment.

Dead battery / or installed
incorrectly.

Loose electrode wire.

Wrong replacement igniter. One spark systems must use a one spark igniter.

Improper gap at electrode tip. Ensure that the collector box is tight, and the gap between the

Lifting flames on burner. Close air shutter slightly - see previous problem

Normal occurance on hot days. This is not a defect. It is caused by internal vibrations in the

Plugged ports along back of
burner.

Grease build up on inside
surfaces.

Close air shutter slightly according to combustion air
adjustment instructions.

(This must be done by a qualified gas installer.)

Replace with heavy duty 'AAA' battery. Install with positive
terminal up.

Check that electrode wire is firmly pushed onto the terminal
on the back of the igniter.

electrode end and the collector box is between 1/8 - 3/16".
The gap can be adjusted by bending the box in or out.

regulator, and does not affect the performance or safety of the
gas grill.

Clean burner ports. See burner maintenance instructions.

This is not a defect. The peeling is caused by hardened
grease, which dries into paint-like shards, that will flake off.
Regular cleaning will prevent this. See cleaning instructions.

Burner output on “high”
setting is too low. (Rum­bling noise and fluttering
blue flame at burner
surface.)

Infrared burner flashes
back (during operation the
burner abruptly makes a
loud “whoosh” sound,
followed by a continuous
blow-torch type sound and
grows dim.)

Lack of gas.
Supply hose is pinched.

Dirty or clogged orifice.

Spider webs in venturi tube, or
other foreign matter.

Cracked ceramic tile.

Propane regulator in “low flow”
state.

Ceramic tiles overloaded with
grease drippings and build-up,
ports are clogged.

Burner overheated due to
inadequate ventilation (too much
grill surface covered by griddle or
pan.)

Cracked ceramic tile.

Leaking gasket surrounding the
ceramic tile, or a weld failure in
the burner housing.

Check gas level in propane cylinder.
Reposition supply hose as necessary.

Clean burner orifice.

Clean out venturi tube.

Order replacement burner from your Authorized Napoleon
dealer.

Ensure lighting procedure is followed carefully. All gas
grill valves must be in the off position when the tank valve
is turned on. Turn tank on slowly to allow pressure to
equalize. See lighting instructions.

Turn burner off and allow to cool for at least two minutes.
Relight burner and burn on high for at least five minutes or
until the ceramic tiles are evenly glowing red.

Ensure that no more than 75% of the grill surface is
covered by objects or accessories. Turn burner off and
allow to cool for at least two minutes, then relight.

Allow burner to cool and inspect very closely for cracks. If
any cracks are found, contact your authorized Napoleon
dealer for ordering a replacement burner assembly.

Contact your authorized Napoleon dealer for instructions
on ordering a replacement burner assembly.

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ORDERING REPLACEMENT P ARTS / RETURNS

Before contacting the customer care department, check the NAC web site for more extensive cleaning, maintenance, troubleshooting and part
replacement instructions at www.napoleongrills.com. Contact the factory directly for replacement parts and warranty claims. The customer care
department is available between 9 AM and 5 PM (Eastern standard time) at 1-866-820-8686 or fax at 1-705-727-4282. In order to process a claim, we
must be provided with the following information:

1. Model and serial number of the unit.

2. Part number and description.

3. A concise description of the problem ('broken' is not sufficient).

4. Proof of purchase (photocopy of the invoice).

In some cases the customer care representative may request to have the parts returned to the factory for inspection, before providing replacement
parts. The parts must be shipped prepaid to the attention of the customer service department with the following information:

1. Model and serial number of the unit.

2. A concise description of the problem ('broken' is not sufficient).

3. Proof of purchase (photocopy of the invoice).

4. SPC number - provided by the customer service representative.

Before contacting customer care, please note that the following items are not covered by the warranty:

-costs for transportation, brokerage or export duties

-labor costs for removal and re-installation

-costs for service calls to diagnose problems

-discoloration of stainless steel parts

-part failure due to lack of cleaning and maintenance, or use of improper cleaners (ovencleaner).

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