PGS K-40, K-30 User Manual
R
Models K-30 and K-40
Gas Grill
click here for Legacy Series
ASSEMBLY, OPERATING
& MAINTENANCE INSTRUCTIONS
(SHOWN WITH OPTIONAL
SIDE BURNER AND INFRA-BROIL KIT)
PACIFIC GAS SPECIALTIES CORPORATION
P.O. BOX 16097, IRVINE, CALIFORNIA 92623
Phone (949) 757-7723 FAX (949) 474-5559
Please note: We have made our catalogs, specification sheets, and other materials relating to our line of outdoor
cooking products as comprehensive and accurate as possible. We are constantly trying to improve all aspects of our
products and therefore, reserve the right to make changes anytime, without notice. Because product improvements
may have been made since the time our materials were printed, please check with your Authorized PGS Dealer or
Distributor, if you have any specific questions concerning our products. PGS is dedicated to producing the finest
leisure gas appliances for the home.
Revised 5/1/2003
TABLE OF CONTENTS
Safety Responsibilities, Warning Symbol.................................................................................................Page 2
Grill Model Identification (Location of Serial Number) ..............................................................................Page 3
Very Important Safety Tips & Warnings ..............................................................................................Page 4 - 5
Liquid Propane Gas Safety, Connections, Handling and Storage.....................................................Page 6 - 87
Natural Gas Pressure Requirements........................................................................................................Page 9
Definition of Key Terms ............................................................................................................................Page 9
Required Tools and Nuts, Bolts and Fasteners Part Numbers...............................................................Page 10
Drawings of Nuts, Bolts, and Fasteners .................................................................................................Page 10
Part Numbers & Descriptions .................................................................................................................Page 11
Parts Breakdown .................................................................................................................................. Pages 12
Check List of Grill Box Contents.............................................................................................................Page 13
Permanent Post Installation ..........................................................................................................Pages 14 - 15
Patio Base/Patio Cart to Grill Head Assembly...............................................................................Pages 15 - 16
Orifice Engagement................................................................................................................................Page 16
Side Shelf Installation.............................................................................................................................Page 17
Finish Assembly .....................................................................................................................................Page 17
Connecting Your Gas Supply .................................................................................................................Page 18
Lighting Your Grill / If Burner Fails to Light.............................................................................................Page 20
Periodic Cleaning ...................................................................................................................................Page 20
Flashback (Spider Fires) ........................................................................................................................Page 21
Electrode Adjustment .............................................................................................................................Page 22
Flare Ups................................................................................................................................................Page 22
Grease Tray Clean Out ..........................................................................................................................Page 22
Gas Grill Conversion ..............................................................................................................................Page 22
Helpful Hints ...........................................................................................................................................Page 23
Flame Adjustment ..................................................................................................................................Page 24
Trouble Shooting ........................................................................ See PGS Web Site for Troubleshooting Guide
PGS Accessories ...................................................................................................................................Page 25
2
SPECIAL ATTENTION:
THIS SYMBOL NOTES SAFETY RELATED
ITEMS OR PRODUCT WARNINGS
IT IS YOUR RESPONSIBILITY TO:
ASSEMBLE, INSTALL, LEAK CHECK, CARE AND
OPERATE YOUR GAS GRILL. SAVE THESE
INSTRUCTIONS FOR FUTURE REFERENCE.
Please consult your authorized PGS dealer if you have
any questions concerning assembly, installation or
operation of your grill.
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.
THIS GAS GRILL IS DESIGNED FOR OUTDOOR
USE ONLY
FOR YOUR SAFETY:
DO NOT STORE OR USE GASOLINE OR OTHER
FLAMMABLE VAPOR AND LIQUIDS IN THE
VICINITY OF THIS APPLIANCE.
THIS GRILL IS NOT INTENDED FOR USE ON A
BOAT/HOUSE BOAT OR RECREATION VEHICLE
STORE THE LP GAS (PROPANE) CYLINDER
OUTDOORS IN A WELL-VENTILATED SPACE.
DO NOT STORE A PROPANE GAS CYLINDER IN
DIRECT SUNLIGHT. DO NOT STORE EXTRA
CYLINDERS IN CART OR NEAR GRILL. DO NOT
STORE THE PROPANE CYLINDER ON IT S SIDE.
Teflon tape or pipe joint compound will be
required on all steel pipe connections.
Never use a sealer when your connection
is brass to brass. Brass to brass is self-sealing.
Using a sealant on a brass to brass connection
may cause a leak!
The grill itself is partially assembled, with the burner,
venturi, ignitor, collector box, and ignitor lead wire
installed. Take your time in assembly. Please read
instructions thoroughly before starting assembly.
This manual is based on information available when
the manual was printed. Continued improvements in
design could cause changes in the grill that may or
may not be included herein.
The display of a test agency certification seal on the
product label indicates that the unit is constructed
according to the certified testing agency.
MODEL IDENTIFICATION
Your PGS Grill is identified by a model number and the
serial number stamped on the stainless steel collar
box located under the control panel and included with
your grill head. TAKE THE TIME NOW TO RECORD
THE MODEL AND SERIAL NUMBER (located on the
collar box) OF YOUR GRILL IN THE SPACE
PROVIDED BELOW. Always use both the model
number and the serial number when calling or writing
PACIFIC GAS SPECIALTIES about your grill. We can
be reached at: PO Box 16097, Irvine, CA 92623-6097
(949) 757-7723 FAX (949) 474-5559. Email:
pgs@pgscorp.com.
PLEASE RETAIN INSTRUCTIONS FOR FUTURE
REFERENCE, AND RETURN THE OWNERS
REGISTRATION CARD IMMEDIATELY. RETURN
OF WARRANTY CARD INSURES WARRANTY
REGISTRATION. MAINTAINING YOUR SALES
RECEIPT WILL EXPEDITE WARRANTY CLAIMS.
DATE PURCHASE: __________________________
DEALERSHIP: ______________________________
CITY, STATE: ______________________________
MODEL NUMBER:___________________________
TYPE OF GAS: NATURAL GAS___PROPANE_____
SERIAL NUMBER ___________________________
The grill must be located no closer than 30" from
any combustible surface above, behind or
to the sides. The grill should not be
located under overhead-unprotected
combustible materials.
3
VERY IMPORTANT SAFETY TIPS AND WARNINGS
PGS is most concerned about the safe use of our product. The following two pages are a summarization of the safety
tips found throughout this manual. Please take the time to review them, as they are critical in the enjoyable use of
your grill. Improper assembly, neglect, or insufficient care of your PGS gas grill may result in serious bodily injury
and/or property damage.
GIVE THIS SYMBOL SPECIAL ATTENTION THROUGHOUT THIS MANUAL. IT NOTES SAFETY
RELATED ITEMS OR PRODUCT WARNINGS
Our grills are tested in accordance with ANSI Z21.58a-1999*CGA 1.6a-M99 Standard for Outdoor Gas Cooking
Appliances. Check your local building codes for the proper methods of installation. In the absence of local codes,
this grill should be installed in compliance with the National Fuel Code No. Z223.1-1995 and the National Electrical
Code ANSI/NFPA No. 70-1995. GAS GRILLS ARE NOT AGA DESIGN CERTIFIED OR RECOMMENDED FOR
USE ON RECREATIONAL VEHICLES, PORTABLE TRAILERS, BOATS/HOUSE BOATS, OR ANY OTHER
MOVING INSTALLATION.
• California Proposition 65 Warning: The burning of gas cooking fuel generates some by-products which are on the
list of substances and are known by the State of California to cause cancer or reproductive harm. California law
requires that businesses warn consumers of potential exposure to such substances. To minimize exposure to these
substances, always operate this gas grill according to the use and care instructions found in this manual. Be certain
to provide adequate ventilation when cooking.
• WARNING: Do not try to light this appliance without first reading: the "LIGHTING YOUR GRILL" section of this
manual found on page 21.
• Do not modify original equipment. Your grill has been designed and engineered to operate safely as outlined in
this manual. Only replace components with genuine PGS replacement parts, which are available from your local
dealer and/or distributor. Use of non-genuine parts may result in inferior performance and/or safety hazards and will
void the warranty.
• Children should not be left alone or unattended in an area where the grill is in operation. We suggest placement
of your grill well away from areas where children play. Do not store items that may interest children in or around the
grill, in the cart, or in the masonry enclosure. Never allow children to crawl or play inside a masonry enclosure.
• NEVER STORE ADDITIONAL OR EMPTY PROPANE CYLINDERS IN GRILL CABINET OR AROUND THE
GRILL. DO NOT STORE A PROPANE CYLINDER INDOORS OR ON ITS SIDE. NEVER ALLOW A PROPANE
CYLINDER TO BE OVERFILLED. Never use a dented, rusty or damaged propane cylinder. Never replace the safety
coupler fittings on the grill with any other connections.
• Never store pool chemicals or other flammable materials in any cabinet below or near the grill. Never allow loose
clothing, potholders, synthetic materials, or other flammable materials to come in contact with the grill and/or its parts.
Flammable materials could ignite and cause personal injury and/or property damage.
• Never move your gas grill when operating. Never move grill when HOT. Never cover grill when HOT.
• Do not heat up unopened food containers on the grill as a buildup of pressure may cause the container to burst.
• The LP cylinder that you use with your grill should be equipped with an overfill protection device (OPD). If you
use a tank exchange system, be sure to exchange this tank for another tank with the same safety system.
• Use an insulated glove when opening and operating the grill. Open grill lid slowly to allow heat and smoke to
escape before fully opening.
4
• Never lean over hot grill surface or look directly into grill when attempting to light. The grill hood must be opened
fully when lighting. Be sure that all family members are aware of safe lighting and operating procedures for the grill.
• If a professional installer or dealer installs the grill, be sure that he shows you where your gas supply shut off is
located. All gas lines must have a shut off that is readily and easily accessible. If you smell gas, check for gas leaks
immediately. Check only with a soap and water solution. Never check for gas leaks with an open flame.
• Never use charcoal, volcanic rock, wood chip materials, or non-PGS briquettes in your grill.
• Keep the optional rotisserie motor and electrical supply cord away from heated casting, cooking grids, other hot
parts or water. Store rotisserie motor and parts in a dry place when not is use.
• Never use grill in a windy area and never use the grill during an extremely windy day. Climatic conditions will
impact the performance of the grill. In consistently windy conditions, we suggest installing a suitable windbreak.
• Always adhere to the required clearances from combustibles. THE GRILL IS DESIGNED FOR USE OUTDOORS
ONLY; never operate in garage, buildings, shed, breezeways or other enclosed areas.
• Store your grill in a well-vented area. Remove the LP cylinder, if equipped with one, and store it outdoors in a
well-ventilated area away from heat and where children may possibly tamper with it.
• When using the optional side burner kit, use pots that have flat bottoms and are large enough to cover the entire
burner. Adjust the flame so that it only heats the bottom of the pot or pan to avoid the possible lighting of clothing.
Position handle in a way that it does not conflict with the opening and closing of grill lid. You cannot operate your side
burner kit and rotisserie motor simultaneously.
• Grease is extremely flammable. Let hot grease cool down before attempting to handle or dispose. Please clean
out your grease tray or grease can on a regular basis.
• Never cover cooking grid with a material that will trap heat beneath cooking grids, such as large pans or aluminum
foil. Heat reflected below may cause damage to rock grates, burners, gas valve assembly and possibly to gas train.
You need only to “Pre-Heat” your grill five to seven minutes before cooking. You do not need to “Burn-Off” your gas
grill for extended times after use.
• Spiders and other small insects can build nests or webs in the burners of your PGS grill, which will cause gas to
flow out from the front of the burner tubes. This can cause a fire to burn behind your control panel, thereby damaging
your grill and makes the grill unsafe to operate. Inspect your grill twice a year or immediately when symptoms
appear. See "FLASHBACK" on page 22.
• Please refer to specific sections of this manual (see Table of Contents) if you have questions regarding different
types of fuels, lighting, or trouble-shooting. If you have questions that are not answered in this manual, please call
your local dealer.
• The grill must be located no closer than 30" from any combustible surface above, behind or to the sides. The grill
should not be located under overhead-unprotected combustible materials.
• Keep the area around the grill clear of combustible materials, flammable vapors or liquids such as gasoline.
The grill surfaces become very hot during use. Keep children and pets away. Use hot pads or oven mitts.
5
GAS
Both natural gas (NG) and propane gas (LP) have a
long history of safe use when simple rules are
followed. If not, there is danger of fire or explosion.
Check Local Codes. Consult your local LP dealer or
Natural Gas company listed in your local directory for
recommended installation procedures and regulations.
In the absence of local codes, installation must
conform with the National Fuel Gas Code, ANSI
Z21.58a-1999*CGA 1.62-M99.
NEVER USE NATURAL GAS IN A UNIT
DESIGNED FOR LIQUID PROPANE OR
THE REVERSE. IF YOU WISH TO
CONVERT YOUR GRILL FROM ONE TYPE OF
GAS TO THE OTHER, PLEASE CONTACT YOUR
LOCAL DEALER OR DISTRIBUTOR.
Never connect an unregulated propane gas cylinder or
unregulated natural gas to your gas grill (Note: most
homes equipped with natural gas have a regulator
near the gas meter.
USER SAFETY INFORMATION OF PROPANE
MODELS
should occur, turn the valves to the “OFF”
position on your grill head, then the valve on the
tank. Wait two minutes and then open the valve on
the tank BEFORE turning the valves of your grill
head. Always turn on the valve at the top of your
tank and then the valves to your grill head to the
“ON” position.
The safety system detailed above has been
incorporated into your PGS gas grill to provide you and
your family the maximum in safety when operating the
grill.
PLEASE DO NOT CHANGE THE LP HOSE
OR USE WITH A STANDARD 20 LB.
P.O.L. CYLINDER OR TANK
EQUIPPED WITH A "QCCI" FITTING.
TURN VALVE THAT IS LOCATED AT THE
TOP OF TANK TO "OFF" WHEN GRILL IS
NOT IN USE.
DO NOT CONNECT THE GRILL TO A PROPANE GAS
CYLINDER GREATER THAN 20 LB. CAPACITY.
Check with your LP gas utility or your PGS dealer for a
PROPANE CYLINDER FILLING AND HANDLING
SAFETY TIPS
• Be certain tank is equipped with an overfill
protection device.
• Do not modify hose or LP fittings. Contact a local
dealer or distributor if tank, hose or fittings need
replacement.
• If it is evident there is excessive abrasion or wear,
or the hose is cut, it must be replaced prior to the
grill being operated. Please see your local PGS
dealer/distributor or call PGS for an exact
replacement.
• Store propane tank outdoors in a cool, wellventilated area. Never store extra tanks in, on, or
around your grill.
• Turn off tank when not in use.
• Transport tanks upright ONLY.
• Never allow a tank to be overfilled. 100% full tank
holds only 4.5 gallons of propane.
• Inspect your grill cabinet often to ensure that
ventilation openings in sides and back of pedestal
are free from debris and have proper air
circulation.
• Never
paint LP cylinder a dark color. This may
cause OVERHEATING. Do not apply heat directly
to tank.
• LP Gas is stored under high pressure and must be
handled with care. Do not handle a tank roughly.
• You must use the "TYPE II" fill adapter that was
provided with your propane grill. If unable to
locate, see your local dealer, distributor or PGS.
• Be sure your LP gas dealer checks the cylinder
with a soapy solution for leaks after filling.
• Do not turn gas valve on unless connection
between regulator and coupler is complete.
• Storage of your gas grill indoors is permissible only
if the cylinder is disconnected, removed from grill
and cylinder stored outdoors.
BEFORE ATTEMPTING TO LIGHT GRILL,
BE CERTAIN THE GAS VALVE KNOBS
ARE IN THE OFF POSITION. TURN TANK
VALVE ON BY TURNING KNOB ON TOP OF TANK,
COUNTER CLOCKWISE. CHECK ALL
CONNECTIONS WITH A SOLUTION OF 50% LIQUID
SOAP, 50% WATER. SOLUTION CAN BE
SPRAYED ON WITH A SPRAY BOTTLE OR
PAINTED ON ALL CONNECTIONS WITH A BRUSH.
IF BUBBLES APPEAR THERE IS A LEAK, TURN
OFF GAS, TIGHTEN FITTINGS AND REPEAT THIS
CHECK.
The cylinder must be provided with a shut-off valve
terminating in an LP-gas supply cylinder, valve outlet
specified, as applicable, for Connection No. 510 in the
Standard for Compressed Gas Cylinder Valve Outlet
and Inlet Connections, ANSI/CGA-V-1, or Connection
No. 600 in the Compressed Gas Association’s Limited
Standard Cylinder Valve Outlet Connection for
Propane Small Valve Series or a combination LP-gas
cylinder valve and quick-disconnect assembly
complying with 1.5.5-c and a safety relief device
making a direct connection with the vapor space of the
cylinder.
The cylinder supply system must be arranged for
vapor withdrawal and must include a collar to protect
the cylinder valve.
**Special Note** All new tanks are filled with air, not
propane. Air must be purged before the tank is filled.
When purchasing an LP gas tank, be certain it meets
all standards, and allow only a qualified LP-gas dealer
to fill the propane gas cylinder.
PROPANE GAS CYLINDER
DISCONNECTED CYLINDER MUST NOT
BE STORED IN A BUILDING, GARAGE OR
ANY OTHER ENCLOSED AREA. BEFORE
LIGHTING YOUR GRILL, INSPECT THE HOSE TO
ENSURE THAT IT IS IN TACT AND THERE ARE NO
LEAKS.
All LP-gas cylinders used with this grill shall be
approximately 12" in diameter and about 18" in height.
The maximum fuel capacity must be 20 lbs. of propane
(47.7 lbs. nominal water capacity or 4.5 gallons). DO
NOT connect your grill to a propane gas cylinder that
exceeds this capacity.
All propane-gas cylinders used with the grill must be
constructed and marked in accordance with the
specifications for propane-gas cylinders of the U.S.
Department of Transportation (DOT). In Canada, gas
cylinders must meet CTC specs. Federal Law
requires any tank used for a gas grill must include an
overfill protection device.
All refillable propane-gas cylinders used with the gas
grill must be inspected at every filling and must be requalified by a licensed LP-gas cylinder filler in
accordance with DOT (US) or CTC (Canadian)
requirements for LP-cylinders.
7
LP-Gas Tank Specifications:
Weight (filled) 40 lbs. (18.14 kg)
Capacity 4.5 gallons
Diameter (outside) 12 1/8" (30.8 cm)
Height 18" (45.7 cm)
Connection TYPE II Couple Safe
FEED LINE
GRILL HEAD: Entire BBQ grill (lid & pit) that can be
mounted on a variety of options.
GRILL MOUNT: Supports gas grill head, can be a
post mount, pedestal mount (stationary or mobile) or
built in frame inserted in a masonry enclosure.
GRILL UPPER CASTING: Top (lid) of gas grill head,
made of aluminum and powder coated black.
GRILL LOWER CASTING: Bottom (pit) of gas grill
head made of aluminum and powder coated black.
BASE: Stationary or designed to be used with wheels
made of aluminum and powder coated black.
RACK: Warming area made of stainless steel and
LP Tank, Hose and Feedline Assembly
TANK CONNECTION
LP REGULATOR TO
TYPE II FILL ADAPTER
QUICK COUPLE VALVE
TYPE II “COUPLE SAFE”
TYPE II LP Connections
NATURAL GAS MODELS
Your PGS gas grill has been designed and produced
for outdoor use only! Every gas-burning appliance
produces carbon monoxide and should not be allowed
to accumulate in confined areas. DO NOT OPERATE
YOUR PGS GAS GRILL INSIDE A HOME, GARAGE,
RECREATIONAL VEHICLE, BOAT/HOUSE BOAT,
OR ANY OTHER ENCLOSED AREA.
When choosing a location for your grill, you must
locate it at least 30" away from any combustible
material and out of traffic paths. The grill and its
individual shutoff valve must be disconnected from the
gas supply piping system during any pressure testing
of that system at test pressures in excess of 1/2 psig
(3.5kPa).
The grill must be isolated from the gas by closing its
valves during any pressure testing of the gas supply
piping system at test pressures equal to or less than
1/2 psig (3.5kPa).
removable.
COOKING GRIDS: Area most used for grilling, with
variably spaced grid tines for flexibility.
ROCK GRATES: Solid stainless steel plates with
square holes in them for heat convection.
MOON ROK II: The highest quality grill rock for great
BBQ flavor and flare control.
COLLAR BOX: Stainless steel box between grill
mount and grill head.
IGNITOR MODULE: Battery powered ignition for
instant spark.
VALVE: Device used to control amount of gas (and
heat) grill produces.
ORIFICES: Openings at end of valve that restrict
amount of gas going to BBQ.
VENTURI: Banana shaped tube that allows gas to
flow from the valve to the burner.
FEEDLINE: Aluminum gas line from back to grill
mount to bottom of valve. Used only on models that
include pedestal.
HINGE PINS AND COTTER PINS: Hinge pin goes
through lower and upper casting with cotter pins
permanently holding.
GASKET: Insulator between pedestal and base.
WATER COLUMN (W.C.): A measurement of gas
pressure.
DEFINITION OF KEY TERMS
8
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