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.
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.......
Please consult your authorized PGS dealer if you have any questions concerning assembly, installation or operation of your grill. 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. FOR YOUR SAFETY IF YOU SMELL GAS: 1. SHUT OFF GAS TO THE APPLIANCE. 2. EXTINGUISH ANY OPEN FLAME. 3. OPEN LID. 4.
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.
• 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.
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.
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. PROPANE CYLINDER FILLING AND HANDLING SAFETY TIPS • • • • • • • • • • • • • • Be certain tank is equipped with an overfill protection device.
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 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.
YOU WILL NEED THE FOLLOWING TOOLS TO ASSEMBLE YOUR PGS GAS GRILL: 1 - Mallet or Hammer 2 - 6" Adjustable Wrenches 50% Soap and Water Solution 1 - Med. Phillips Head Screw Driver 1 - Small Roll of Teflon Tape (Natural Gas Only) 1 - Spray bottle or brush Having these additional tools on hand will make assembly easier: 1 - 1/2" Socket and Drive 1 - 7/16" Socket and Drive PGS NUTS, BOLTS AND FASTENERS FOR IDENTIFICATION (PLEASE NOTE: NOT ALL OPTIONS REQUIRE QTY. BELOW) REF # DESCRIPTION QTY.
DRAWINGS OF NUTS & BOLTS AND FASTENERS REF # DESCRIPTION (QUANTITY) REF # DESCRIPTION (QUANTITY) BASE TO PEDESTAL COLLAR BOX TO PEDESTAL AND CONTROL PANEL 1. 5/16 X 3/4" BOLT (6) 13. 8 X 1/2” SHEET METAL SCREW (2) 2. 5/16” WASHER (6) 14. TINNERMAN CLIP (2) FEEDLINE 3. 5/16” LOCK WASHER (6) 15. FEEDLINE MOUNTING CLIP (1) 4. 5/16” NUT (6) 16. 10-32 S.S. MACHINE SCREW (3) HEAD TO PEDESTAL ASSEMBLY 5. 1/4 X 20 X 1-1/4" BOLT (4) SIDE SHELF ASSEMBLY 17. 1/4 X 20 X 3/4" BOLT (4) 6. CAGE NUT (4) 18.
PART NUMBERS AND DESCRIPTIONS PLEASE NOTE: ALL PARTS MAY NOT COME WITH ALL MOUNTING OPTIONS REF # 1 2 3 4 5 6 7 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 28 29 30 31 32 33 34 35 36 37 38 39 DESCRIPTION QTY MODEL K-40 MODEL K-30 UPPER GRILL CASTING 1 140125 130125 LOWER GRILL CASTING 1 140120 130120 WARMING RACK 1 140200 130200 COOKING GRID 2 140140 130140 ROCK GRATES (Not shown) 2 140170 130170 BURNER ASSEMBLY 1 140105 130110 VALVE ASSEMBLY FOR NATURAL GAS (Not shown) 1 140190 130190
PGS GAS GRILL PARTS BREAKDOWN GRILL HEAD LID TO GRILL HEAD SIDE SHELVES TO GRILL HEAD (OPTIONAL) LCS/LCB COLLECTOR BOX FOR IGNITOR CONTROL PANEL TO GRILLHEAD GREASE TRAY CONTROL PANEL STIFFENING BRACKETS CAGE NUT K30 BURNER IN-GROUND 48” POST COLLAR BOX K40 BURNER PEDESTAL TO BASE STAINLESS STEEL TUBING ACCESS DOOR (CART OR PATIO BASE) STAINLESS BLACK 3/8” FLARE COUPLING (Not included) GAS SUPPLY LINE WHEELS, AXLE & HUB CAP (FOR PORTABLE CART) PATIO BASE ACCESS HOLE ON BACK OF POST 8” ROUND
CHECK LIST OF GRILL BOX CONTENTS 1. REMOVE ALL CONTENTS FROM BASE AND PEDESTAL OR 48" POST BOX. YOU WILL FIND: IF YOU PURCHASED A "B" PED (Black Pedestal Kit) YOU WILL FIND All parts listed above in the "S" Ped box except pedestal and: Qty 1 Black Galvanized Steel Pedestal IF YOU PURCHASED AN LC (Liquid Propane Cart) YOU WILL FIND: Qty 1 Cast Alum.
access hole is on the BACK of the post and the notches at the top are on the front of the post. Center the post in the hole and plumb it with a level. Pour cement up to the gas line access hole. Be sure that the fuel source designated on your grill head is the same as that of the support system. DO NOT USE A GRILL HEAD EQUIPPED FOR NATURAL GAS WITH LP GAS OR THE OPPOSITE. 3. Run the gas supply line into the post making a 90degree bend to reach the access door.
9. TEST ALL FITTINGS FOR LEAKS. BEFORE ATTEMPTING TO LIGHT GRILL, BE CERTAIN BOTH CONTROL PANEL VALVES ARE IN THE OFF POSITION. TURN GAS SUPPLY ON AT THE SOURCE AND 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, TURN OFF GAS, TIGHTEN FITTINGS AND TRY AGAIN. NEVER CHECK FOR LEAKS WITH A MATCH OR FLAME. Figure 1 10.
4. K-40 Figure 6 Control Panel/ Feedline to Valve Connection Figure 4 Installation of Cage Nuts on Pedestal ORIFICE ENGAGEMENT 4. Place lower grill casting on top of pedestal lining up four bolt holes (located just above air vents) with cage nuts just installed (see Fig. 5). Then insert the 41/4" X 20" X 1 1/4" hex bolt each with a 1/4" flat washer and 1/4" lock washer. When all four are in place, tighten bolts securely. At the end of each valve there is a tiny gas opening known as an orifice.
THIS CONNECTION WILL REQUIRE LEAK CHECK UPON ASSEMBLY COMPLETION. (see Fig. 18). 8. Attach feed line mounting clip to pedestal using #8 X 1/2" S.S. machine screw. BE SURE TO ALIGN SCREW TO AVOID STRIPPING THREADED NUTSERT. 9. Remove "Sure Start" Ignitor module from the underside of control panel by unscrewing black ring. Remove rear cover of module and insert a fresh AA alkaline battery into unit (included). Plug the end of the ignitor wire lead to the electronic ignitor module.
6. Attach twin lid side "Stay Cool" handles using 5/16" X 3/4" bolt and star washer, tighten securely. 7. Slide grease tray into slot at top rear of pedestal. Tray must be tilted up before inserting in. 8. If you purchased a LC base kit you will need to attach the tank strap to the back of the cart. Attach as follows: Screw one of the #8 X 1/2" S.S. screws into the left hand nut that is pre-attached at the midpoint of the back of the pedestal so that it remains 1/4" out. Push the other #8 X 1/2" S.S.
Figure 17 Leak Checking the Valve Connection Figure 15 4. If no gas leaks appear (bubbles), turn off gas supply and continue assembly. IF YOU ARE UNABLE TO STOP A LEAK, CONTACT YOUR LOCAL DEALER FOR ASSISTANCE BEFORE PROCEEDING. LP Hose/Regulator Connection 5. If there are no gas leaks, attach the collar box with AGA/CGA rating sticker attaching to the pedestal as follows (see Fig. 18): • Remove two #8 x 1/2" screws from bottom of control panel leaving attached Tinnerman clips.
LIGHTING YOUR GRILL IF THE GRILL STILL FAILS TO LIGHT, CHECK THE GAS SUPPLY. YOU COULD BE OUT OF LP GAS OR THE MAIN GAS SUPPLY FOR NATURAL GAS MAY HAVE BEEN TURNED OFF. IF THE LP TANK HAS GAS OR THE NATURAL GAS IS TURNED ON AND THE GRILL STILL WILL NOT LIGHT: CHECK THE ELECTRONIC IGNITOR TO MAKE SURE IT IS SPARKING. IF NOT, CHECK THE BATTERY IN THE MODULE AND ALSO MAKE SURE THE IGNITOR WIRE IS CONNECTED BOTH TO THE MODULE AND TO THE BOTTOM OF THE ELECTRODE.
After cleaning burner assembly and the lower casting of grill, reinstall burner to lower casting. In many areas, spiders or small insects have been found to create "flashback" problems. The spiders spin webs and/or insects build nests in the grill's venturi tube(s). The web and/or nests can lead to gas flow obstruction, which can damage your grill as it results in a "flashback" (a fire in the venturi tube(s). The grill may still light, but the obstruction does not allow full gas flow to the burner.
BEFORE LIGHTING YOUR GRILL: TURN YOUR GAS SUPPLY (LP OR NAT) ON AND TEST ALL FITTINGS FOR LEAKS. BEFORE ATTEMPTING TO LIGHT GRILL, BE CERTAIN BOTH VALVES ARE IN THE OFF POSITION. BE CERTAIN THAT YOUR GAS SUPPLY IS OFF AND YOUR GAS FEED LINE HAS BEEN BLED OF ANY FUEL. WHEN REINSTALLING BURNER, BE CERTAIN THAT THE BURNER VENTURIS ARE ENGAGED ON THE VALVES AT LEAST 1/4".
PLEASE NOTE: IMPROPER ORIFICE SIZE COULD RESULT IN EITHER INSUFFICIENT OR EXCESS GAS GOING TO BURNER, AND MAY POSE A SAFETY RISK. HELPFUL TIPS 1. Before using your grill for the first time, please light and turn both burners on HI heat for ten to fifteen minutes. This will burn off any oils that are on new surfaces. Before grilling, we suggest putting a light coat of vegetable oil on your cooking grids. This should be done before you turn on your grill.
FLAME ADJUSTMENT TIPS Your PGS burner has been designed to operate the open position to allow more air to the burner. efficiently under widely varying operating conditions Tighten screw to insure mixer stays in this position. and is adjusted at the factory for proper operation so no adjustments should be required. Occasionally, 4.
PGS ACCESSORIES To more fully enjoy your gas grilling experience, PGS has designed and manufactures a variety of accessories and barbecue Covers (not pictured). Please find a brief description of PGS accessories below: INFRA-BROIL KIT The PGS Infra-Broil Kit comes as a standard feature on our models K60, K40 ULTRA and K40 Delux and may be purchased as an accessory for any Model K30 or K40. The Infra-Broil is a rear burner especially designed for those back yard chefs who love to rotisserie.
