BIG JOHN PG-36 User manual

Owner’s Manual

for Assembly, Operating & Maintenance of

Model PG-36 Table Top Gas Griddle

DANGER

IF YOU SMELL GAS:

1. SHUT OFF GAS TO APPLIANCE

2. EXTINGUISH OPEN FLAMES

3. IF ODOR CONTINUES, KEEP AWAY FROM THE

APPLIANCE AND IMMEDIATELY CALL YOUR

GAS SUPPLIER OR FIRE DEPARTMENT.

LEAKING GAS MAY CAUSE FIRE, EXPLOSION,

PERSONAL INJURY, DAMAGE TO PROPERTY, AND

DEATH.

THIS GAS GRIDDLE IS DESIGNED FOR OUTDOOR USE ONLY.

526 EAST ROLLING RIDGE DRIVE, BELLEFONTE, PA 16823

P: 814-359-2755 F: 814-359-2621 sales@bigjohngrills.com

WARNING: Do not ignite this griddle

without reading the LIGHTING INSTRUC-

TIONS first.

WARNING: DO NOT store or use

gasoline or other flammable liquids/

vapors in the vicinity of this griddle.

An LP Cylinder not connected for use

should not be stored in the vicinity of this

unit.

www.bigjohngrills.com

YOU MUST READ THIS OWNER’S MANUAL

BEFORE OPERATING YOUR GAS GRIDDLE.

WARNING: Follow all leak-check

procedures listed in this manual carefully

prior to operation of this unit. Do this

even if the griddle was assembled by a

professional.

1. PROPANE SAFETY - GENERAL Page 3

2. PROPANE SAFETY - CYLINDER Page 4 & 5

3. PROPANE SAFETY - QCC Page 6

4. GENERAL INFORMATION Page 7

5. ASSEMBLY INSTRUCTIONS Page 8

6. SET-UP INSTRUCTIONS Page 9

7. OPERATING INSTRUCTIONS Page 10

8. CLEANING & CARE INSTRUCTIONS Page 11

9. PARTS LIST Page 12

10. ACCESSORY LIST Page 13

11. TROUBLESHOOTING GUIDE Page 14

12. WARRANTY Page 15

13. WARNINGS Page 16

TABLE OF CONTENTS

 Liquid propane (LP) gas is a petroleum product as are gasoline and natural gas. In normal tempera-

tures and pressures, LP gas is a gas. When moderate pressure is applied, inside a cylinder, LP gas

becomes a liquid. As the pressure is released the liquid readily vaporizes and boils off as a gas.

 LP gas has no odor, but rather an odor additive so you can smell it.

 Propane gas is denser than air, if a propane tank purges to relieve pressure build-up, the propane

will collect in low lying areas. These areas can be easily ignited and are highly flammable. Use cau-

tion when dealing with a propane tank that may have recently self-purged.

 DO NOT paint propane tanks any color other than white. Any alteration to tank color will result in

tank purging, fire, personal injury, or death.

 Big John Grills & Rotisseries uses high quality Worthington Cylinders in 30 lb. and 40 lb. sizes.

These tanks are protected with a rust-resistant white powder coat finish.

 Always keep the cylinder valve closed when not in use.

 Cylinders are designed to function with the valve completely open or completely closed, there is no

in-between. Never open the valve just a “crack” or “half way”.

 Always position the propane cylinder so that the connection between the valve and the regulator will

not cause any sharp bends in the hose.

 NEVER store or use propane cylinders indoors.

 Make sure the POL or QCC Connector is free from scratches or nicks which can cause gas leaks.

 DO NOT store or use gasoline or other flammable liquids or vapors in the vicinity of a gas appliance.

 DO NOT store extra liquid propane cylinders within the vicinity of a gas appliance.

 DO NOT store a liquid propane cylinder in/on any part of an appliance not intended for such use.

Improper storage of a cylinder could lead an explosion, fire, personal injury, or death.

 DO NOT store or lean items against unit surface or fuel cylinders while operating.

 Shut off unit and all gas sources if the odor of unburned gas is detected. Make no attempt to use the

unit until gas leaks are fixed and/or the odor is accounted for.

 Do NOT use a damaged, dented, or rusty LP cylinder or a cylinder with a damaged valve - replace

with a new one immediately.

 Replacement LP tanks must match the regulator connection supplied with this grill and be a mini-

mum of 30 lb. capacity.

PROPANE SAFETY - GENERAL

LIQUID PROPANE TANK REQUIREMENTS

 For tanks not purchased from Big John Grills & Rotisseries: check to be sure cylinders have been

tested within the past 5 years and have a D.O.T. certification. Your LP gas supplier can do this for

you.

 All LP tank supply systems must have a collar to protect the cylinder valve.

 All tanks used on Big John Grills equipment must be a minimum of 30 lb. size.

 Tanks larger than 100 lbs. in size may require a POL for connection. Please call a Big John Cus-

tomer Service Representative if you are using a 100 lb. propane tank.

DISCONNECTING AND TRANSPORTING PROPANE CYLINDERS FOR REFILLING

 Turn off all control knobs and close the main cylinder valve. Disconnect regulator with QCC.

 Place cylinder valve plug snugly in the main cylinder valve outlet. Only use the cylinder valve plug

that is provided with the cylinder. Other types of caps or plugs may result in leakage of propane.

 Treat “empty” LP cylinders with the same care as full ones. Even when the tank is empty, there is

still some gas pressure left in the cylinder.

 Always transport and store propane cylinders in a secure, upright position. Never store these pro-

pane tanks on their side, handle them roughly, or drop them.

 Never keep propane cylinders (full or empty) in a hot vehicle. Heat can cause the relief valve to

purge propane creating a very dangerous situation.

 To fill, take the LP cylinder to a propane gas dealer WARNING: We strongly recommend that your

LP cylinder be filled by an authorized propane dealer, by a qualified attendant, who fills the

tank by weight. IMPROPER FILLING IS DANGEROUS.

 Air must be purged from a new LP cylinder before the initial filling. Your LP dealer will do this.

STORING PROPANE CYLINDERS

 Turn off all control knobs and close the main cylinder valve.

 Place cylinder valve plug or cap snugly in main cylinder valve outlet.

 Always store propane cylinders in a secure, cool/dry place in the upright position.

 Never store propane cylinders in a vehicle of any kind and or anywhere the temperatures can reach

125° F.

PROPANE SAFETY - CYLINDER

CONNECTING A FILLED 30 LB. CYLINDER

 Remove the main cylinder plug.

 Make sure that all gas valves on the grill are in the “OFF” position.

 Thread the QCC Connector or POL Connection snugly into main cylinder.

 ALWAYS check for leaks. Apply soapy water with a brush or spray bottle to areas where the QCC

(or POL) screw into tank, where the QCC (or POL) attach to regulator, where the hose screws into

the regulator, and where the hose screws into the appliance.

 Open the cylinder valve and watch for bubbles.

 If bubbles appear, tighten the connections further. If this does not remedy the problem, call your

propane dealer.

 If the system is free of leaks, light the burners and proceed to cook.

 In the event of a QCC failure, your grill will not light or stay lit, see page 14 for troubleshooting.

If you suspect any problems, have your grill and tank serviced by a qualified professional.

PROPANE SAFETY - CYLINDER

Spray Soapy Water on All Propane

Connections between Cylinder Valve

and Unit to Test for Leaks

Cylinder Valve to

QCC Connection

Lime Green QCC

to Regulator

Connection

Hose to Regulator

Connection Hose to Unit

Connection

HOW A QCC VALVE WORKS

There is a safety check valve inside our bright green QCC-1 fitting. Once the regulator is connected to the

propane tank and the main cylinder is “OPEN”, a minimal amount of gas is allowed to flow through the

check valve. If there are no downstream leaks, the pressure on both sides of the check valve will equalize

and the spring loaded stopper will open allowing maximum gas to flow. This only takes a few seconds to

complete and then you can start the lighting procedure.

IF THE QCC INDICATES FAILURE

If there is a downstream leak, or if you have started with a control valve “OPEN”, the pressure will not

equalize on both sides of the QCC check valve and it will fail. The only gas flow you will have is a small

amount that is designed to flow around the check-valve, the equivalent of 5,000 BTU’s. This may allow

you to light part of a burner, but not much more. When you open a control valve to light another burner,

you will not get any additional flame and may experience a blow out where none of the burners will light.

In case of a QCC failure, follow procedure below:

TO TROUBLESHOOT THE PROBLEM

CHECK: 1. Check that all of the control valves are in the “CLOSED” position.

2. Check that you are using at least a 30# propane tank

3. Check that you have lava rock in the grill

4. Check that the QCC is lime green - black or dark green will cause lighting problems.

If everything is correct, reset the system.

SOLUTION: To reset: Close all of the control valves on the grill & close propane tank valve.

Then start the lighting procedure from the beginning. If the problem persists, Check for

Leaks:

If you experience a QCC Failure, first check your system for leaks:

1. Turn off all control valves and turn off propane tank

2. Extinguish any remaining open flames

3. Let gas dissipate until odor is no longer detected

4. Make sure all control valves are closed and gas tank valve is off

5. In a spray bottle, mix together dish soap and water

6. Spray the following with soapy water mixture

a. Tank Valve to QCC (part that screws into tank from regulator)

b. QCC to Regulator

c. Regulator to Hose

d. Entire hose

e. Hose to Grill

f. Each Control Valve where it Connects to Manifold

g. Manifold end cap (opposite side from hose connection)

7. Turn on propane tank

8. Inspect each connection and length of hose for any bubbles being produced

9. If bubbles are detected (bubbles indicate gas is escaping), turn off propane tank

and call Big John Grills to order replacement parts. Do not go to your local hard-

ware store.

10.If no bubbles are detected, check to see if propane tank is empty.

11.If tank is not empty, please call Big John Grills for further assistance

If you need assistance at any time please call

Big John’s Customer Service at 1-800-326-9575 or 814-359-2755

PROPANE SAFETY - QCC

 Big John products are designed for OUTDOOR USE ONLY! Only operate this equipment in a well-

ventilated area. Do not use in garage, building, or other enclosed area. Operation of this equipment

indoors or in a poorly ventilated area may cause an explosion, fire, personal injury, or death.

 ONLY use the hose and regulator supplied with this griddle from the manufacturer. Any attempt to

use parts found in a hardware store may result in the grill not functioning properly which could lead

to an explosion, fire, personal injury, or death.

 Do not retrofit any equipment or accessories to the unit that are not part of the original equipment

provided by Big John Grills & Rotisseries. Replacement parts must be obtained from the manufac-

turer. Any attempt to change or modify this unit could result in an explosion, fire, personal injury to

yourself or someone else, or death and will void your warranty.

 Do not touch or allow any contact with the sides, back, or top of griddle after lighting. The unit is

EXTREMELY HOT! Allow the griddle to cool completely before touching any metal surface.

 DO not operate griddle within 12” of a combustible or non-combustible surface. Provide adequate

clearance and ventilation at all times.

 WARNING! Use of this griddle in high wind conditions may result in poor burner operation (low

flame, blowing out, flaring up, etc.). Avoid these conditions if possible by repositioning griddle. If re-

positioning does not improve operation, discontinue use and turn off grill until conditions improve.

 DO NOT perform any maintenance until griddle is completely cooled down.

GENERAL INFORMATION

Thank you for purchasing a Big John Gas Griddle! We take pride in producing and selling equipment

made right here in America and are pleased that you recognized the quality and durability of our prod-

ucts. Your new Big John griddle is a commercial grade, outdoor piece of cooking equipment. With this

griddle, you will be able to cook a variety of foods quickly and easily. This griddle is portable meaning

you can take it and use it anywhere. Big John griddles are used at offsite catering events & festivals,

restaurants, hotels & resorts, golf courses, personal homes and many more. Please read the infor-

mation provided below before using your griddle for the first time.

This unit ships 90% assembled and we make sure the instructions for the rest are easy to follow and

perform. Please follow the instructions below to ensure your griddle is properly assembled for safe op-

eration. Please remember this is a commercial piece of equipment and therefore the materials used to

build it are of the best quality. Because of this, the grill weight is considerable and will require 2 people

to un-package, assemble, and set-up the unit.

1. Unbox the unit and, while upside down, attach the wheels.

2. Bolt drip pan holders to each side of the frame.

3. Place 1/6 size stainless steel drip trays into holders and check that they are level

4. If you purchased the Folding Leg Cart, open it up and lock the legs.

5. Place the Folding Leg Cart on a level area, clear of any combustible materials.

6. Place the griddle on the Folding Leg Cart, making sure the legs of the griddle fit down inside the

stand.

ASSEMBLY INSTRUCTIONS

SET-UP INSTRUCTIONS

1. Place griddle on a level area clear of any combustible materials. THIS UNIT IS BUILT FOR OUT-

DOOR USE ONLY and should be operated in a well ventilated area.

2. Ensure all control valves are in the CLOSED position (parallel to the manifold).

3. Securely connect the regulator to the propane cylinder and test for leaks according to the instruc-

tions found on PAGE 6 of this manual.

A. QCC Connection: The bright green QCC connector on a regulator threads snuggly and easily

onto the external threads of the propane cylinder valve by turning the QCC clockwise (to the

right) only.

B. POL Connection: The POL connector on a regulator is inserted into the propane cylinder

valve and screws in by turning counter clockwise (to the left) only using the black plastic hand

wheel or wrench.

4. Your griddle comes cured with a layer of vegetable oil. We recommend burning the griddle for ap-

proximately 20 minutes prior to using them for the 1st time. This will burn off any dust that accumulat-

ed during transportation. Simply wipe griddle plate down with a damp cloth and then follow lighting

instructions below. Bacon is a great first meal to break in your griddle. You will build up a black car-

bon seasoning which provides a non-stick cooking surface that should not be scrubbed off.

CAUTION: GRIDDLE WILL BE EXTREMELY HOT.

6. Open cylinder valve completely and allow system to pressurize - takes about 1 minute.

7. TO LIGHT THE GRIDDLE: Make sure all control knobs are CLOSED - knobs are parallel to man-

ifold. Open propane cylinder control valve and let system pressurize for 1 minute. Hold a lit long

handled butane lighter gun next to the front burner and open the control valve (push in turn the knob

to OPEN - so it is straight up and down - perpendicular to the manifold). The front burner will ignite

instantly with a *POOF* sound. Remove lighter and open 2nd control valve - it will light instantly

from the 1st. Repeat for back burner until all are lit. If for some reason the first burner does not light,

turn off gas source, wait 5 minutes for gas to dissipate, and restart lighting instructions. CAUTION:

GRIDDLE WILL BE EXTREMELY HOT.

8. Your griddle is designed to provide a large warming area under the burners. Standard food pans

(not included) can be placed in this warming area. Cover the food pans with aluminum foil to prevent

drying out/changing texture or presentation.

9. TO TURN OFF GRIDDLE: Simply turn all of the control knobs to the CLOSED position

(parallel to the manifold), close main cylinder valve, and disconnect the propane cylinder. CAUTION:

GRIDDLE WILL BE EXTREMELY HOT! LET COOL COMPLETELY BEFORE STORING OR

TRANSPORTING.

OFFON

OPERATING INSTRUCTIONS

1. Place griddle on a level area clear of any combustible materials. THIS UNIT IS BUILT FOR OUT-

DOOR USE ONLY and should be operated in a well ventilated area.

2. Ensure all control valves are in the CLOSED position (parallel to the manifold).

3. Securely connect the regulator to the propane cylinder and test for leaks according to the instruc-

tions found on PAGE 6 of this manual.

4. Generously coat grates with vegetable oil or oil-based cooking spray.

5. Open cylinder valve completely and allow system to pressurize - takes about 1 minute.

6. TO LIGHT THE GRIDDLE: Hold a lit long handled butane lighter gun or fireplace match next

to the front burner and open the control valve (push in turn the knob to OPEN - so it is straight up

and down - perpendicular to the manifold). The front burner will ignite instantly with a *POOF* sound.

7. Remove lighter or match and open 2nd control valve - it will light instantly from the 1st.

8. If for some reason the first burner does not light, turn off gas source, wait 5 minutes for gas to dissi-

pate, and restart lighting instructions.

9. Once burners are lit, adjust the control knobs to set desired temperature.

10. Your griddle is designed to provide a large warming area under the burners. Standard food pans

(not included) can be placed in this warming area. Cover the food pans with aluminum foil to prevent

drying out/changing texture or presentation.

11.TO TURN OFF GRIDDLE: Simply turn all of the control knobs to the CLOSED position

(parallel to the manifold), close main cylinder valve, and disconnect the propane cylinder. CAUTION:

GRIDDLE WILL BE EXTREMELY HOT! LET COOL COMPLETELY BEFORE STORING OR

TRANSPORTING.

12.Wait approximately 10 minutes before attempting to clean or coat the griddle plate with vegetable oil.

Table of contents

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