Pit Boss PBK24 - Ceramic Charcoal Grill Manual

NOTE: Due to ongoing product development, parts are subject to change without notice. Contact Customer Care if parts are missing when assembling the unit.

ASSEMBLY PREPARATION

Parts are located throughout the shipping carton, including underneath the grill. Inspect the grill, parts, and hardware blister pack after removing from the protective shipping carton. Before assembly of product, review all parts and reference the parts list. If any part is missing or damaged, do not attempt to assemble. Shipping damage is not covered under warranty. Contact your dealer or Customer Care for parts.
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To ease installation and avoid injury, use two people when assembling this appliance.
Tools required for assembly: Flat Wrench, Wrench 9/11, Wrench 16/19, Screwdriver. Tools included.

ASSEMBLY INSTRUCTIONS

It is advised to read each step entirely before starting assembly on instructions. Do not tighten screws completely until all screws for that step have been installed. Hardware combination involving a locking washer and washer should be installed with the locking washer closest to the head of the screw.

1. ATTACHING THE CASTER WHEELS
   Parts Required:
   4 x Support Bracket (#12)
   2 x Locking Caster Wheel (#14)
   2 x Caster Wheel (#15)
   4 x Large Nut (#B)
   Installation:
   
   • • Attach the four pre-threaded caster wheels to each of the four support brackets by hand-tightening them into the hole. Secure each caster wheels with large nut.
     NOTE: To keep support brackets level, ensure the bolt on the wheel does not extend the large nut.
2. ASSEMBLING THE CART
   Parts Required:
   2 x Support Bracket Crosspiece (#13)
   16 x Screw (#E)
   16 x Washer (#D)
   16 x Locking Washer (#C)
   16 x Nut (#A)
   • To assemble the cart, attach the support bracket crosspiece to one of the four support brackets. Secure the support brackets to the crosspieces by using a screw, locking washer, washer, and nuts. Note the position shown in 2A.
     
   • Continue to attach the crosspieces into the other three support brackets. The cart is now complete. Note 2B.
     
3. LIFTING THE CERAMIC BODY ONTO THE CART
   Parts Required:
   1 x Ceramic Body (#4)
   Installation
   
   • First, remove all of the parts that are inside of the ceramic body to make lifting easier. Make sure the cart is secure, and all of the bolts are tight before placing the ceramic body into it. Press down on the caster levers to lock the castor wheels to ensure the ceramic charcoal barbecue cannot move.
     
     Use a minimum of two people when lifting the ceramic body onto the cart. Failure to comply may result in serious injury or damage to the product.
   • To place the ceramic body on the cart, place one of your hands in the bottom vent of the ceramic body and the other under the grill. Place the ceramic charcoal barbecue on the cart with the bottom vent facing to the front of the cart, allowing the vent to open and close without any interruption.
4. ATTACHING THE TOP DAMPER
   Parts Required:
   1 x Top Damper Vent (#3)
   Installation
   
   • Align the side notch of the top damper vent with the thermometer on the front of the ceramic body, and set over the top opening. Secure with pre-attached screws, washers, and nuts.
5. INSTALLING THE SIDE SHELF BRACKETS
   Parts Required:
   2 x Left Side Shelf Bracket (#6)
   2 x Right Side Shelf Bracket (#7)
   Installation
   
   • Attach the left side shelf brackets to the ceramic body using the preattached screws with their corresponding washers, locking washers, and nuts on the trim.
   • Repeat the same installation for the right side shelf brackets. Tighten all screws securely once all brackets are installed.
6. MOUNTING THE SIDE SHELVES
   Parts Required:
   2 x Side Shelf (#8)
   Installation
   
   • Insert the hinges of each side shelf into each of the side shelf brackets on both sides of the ceramic body.
7. ATTACHING THE LID HANDLE
   Parts Required:
   1 x Lid Handle (#5)
   Installation
   
   • Attach the lid handle to the ceramic body use the pre-attached screws washers, locking washers, and nuts on the trim.
8. PLACING THE COOKING COMPONENTS
   Parts Required:
   1 x Upper Cooking Grid (#2)
   1 x Main Cooking Grid (#1)
   1 x Heat Deflector (#9)
   1 x Charcoal Plate (#10)
   1 x Firebox (#11)
   Installation:
   • Open the lid of the ceramic body and insert the firebox into the base of the ceramic body. The front of the firebox with the arch of the bottom rim should face the front of the unit, aligning with the bottom damper for ash clean out. Note 8A.
     NOTE: The expansion joint in the firebox is created to account for expansion of the ceramic in extreme heat. This crack is not a fault in the ceramic, but intentional in the structure design.
     
   • Place the charcoal plate to rest on the interior base of the firebox.
     
     The charcoal plate must be in the firebox while in use. Missing this part could result in lighting failure due to lack of oxygen to the charcoal once lit.
   • Place the heat deflector to rest inside the firebox.
     NOTE: The heat deflector can be used for indirect cooking.
   • Place the main cooking grid inside of the ceramic body. Place the upper cooking grid on top of the main cooking grid.
     NOTE: To maintain the grilling performance of your cooking grids, regular care and maintenance is required.
   • The ceramic charcoal barbecue is now ready to use. Note 8B.
     
     Ensure that unit curing instructions are read thoroughly prior to use.
     

OPERATING INSTRUCTIONS

INTRODUCTION TO CERAMIC GRILLING
Ceramic charcoal barbecues are extremely versatile. Not only can they be used for grilling or smoking, but also pizzas, bread, pies and cookies can be baked effortlessly inside them. Due to their excellent heat-retention properties, high temperatures can be achieved and maintained by precise control of airflow via the top and bottom vents. High temperatures are ideal for quickly cooking burgers and sausages, while low heats can cook larger cuts over a longer period of time. Try adding some wood chips to the charcoal, or try combining different flavor wood chips to make your meats even more flavorful.

UNDERSTANDING AIRFLOW AND DAMPER CONTROL
The heart of your grill lies in the relationship between the top and bottom ventilation dampers. Opening the dampers, allowing more air to flow through the system, allows the charcoal to burn very hot and create firey embers. To cook at lower temperatures, keep the dampers open only a small distance, allowing for minimal airflow and maximum heat retention in the ceramic chamber.
To ensure the grill performs correctly, proper maintenance and clean out of the firebox are essential. If the grill is not achieving the desired temperature, check to ensure that there is proper airflow to the fuel and that none of the dampers are blocked. TIP: The grill can run efficiently over extended periods of time as long as there is dry and sufficient fuel, proper airflow, and the cooking components are clean.

FIRST USE – CURING THE UNIT
Curing your ceramic charcoal barbecue is important for its long-term operation and care. Avoiding the curing procedure could lead to damage on the unit. If the first burns are too hot, they could damage the felt gasket seal before it has had the chance to mature with use. To start your first fire:

1. Place one lighter cube, or solid firelighters and one handful of lump charcoal on top of the charcoal plate. Open the bottom vent and light the lighter cube using a long-nosed lighter or safety matches.
   Do not use gasoline, white spirit, lighter fluid, alcohol or other similar chemicals for lighting or relighting.
2. Once the lump charcoal has caught, cure the unit by closing the lid, and leaving both vents mostly closed. Burn until all the fuel is used and the fire is extinguished. This should take approximately two hours. Do not overload the unit with fuel.
3. After grill has cooled, inspect all fasteners. The metal band connecting your lid to the base will expand from the heat and could become loose. It is recommended you check and tighten the band, if necessary, with a wrench.
4. The ceramic charcoal barbecue can now be used as normal.

LIGHTING PROCEDURE
When using the ceramic charcoal barbecue, push down on both of the locking wheels to stop the unit from moving around during use. Ensure the ceramic barbecue is positioned on a permanent, flat, level, heat-resistant non-flammable surface, away from flammable items. Position the ceramic charcoal barbecue with a minimum of 2 m / 78 in overhead clearance and at least 2 m / 78 in clearance from other surrounding items.

1. To start a fire, place rolled-up newspaper and some lighter cubes or solid firelighters on the charcoal plate, in the base of the ceramic charcoal barbecue. Then, place two or three handfuls of lump charcoal over the top of the newspaper.
   Do not use gasoline, white spirit, lighter fluid, alcohol or other similar chemicals for lighting or relighting.
2. Open the bottom vent and light the newspaper using a long-nosed lighter or safety matches. Once it has caught, leave the bottom vent and lid open for about 10 minutes to build a small bed of hot embers.
3. Allow the charcoal to heat up and keep it red hot for at least 30 minutes prior to the first cooking on the ceramic charcoal barbecue. Do not cook before the fuel has a coating of ash.
   It is recommended that you do not stoke or turn the coals once they are alight. This allows the charcoals to burn more uniformly and efficiently.
4. Once alight, only use heat-resistant gloves when handling hot ceramics or cooking surfaces.

REFUELING PROCEDURE
With the top and bottom vent closed, the ceramic charcoal barbecue will stay at a high temperature for several hours. If you require a longer cooking time (e.g. when roasting a whole cut or slow-smoking), it may be necessary to add more charcoal.

1. Open the lid and remove the cooking grids and heat deflector using heat-resistant gloves or a spatula.
2. Add additional charcoal to the fire box
3. Replace cooking grids and heat deflector then continue to cook as normal.

Do not use spirit, petrol, gasoline, lighter-fluid or kerosene for lighting or refreshing a fire in your grill. Also, do not attempt to add more fire starter into a fire that is already burning or into a hot burn grate. This may cause injury.

EXTINGUISHING THE GRILL

1. When finished cooking and extinguish unit, stop adding fuel. Close all the vents and the lid to allow the fire to die naturally by lack of oxygen.

Do not use water to extinguish the charcoal as this could damage the ceramic charcoal barbecue.

CARE & MAINTENANCE

Any Pit Boss® unit will give you many years of flavorful service with minimum cleaning. An important step is allowing the grill and cooking grids to self-clean by running the grill at a high temperature after each use. Follow these cleaning and maintenance tips to service your grill:

1. INSIDE SURFACES

• It is recommended to clean the interior of the unit after every few uses. This will ensure proper lighting and avoid any hard build-up of debris or ash on the cooking components. Heat it up to 260ºC / 500ºF for 30 minutes and it will scorch off all food and debris.
  NOTE: Do not use water or any other types of cleaning product to clean the inside of your ceramic charcoal barbecue. The walls are porous and will absorb any fluids used, which could cause the ceramic charcoal barbecue to crack.
• Use a long-handled grill cleaning brush, remove any food or build-up from the cooking grids. Best practice is to do this while they are still warm from a previous cook. Grease fires are caused by too much fallen debris on the cooking components of the grill. Clean the inside of your grill on a consistent basis. In the event you experience a grease fire, keep the grill lid closed to choke out the fire. If the fire does not go out quickly, carefully remove the food, turn the grill off, and shut the lid until the fire is completely out. Lightly sprinkle baking soda, if available.
• The chrome-plated charcoal plate is not dishwasher safe; use a mild detergent with warm water.
• After the unit has completely cooled, use the ash tool to scrape out carbon remnants through the bottom damper vent. Carefully open the slide plate and rake the ash into a small waste container under the vent opening. Dispose of container, or store for future use.

2. OUTSIDE SURFACES

• Upon close inspection, the finish of your ceramic charcoal barbecue may appear to have crack lines. This is not cracking of the ceramic. This is known as crazing and is caused by the different expansion rates between the glaze finish and the clay. The spider-web pattern of cracking is different from a break in the aspect that it cannot be felt on the surface, unless using a fingernail; however, it does become more visually apparent when the surface is dusty or magnified.
• Wipe your grill down after each use. Use warm soapy water to cut the grease. Do not use oven cleaner, abrasive cleansers or abrasive cleaning pads on the outside surfaces.
• Check and tighten the metal rings of the ceramic body and lid, and oil the hinges, twice a year or more if needed. You should not be able to easily turn a hex key while holding the nut in place.
• Use a grill cover to protect your grill for complete protection! A cover is your best protection against weather and outside pollutants. When not in use or for longterm storage, keep the unit under a cover in a garage or shed.

CLEANING FREQUENCY TIME TABLE (NORMAL USE)

TROUBLESHOOTING

Proper cleaning, maintenance and the use of clean, dry, quality fuel will prevent common operational problems. When your Pit Boss® grill is operating poorly, or on a less frequent basis, the following troubleshooting tips may be helpful.
For FAQ, please visit www.pitboss-grills.com. You may also contact your local Pit Boss® authorized dealer or contact Customer Care for assistance.

Ensure the grill is completely cooled prior to any inspection, cleaning, maintenance or service work. Failure to comply may result in serious injury or damage to your unit.

PROBLEM	CAUSE	SOLUTION
Grill Will Not Light	Damper Vents Are Closed, Lack of Air	Ensure that both the top and bottom vents are open. The fire needs oxygen to catch. Once it has caught, leave the bottom vent and lid open for about 10 minutes to build a small bed of hot embers.
	Incorrect Fuel Used	This grill requires the use of lump charcoal. Follow Lighting Procedure to continue use of grill; however, call Customer Care for assistance if required.
Grill Will Not Achieve Or Maintain Stable Temperature	Grill Gets Too Hot	Close the lid, mostly close both vents, and allow the barbecue to smother with lack of oxygen. For low temperature cooking, use less fuel.
	Grill Does Not Get Hot Enough	Check fuel level. The grill may quickly lose fire if there is not enough charcoal in the ceramic body. The recommended use of lump charcoal is a maximum of 1.81kg / 4lbs per burn. Add more fuel and leave both vents completely open. More oxygen flow will allow the fire to increase, burning more lump charcoal.
	Insufficient Air Flow Through Ceramic Body	Check bottom damper vent for ash build-up or obstructions. Follow Care and Maintenance instructions for ash build-up. Check top damper vent, and ensure it is working properly and airflow is not blocked. Follow Care and Maintenance instructions if dirty. Once all the above steps have been done, light the grill and perform a burn-off.
Flare-Ups	Cooking Temperature Too High	Attempt cooking at a lower temperature. Grease does have a flash point. Keep the temperature under 176°C / 350°F when cooking highly greasy food.
	Grease Build-Up On Cooking Components	Follow Care and Maintenance instructions.
	Need to Burp The Grill	To prevent any back-draft or flare-ups that may cause injury, it is well advised to lift the lid only slightly (also known as burping), which allows air to enter slowly and safely.
Bottom Damper Won't Slide	Damper Stuck On Ash	Tap the damper lightly with a rubber hammer to loosen. Follow Care and Maintenance instructions. If no improvement, call Customer Care.
Finishing on Unit	Finish is chipped	The finish of your unit may chip on the ceramic, but this does not affect the performance or lifespan of your unit. If chipping is substantial, call Customer Care.
	Spider-web pattern of cracking	This is not cracking of the ceramic. This is known as crazing and is caused by the different expansion rates between the glaze finish and the clay. The spider-web pattern of cracking is different from a break in the aspect that it cannot be felt on the surface, unless using a fingernail; however, it does become more visually apparent when the surface is dusty or magnified. Follow Care and Maintenance instructions. While these cracks may appear as imperfections, crazing does not affect the performance or life span of your ceramic charcoal barbecue; therefore, it is not a warranty issue.
Lid Is Stuck	Unit Not Cured Properly	Curing your ceramic charcoal barbecue is important for its long-term operation and care. If the first burns are too hot, they could damage the felt gasket seal before it has had the chance to mature with use. If the lid gets stuck, or sealed, together with the base, use a knife to carefully unseal and cut off the felt gasket that trims the lid opening. Once removed, you will be able to open the lid. Before continuing to use the unit, replace the high-heat felt gasket, which can be purchased at your local fireplace store.

WARRANTY

CONDITIONS
All ceramic grills by Pit Boss® Grills, manufactured by Dansons, carry a limited warranty from the date of sale by the original owner. The warranty coverage begins on the original date of purchase and proof of date of purchase, or copy of original bill of sale, is required to validate the warranty. Customers will be subject to parts, shipping, and handling fees if unable to provide proof of purchase or after the warranty has expired.
Dansons carries a Limited Lifetime Warranty on all ceramic parts used to manufacture the ceramic charcoal barbecue. Dansons warrants that all part(s) are free of defects in material and workmanship, for the length of use and ownership of the original purchaser. Warranty does not cover damage from wear and tear, such as scratches, dents, dings, chips or minor cosmetic cracks. These aesthetic changes of the grill do not affect its performance. Upon close inspection, the finish of your ceramic charcoal barbecue may appear to have crack lines. This is not cracking of the ceramic. This is known as crazing and is caused by the different expansion rates between the glaze finish and the clay. The spider-web pattern of cracking is different from a break in the aspect that it cannot be felt on the surface, unless using a fingernail; however, it does become more visually apparent when the surface is dusty or magnified. While these may appear as imperfections, crazing does not affect the performance or life span of your ceramic charcoal barbecue; therefore, it is not a warranty issue.
Dansons carries a five-year warranty on all metal and cast-iron parts used to manufacture the ceramic charcoal barbecue. Dansons warrants that all part(s) are free of defects in material and workmanship, for the length of use and ownership of the original purchaser. High temperatures, excessive humidity, chlorine, industrial fumes, chemicals, fertilizers, lawn pesticides and salt are some of the substances that can affect metal parts. For these reasons, the warranty does not cover rust or oxidization. Dansons recommends that you cover your grill when not in use. Even with these safeguards, the ceramic charcoal barbecue can be compromised by various substances and conditions beyond Dansons' control.
Dansons carries a one-year warranty on all plastic and composite components, thermometer, and caster wheels used to manufacture the ceramic charcoal barbecue. Warranty does not cover cosmetic or colour changes, weathering or cracks, unless there is a loss of structural integrity. Warranty does not cover damage from wear and tear, such as scratches, dents, dings, chips or minor cosmetic cracks. These aesthetic changes of the grill do not affect its performance. Repair or replacement of any part does not extend past the limited warranty. During the term of the warranty, Dansons' obligation shall be limited to furnishing a replacement for defective and/or failed components. As long as it is within the warranty period, Dansons' will not charge for repair or replacement for parts returned, freight prepaid, if the part(s) are found by Dansons' to be defective upon examination. Dansons' shall not be liable for transportation charges, labor costs, or export duties. Except as provided in these conditions of warranty, repair or replacement of parts in the manner and for the period of time mentioned heretofore shall constitute the fulfillment of all direct and derivate liabilities and obligations from Dansons to you.
This warranty is based on normal domestic use and service of the grill, and neither limited warranty coverage's apply for a grill which is used in commercial applications.

Documents / Resources

References

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