Pit Boss PB440FB1, 10906 Manual

PARTS & SPECS

Part#	Description
1	Power Cord Bracket (x1)
2	Probe Wire Casing (x1)
3	Porcelain-Coated Steel Cooking Grids (x2)
4	Porcelain-Coated Steel Upper Cooking Rack (x1)
5	Lid Stopper (x1)
6	Flame Broiler Slider (x1)
7	Flame Broiler Main Plate (x1)
8	Lid Handle Bezel (x2)
9	Lid Handle (x1)
10	Hopper Assembly (x1)
11	Plate Screw (x1)
12	Drop Chute Plate (x1)
13	Main Barrel (x1)
14	Left Support Leg - Front (x1)
15	Left Support Leg - Back (x1)
16	Right Support Leg - Front (x1)
17	Right Support Leg - Back (x1)
18	Flame Broiler Adjusting Bar Handle (x1)
19	Flame Broiler Adjusting Bar (x1)
20	Front Panel (x1)
21	Bottom Shelf (x1)
22	Grease Bucket (x1)
23	Wheel (x2)
A	Screw (x20)
B	Washer (x20)
C	Locking Washer (x20)
D	Wheel Cotter Pin (x2)
E	Wheel Washer (x2)
F	Wheel Axle Pin (x2)
G	Screw (x4)

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

PB – ELECTRIC REQUIREMENTS
110-120 V, 60 Hz, 250 W, 3-PRONG GROUNDED PLUG

MODEL		ASSEMBLED (WxDxH)	WEIGHT		COOKING AREA	TEMPERATURE RANGE
PB	PB440FB1	1,020 MM X 616 MM X 1,148 MM / 40.1 IN. X 24.2 IN. X 45.2 IN.	40.5 KG / 89.3 LB		MAIN - 2,403 CM² / 372.5 IN² UPPER - 939 CM² / 145.5 IN² TOTAL - 3,342 CM² / 518.0 IN²	82-260°C / 180-500°F

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. Discard all packaging materials from inside and outside of the grill before assembly, then review and inspect all parts by referencing 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 Pit Boss Customer Care for parts.

USA: (480) 923-9630 | Canada (Toll Free): 1-877-942-2246
www.pitboss-grills.com

To ease installation, using two people is helpful (but not necessary) when assembling this unit

Tools required for assembly: screwdriver and level. Tools not 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.

ASSEMBLING THE CART

See illustration 1

Parts Required:
1 x Left Support Leg - Front (#14)
1 x Left Support Leg - Back (#15)
1 x Right Support Leg - Front (#16)
1 x Right Support Leg - Back (#17)
1 x Bottom Shelf (#21)
4 x Screw (#A)
4 x Washer (#B)
4 x Locking Washer (#C)

Installation:

• Place a piece of cardboard on the floor to prevent scratching the unit and parts during assembly.
• Mount the Bottom Shelf to each Support Leg using a screw, locking washer, and washer. Ensure the flat surface of the shelf is facing up.

TIP: Fasten the screws of the Support Legs on half-way to allow easier installation of Main Barrel in the third step.

MOUNTING THE SUPPORT PANEL

Parts Required:
1 x Support Panel (#20)
2 x Screw (#G)

Installation:

• Mount the Support Panel to the front two Support Legs of the unit using two screws. Ensure the flat side of the Support Plate is facing outwards. Note illustration 2
  

SECURING THE MAIN BARREL TO THE CART

Parts Required:
1 x Main Barrel (#13)
12 x Screw (#A)
12 x Washer (#B)
12 x Locking Washer (#C)
2 x Screw (#G)

Installation:

• Lay Main Barrel down on its side on the cardboard, hopper end pointed upward. Lay the Cart next to the Main Barrel with the Support Panel facing the front.
• Secure the Main Barrel to each Support Leg using three screws, locking washers, and washers. Install the hardware from the inside of the Main Barrel. Note illustration 3A.
  
• Secure the Support Panel to the Main Barrel using two screws (#G). Note illustration 3B.
  

NOTE: Once all screw are installed, then tighten securely into the legs.

MOUNTING THE WHEELS TO THE CART ASSEMBLY

Parts Required:
2 x Wheels (#23)
2 x Wheel Cotter Pin (#D)
2 x Wheel Washer (#E)
2 x Wheel Axle Pin (#F)

Installation:

• Attach the Wheel to the Support Leg by inserting the Wheel Axel Pin through the leg hole, Wheel Washer, and finally secure using the Wheel Cotter Pin. Note illustration 4. Repeat installation for the other wheel.
  
• Carefully lift the grill into an upright position.

SECURING THE LID STOPPER

Parts Required:
1 x Lid Stopper (#5)

Installation:

• Secure the Lid Stopper onto the top of the Main Barrel using the pre-installed hardware on top of the Main Barrel. Note illustration 5
  

INSTALLING THE HOPPER TO THE BARREL

Parts Required:
1 x Power Cord Bracket (#1)
1 x Probe Wire Casing (#2)
1 x Hopper Assembly (#10)
1 x Plate Screw (#11)
1 x Drop Chute Plate (#12)
4 x Screw (#A)
4 x Washer (#B)
4 x Locking Washer (#C)

Installation:

• Secure the Plate Screw to the Drop Chute Plate, and insert into the horizontal slit on the rear side of the hopper.
• Align the Burn Pot end of the Hopper Assembly into the opening on the left side of the Main Barrel. Insert half-way, then carefully slide the Hopper Assembly completely into the opening. Secure the Hopper Assembly to the Main Barrel, from the inside, using four screws, locking washers, and washers. Take care not to over-tighten to avoid stripping the screws. Note illustration 6A.
  
• On the rear side of the hopper, connect the silver Grill Probe temperature wires – extruding from the Main Barrel – to the wire connections from the rear of the Hopper Assembly. Note 6B. Remove the two pre-mounted screws. Tuck the excess wire into the Probe Wire Casing, placing the wire distinctly in the divet along the edge to avoid pinching. Next, secure the Probe Wire Casing to the hopper using the two screws previously removed. Note 6C.
  

Ensure the Grill Probe temperature wires do not get pinched. Damage to the Grill Probe temperatures wires may result in incorrect readings, or inability to funtion.

• Secure the Power Cord Bracket using the two screws pre-installed on the rear side of the hopper, above the Drop Chute Plate. Note illustration 6D.
  

ASSEMBLING THE LID HANDLE

Parts Required:
2 x Lid Handle Bezel (#8)
1 x Lid Handle (#9)

Installation:

• Remove the pre-installed hardware from the lid handle. From inside the barrel lid, insert one screw to protrude to the outside. Add a bezel on the screw, then hand-tighten the screw, locking washer, and washer (from the inside) into the lid handle. Repeat same installation for other end of lid handle. Note illustration 7
  

INSTALLING THE FLAME BROILER COMPONENTS

Parts Required:
1 x Flame Broiler Slider (#6)
1 x Flame Broiler Main Plate (#7)
1 x Flame Broiler Adjusting Bar Handle (#18)
1 x Flame Broiler Adjusting Bar (#19)

Installation:

• Insert the Flame Broiler Main Plate into the Main Barrel, right side first. Rest the Flame Broiler Main Plate on the built-in ledge (on the inside right) of the Main Barrel that directs grease towards the grease bucket. Slide the entire piece to the left side, and the two slots on the Flame Broiler Main Plate will fit into the rounded ledge above the Burn Pot. It will sit slightly at a downward angle. Note 8A.
  

If the Flame Broiler Main Plate is on the base of the barrel, it is installed incorrectly. The Flame Broiler Main Plate should sit at an angle, with the left side sitting higher than the right. Poor installation of this part may result in damage to your Main Barrel.

• Place the Flame Broiler Slider on top of the Flame Broiler Main Plate, covering the slotted openings. Ensure the raised tab is closest to the front edge. Note illustration 8B. Both Flame Broiler parts are lightly coated with oil to avoid rusting when shipped.
  
• Next, remove the Flame Broiler Adjusting Bar Handle from the Flame Broiler Adjusting Bar. Insert the Flame Broiler Adjusting Bar through the opening hole on the left side of the Main Barrel. Add the Flame Broiler Adjusting Bar Handle back onto the end outside the barrel. Next, slide the notched end of the adjusting bar into the locking tab on the Flame Broiler Slider, giving you adjustable access to the Flame Broiler Slider on the main plate. Note steps in 8C.
  

NOTE: When the Flame Broiler Slider is open and direct flame is used, do not leave the grill unattended for any period of time.

INSTALLING THE COOKING COMPONENTS

Parts Required:
2 x Cooking Grids (#3)
1 x Upper Cooking Rack (#4)

Installation:

• Place the Cooking Grids, side-by-side, on the grid ledges inside the Main Barrel. Place the Upper Cooking Rack on the upper ledge inside the Main Barrel. The cooking rack will lock into place. Note illustration 9
  

NOTE: To maintain the searing and grilling performance of your Cooking Grids, regular care and maintenance is required.

PLACING THE GREASE BUCKET

Parts Required:
1 x Grease Bucket (#22)

Installation:

• Place the grease bucket on the spout hook on the end of the Main Barrel. Ensure it is level to avoid grease spills. Note illustration 10
  
• The unit is now completely assembled.

CONNECTING TO A POWER SOURCE

See illustration 11

• STANDARD OUTLET
  This appliance requires 110-120 volt, 60 Hz, 250 W. It must be a 3-prong grounded plug. Ensure grounded end is not broken off before use. The control uses a 110-120 volt, fast-blow fuse to protect the board from the ignitor.
• GFCI OUTLETS
  This appliance will work on most GFCI outlets, with a recommended size of 15 amp service. If your GFCI outlet is highly sensitive to power surges, it will likely trip during the start-up phase of operation. During the start-up phase, the ignitor draws 200-700 watts of electricity which can be too much power for a GFCI outlet to handle. Each time it trips, it increases in sensitivity. If the GFCI keeps tripping, replace the outlet or change to a non-GFCI outlet.
• ON THE ROAD
  Disconnect the ignitor from the main wiring harness. Use the manual start-up procedure. A Pit Boss unit can operate using a 12 volt, 100 watt inverter plugged into your automobile outlet. To use the automatic ignitor, it is recommended to use a minimum of a 1000 watt inverter.

Disconnect unit from power source when not in use.

OPERATING INSTRUCTIONS

With today's lifestyle of striving to eat healthy and nutritious foods, one factor to consider is the importance of reducing fat intake. One of the best ways to cut down on fat in your diet is to use a low fat method of cooking, such as grilling. As a pellet grill uses natural wood pellets, the savory wood flavor is cooked into the meats, reducing the need for high sugar content sauces. Throughout this manual, you will notice the emphasis on grilling food slowly at LOW or MEDIUM temperature settings.

COOKING ENVIRONMENT

1. WHERE TO SET-UP THE GRILL
   With all outdoor appliances, outside weather conditions play a big part in the performance of your grill and the cooking time needed to perfect your meals. All Pit Boss units should keep a minimum clearance of 305mm (12 inches) from combustible constructions and this clearance must be maintained while the grill is operational. This appliance must not be placed under an overhead combustible ceiling or overhang. Keep your grill in an area clear from combustible materials, gasoline and other flammable vapors and liquids.
2. COLD WEATHER COOKING
   As it becomes cooler outside, that does not mean that grilling season is over! The crisp cool air and heavenly aroma of smoked foods will help cure your winter blues.
   Follow these suggestions on how to enjoy your grill throughout the cooler months:
   • If smoking at low temperatures fails, increase the temperature slightly to achieve the same results.
   • Organize – Get everything you require ready in the kitchen before you head outdoors. During the winter, move your grill to an area that is out of the wind and direct cold. Check local bylaws regarding the proximity of your grill in relation to your home and/or other structures. Put everything you need on a tray, bundle up tight, and get it done!
   • To help keep track of the outside temperature, place an outdoor thermometer close to your cooking area. Keep a log or history of what you cooked, the outdoor temperature, and the cooking time. This will help later down the road to help you determine what to cook and how long it will take.
   • In very cold weather, increase your preheating time by at least 20 minutes.
   • Avoid lifting the lid any more than necessary. Cold gusts of wind can completely cool your grill temperature. Be flexible with your serving time; add extra cooking time each time you open the lid.
   • Have a heated platter or a dish cover ready to keep your food warm while making the trip back inside.
   • Ideal foods for winter cooking are those that require little attention, such as roasts, whole chickens, ribs, and turkey. Make your meal preparation even easier by adding simple items such as vegetables and potatoes.
3. HOT WEATHER COOKING
   As it becomes warmer outdoors, the cooking time will decrease. Proper dress is important when it gets really hot: shorts, shirt, shoes, hat, apron and a generous slab of suntan lotion is recommended.
   Follow these few suggestions on how to enjoy your grill throughout the hot months:
   • Adjust your cooking temperatures downward. This helps to avoid unwanted flare-ups.
   • Use a meat thermometer to determine the internal temperature of your foods. This helps in preventing your meat from over cooking and drying out.
   • Even in hot weather it is still better to cook with the lid of your grill down.
   • You can keep foods hot by wrapping them in foil, and placing them in an insulated cooler. Stuff crumpled up newspaper around the foil and this will keep food hot for 3 to 4 hours.

TEMPERATURE RANGES

Temperature readouts on the control board may not exactly match the thermometer. All temperatures listed below are approximate and are affected by the following factors: outside ambient temperature, the amount and direction of wind, the quality of pellet fuel being used, the lid being opened, and the quantity of food being cooked.

HIGH TEMPERATURES 205-260°C / 401-500°F	This range is best used to sear and grill at a high heat. Use in tandem with the flame broiler (slide plate) for indirect or direct flame cooking. With the Flame Broiler open, direct flame is used to create those "blue" steaks, as well as flame-kissed vegetables, garlic toast or s'mores! When the Flame Broiler is closed, the air circulates around the barrel, resulting in convection heat. High temperature is also used to preheat your grill, burn-off the cooking grates, and to achieve high heat in extreme cold weather conditions.
MEDIUM TEMPERATURES 126-204°C / 258-400°F	This range is best for baking, roasting, and finishing off that slow smoked creation. Cooking at these temperatures will greatly reduce the chances of a grease flare-up. Ensure that the flame broiler slider in the closed position, covering the slotted openings. Great range for cooking anything wrapped in bacon, or where you want versatility with control.
LOW TEMPERATURES 82-125°C / 180-257°F	This range is used to slow roast, increase smoky flavor, and to keep foods warm. Infuse more smoke flavor and keep your meats juicy by cooking longer at a lower temperature (also known as low and slow). Recommended for the big turkey at Thanksgiving, juicy ham at Easter, or the huge holiday feast.

Smoking is a variation on true barbecuing and is truly the main advantage of grilling on a hardwood pellet grill. Hot smoking, another name for low and slow cooking, is generally done between 82-125oC / 180-257oF. Hot smoking works best when longer cooking time is required, such as large cuts of meats, fish, or poultry.

TIP: To intensify that savory flavor, switch to a low temperature range immediately after putting your food on the grill. This allows the smoke to penetrate the meats.

The key is to experiment with the length of time you allow for smoking, before the meal is finished cooking. Some outdoor chefs prefer to smoke at the end of a cook, allowing the food to keep warm until ready to serve. Practice makes perfect!

UNDERSTANDING THE PROBES

• GRILL PROBE
  Located inside the main barrel, on the left side wall, is the Grill Probe. It is a small, vertical piece of stainless steel. The Grill Probe measures the internal temperature of the unit. When the temperature is adjusted on the Control Board, the Grill Probe will read the actual temperature inside the unit and adjust to the desired temperature.

The temperature of your unit is highly affected by ambient outdoor weather, quality of pellets used, flavor of pellets, and the quantity of food being cooked.

• MEAT PROBE
  The meat probe measures the internal temperature of your meat in the grill, similar to your indoor oven. Plug-in the meat probe adapter to the meat probe connection port on the Control Board and insert the stainless steel meat probe into the thickest portion of your meat and the temperature will be displayed on the control board. To ensure the meat probe is connected properly to the connection port, feel and hear it snap into place.
  NOTE: When placing the meat probe into your meat, ensure the meat probe and meat probe wires avoid direct contact with flame or excess heat. This can result in damage to your meat probe. Run the excess wire out the hole located on the left side of the main grill or the top of the main grill (near the grill lid hinge). When not in use, disconnect from the meat probe connection port and place aside to keep protected and clean.

UNDERSTANDING THE CONTROL BOARD

CONTROL	DESCRIPTION
	Press the Power Button to power on the unit. The button will glow blue if connected to a power source. Press the button again to turn the unit off.
	The Temperature Control Dial allows you to set your desired smoking temperature. Once connected to a power source and the Power Button is pressed, turn the dial and select from any of the ten preset temperatures, between 82-260°C / 180-500°F. When the dial is turned to a temperature preset, the Digital LCD Screen with light up, displaying that it is ready to operate. When the dial is turned to off, the Digital LCD Screen will remain off.
	The "P" Set Button is used to select one of the eight fine tunings when the Temperature Control Dial is set to the Smoke Setting. Press the button to change the "P" setting to accommodate to your cooking style and cooking environment, as preferred. With a short push of the button, the setting increases from P0 to P7, then repeats. Adjustments are only possible in the Smoke Setting. Factory default setting is "P4". If the "P" setting is adjusted, your preference will be locked-in (saved) until further adjustment is made. The "P" Set Button is also used as a Temperature Switch Control to change the temperature readout on the LCD Screen. Press and hold the button for two seconds to switch to Celsius (ºC) or to Fahrenheit (ºF), as preferred. Default is set to Fahrenheit.
	The LCD Screen is used as the information center for your unit. The LCD screen will display your Desired Cook Temperature, Actual Cook Temperature, and Meat Probe Temperatures (if connected). If only one Meat Probe is connected, only one reading will be displayed.
	Press and hold the Prime Button to activate an extra feed of pellets to the Burn Pot. This can be used to add more fuel to the fire before opening the barrel lid, resulting in a quick heat recovery time. It can also be used while smoking, to increase the intensity of clean smoke flavor. Requested from competition cookers.
	The Smoke Setting on the Temperature Control Dial is the start-up mode for the unit. The grill operates at the lowest temperature, without the fire going out.
	The plug-in connection port(s) on the front of the Control Board are for a Meat Probe(s). When a meat probe is connected, the temperature is displayed on the LCD Screen. When not in use, disconnect the meat probe from the connection port. Compatible with Pit Boss branded meat probes only. Additional meat probe(s) sold separately.

UNDERSTANDING THE P SETTING

When the recessed "P" SET button is pushed, the "P" setting displayed on the LCD screen will change to the next value (upward). Once P7 is reached, it will restart at P0. There are eight "P" settings, ranging from P0 to P7. The recessed "P" SET button can be pushed using a thin-tipped object.

Do not push the "P" SET button too hard, as this may cause damage. Only a light push is needed.

• USING THE "P" SETTING IN SMOKE MODE
  Anytime the grill is set to SMOKE, the auger will run on more of a manual mode of cooking versus using one of the preset dial temperatures. After the start-up cycle of the grill is completed, the auger begins to run a feed cycle based on the "P' setting selected on the Digital Control Board. The default setting is P4.

	AUGER CYCLE (seconds)
"P" SET	ON	OFF
P0	18	55
P1	18	70
P2	18	85
P3	18	100
*P4	18	115
P5	18	130
P6	18	140
P7	18	150

*factory default setting

AUGER PRIMING PROCEDURE

These instructions should be followed the first time the grill is ignited, and each time the grill runs out of pellets in the hopper. The auger must be primed to allow pellets to travel through the length of the auger, and fill the Burn Pot. If not primed, the igniter will timeout before the pellets are ignited, and no fire will start. Follow these steps to prime the hopper:

1. Open the hopper lid. Make sure there are no foreign objects in the hopper or blocking the auger feed system at the bottom.
2. Remove all cooking components from the interior of the grill. Locate the Burn Pot in the bottom of the main barrel.
3. Plug the power cord into a power source. Press the Power Button to turn the unit on, and turn the Temperature Control Dial to the SMOKE position. Check the following items:
   • That you can hear the auger turning. Place your hand above the Burn Pot and feel for air movement. Do not place your hand or fingers inside the Burn Pot. This can cause injury.
   • After approximately a minute, you should smell the igniter burning and begin to feel the air getting warmer in the Burn Pot. The igniter tip does not glow red, but gets extremely hot and will burn. Do not touch the igniter.
4. Once verified that all electric components are working correctly, press the Power Button to turn the unit off.
5. Fill the hopper with all natural barbecue wood pellets.
6. Press the Power Button to turn the unit on. Keep the Temperature Control Dial in the SMOKE position. Press and hold the Prime Button until you see pellets on the inside of the grill from the auger tube. Once pellets begin to drop into the Burn Pot, release the Prime Button.
7. Press the Power Button to turn the unit off.
8. Re-install the cooking components into the main barrel. The grill is now ready to use.

FIRST USE AND BURN-OFF

Once your hopper has been primed and before cooking on your grill for the first time, it is important to complete a grill burn-off. Start the grill and operate at any temperature over 176°C / 350°F (with the lid down) for 30 to 40 minutes to burn-off the grill and rid it of any foreign matter.

AUTOMATIC START-UP PROCEDURE

1. Plug the power cord into a grounded power source. Open the main barrel lid. Check the Burn Pot to ensure there is no obstruction for proper ignition. Open the hopper lid. Ensure there are no foreign objects in the hopper or auger feed system. Fill the hopper with dry, all natural barbecue hardwood pellets.
2. Ensure the Temperature Control Dial is in the SMOKE position. Press the Power Button to turn the unit on. This will activate the start-up cycle. The auger feed system will begin to turn, the igniter will begin to glow and the fan will supply air to the Burn Pot. The grill will begin to produce smoke while the start-up cycle is taking place. The barrel lid must remain open during the start-up cycle. To confirm the start-up cycle has begun properly, listen for a torchy roar, and notice some heat being produced.
3. Once the heavy, white smoke has dissipated, the start-up cycle is complete and you are ready to enjoy your grill at your desired temperature!

IGNITER FAILURE PROCEDURE
If for any reason your electric igniter fails or your grill's flame dies out during a cook, check the following steps, or start your grill using the manual method.

1. Press the Power Button to turn the unit off, and ensure the Temperature Control Dial is in the OFF position. Open the barrel lid. Remove the cooking components from inside. Remove all unburnt pellets and ash from the Burn Pot. Avoid touching the igniter to avoid injury, as it may be extremely hot.
2. Once all cooking components are removed and cleaned, turn the Temperature Control Dial to the SMOKE position and press the Power Button to turn the unit on. Check the following:
   • Visually confirm that the igniter is working by placing your hand above the Burn Pot and feeling for heat.
   • Visually confirm that the igniter is protruding approximately 13mm / 0.5 inches in the Burn Pot.
   • Visually confirm that the auger is dropping pellets into the Burn Pot.
   • Confirm that the combustion fan is working by listening for a torchy roar.
3. If any of the above points are not working, follow Troubleshooting instructions

MANUAL START-UP PROCEDURE

1. Ensure the Temperature Control Dial is in the OFF position. Plug the power cord into a grounded power source.
2. Check Burn Pot to ensure there is no obstruction for proper ignition. Open the hopper lid. Ensure there are no foreign objects in the hopper or auger feed system. Fill hopper with dry, all natural hardwood barbecue pellets.
3. Open the barrel lid. Remove the cooking components to expose the Burn Pot. Place a generous handful of pellets into the Burn Pot. Squirt a gelled fire starter, or other appropriate pellet starter, over the top of the pellets. A small amount of solid fuel fire starter, such as one composed of sawdust and wax, or wood shavings, is also appropriate. Add another small amount of pellets in the Burn Pot.
   NOTE: Do not use spirit, petrol, gasoline, lighter-fluid or kerosene for lighting or refreshing a fire in your grill.
4. Light the contents of the Burn Pot using a long match or long-nosed lighter. Allow the starter to burn for 3 to 5 minutes. Do not attempt to add more starter into the Burn Pot. This can cause injury.
5. Quickly and carefully replace the cooking components to the inside of the main barrel. Continue start-up at step two of Automatic Start-Up Procedure.

SHUTTING OFF

When finished cooking, with the main barrel lid remaining closed, press the Power Button to turn the unit off and turn the Temperature Control Dial to OFF. The grill will begin its automatic shut-down cycle. The auger system will stop feeding fuel, the flame will burn out, and the fan will continue to run until the shut-down cycle is complete.

Once the shut-down cycle is complete, unplug the power cord.

CARE AND 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 for 5 to 10 minutes after each use. Follow these cleaning and maintenance tips to service your grill:

1. HOPPER ASSEMBLY
   • The hopper includes a clean-out feature to allow for ease of cleaning and change out of pellet fuel flavors. To empty, locate the plate and the cover of the drop chute on the back side of the hopper. Place a clean, empty pail under the drop chute cover, then remove the cover piece. Unscrew the plate, slide outwards, and pellets will empty.
     NOTE: Use a long handled brush or Wet/dry vacuum to remove excess pellets, sawdust, and debris for a complete clean-out through the hopper screen.
     
   • Check and clean off any debris from the fan air intake vent, found on the bottom of the hopper. Once the hopper access panel is removed (see Electric Wire Diagram for diagram), carefully wipe off any grease build-up directly on the fan blades. This ensures airflow is sufficient to the feed system.
2. INSIDE SURFACES
   • It is recommended to clean your Burn Pot after every few uses. This will ensure proper ignition and avoid any hard build-up of debris or ash in the Burn Pot.
   • Use a long-handled grill cleaning brush (brass or soft metal), 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.
   • Check your grease bucket often, and clean out as necessary. Keep in mind the type of cooking you do.

Due to high heat, do not cover the Flame Broiler or probes with aluminum foil.

3. OUTSIDE SURFACES
   • 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 grill surfaces. All painted surfaces are not covered under warranty, but rather are part of general maintenance and upkeep. For paint scratches, wearing, or flaking of the finish, all painted surfaces can be touched up using high heat BBQ paint.
   • 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)
ITEM	CLEANING FREQUENCY	CLEANING METHOD
Bottom of Main Grill	Every 5-6 Grill Sessions	Scoop Out, Wet/dry vacuum Excess Debris
Burn Pot	Every 2-3 Grill Sessions	Scoop Out, Wet/dry vacuum Excess Debris
Cooking Grids	After Each Grill Session	Burn Off Excess, Brass Wire Brush
Flame Broiler	Every 5-6 Grill Sessions	Scrape Main Plate with Slider, Do Not Wash Clean
Shelf	After Each Grill Session	Scrub Pad & Soapy Water
Grease Bucket	After Each Grill Session	Scrub Pad & Soapy Water
Auger Feed System	When Pellet Bag is Empty	Allow Auger to Push Out Sawdust, Leaving Hopper Empty
Hopper Electric Components	Once A Year	Dust Out Interior, Wipe Fan Blades with Soapy Water
Air Intake Vent	Every 5-6 Grill Sessions	Dust, Scrub Pad & Soapy Water
Grill Probe	Every 2-3 Grill Sessions	Scrub Pad & Soapy Water

COOKING GUIDELINES

Smoking and grilling styles of cooking can give you different results based on time and temperature. For best results, keep a record of what you cooked, at what temperature, how long you cooked for, and the results. Adjust to your taste for the next time. Practice makes perfect.
The culinary art of hot smoking refers to longer cooking times, but results in more natural wood flavor (and a sought-after smoke ring) on your meats. Higher cooking temperatures result in a shorter cooking time, locking in less smoke flavor.
TIP: For best results, allow time for meats to rest after cooking. This allows the natural juices to migrate back into the meat fiber, giving a much juicer, flavorful cut. Resting times can be as little as 3 minutes and up to 60 minutes, depending on the size of the protein.

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.

Always disconnect the electrical cord prior to opening the grill for any inspection, cleaning, maintenance or service work. Ensure the grill is completely cooled to avoid injury.

PROBLEM	CAUSE	SOLUTION
No Power Lights On The Control Board	Temperature Control Dial is still off.	Press the Power Button, and ensure the button glows blue to show there is a power connection. Turn the Temperature Control Dial to a temperature setting.
	Not Connected To Power Source	Ensure unit is plugged into a working power source. Reset breaker. Ensure GFCI is a minimum 10 Amp service (see Electric Wire Diagram for access to electric components) Ensure all wire connections are firmly connected and dry.
	Fuse Blown On The Control Board	Remove hopper access panel (see Electric Wire Diagram for diagram), press in plastic tabs holding the control board in place and carefully pull controller inside the hopper to release controller. Check the fuse for a broken wire or if the wire has turned black. If yes, fuse needs to be manually replaced.
	The GFCI outlet has been tripped.	Remove hopper access panel (see Electric Wire Diagram for diagram), and ensure all wire connections are firmly connected and dry. Ensure GFCI is a minimum 10 Amp service.
	Faulty Control Board	Control Board needs to be replaced. Contact Customer Care for a replacement part.
Fire in Burn Pot Will Not Light	Auger Not Primed	Before the unit is used for the first time or anytime the hopper is completely emptied out, the auger must be primed to allow pellets to fill the auger tube. If not primed, the igniter will timeout before the pellets reach the Burn Pot. Follow Auger Priming Procedure .
	Auger Motor Is Jammed	Remove cooking components from the main barrel. Press the Power Button to turn the unit on, turn Temperature Control Dial to SMOKE, and inspect the auger feed system. Visually confirm that the auger is dropping pellets into the Burn Pot. If not operating properly, call Customer Care for assistance or a replacement part.
	Igniter Failure	Remove cooking components from the main barrel. Press the Power Button to turn the unit on, turn Temperature Control Dial to SMOKE, and inspect the igniter. Visually confirm that the igniter is working by placing your hand above the Burn Pot and feeling for heat. Visually confirm that the igniter is protruding approximately 13mm / 0.5 inches in the Burn Pot. If not operating properly, follow Manual Start-up Procedure to continue use of grill; however, call Customer Care for assistance or a replacement part.
Flashing Dots On LCD Screen	The Igniter Is On	This is not an error that effects the grill. Used to show that the unit has power and is in Start-Up mode (igniter is on). The igniter will turn off after five minutes. Once the flashing dots disappear, the grill will begin to adjust to the desired temperature selected.
Flashing Temperature On LCD Screen	Grill Temperature Is Below 65°C /150°F	This is not an error that effects the unit; however, it is used to show that there is some risk that the fire could go out. Check hopper for sufficient fuel or if there is an obstruction in the feed system. Remove pellets and follow Care and Maintenance instructions. Check grill Grill Probe and follow Care and Maintenance instructions if dirty. Check Burn Pot for ash build-up or obstructions, and follow Care and Maintenance instructions for ash build-up. Check fan. Ensure it is working properly and air intake is not blocked. Follow Care and Maintenance instructions if dirty. Check auger motor to confirm operation (rotation), and ensure there is no blockage in the auger tube.
ErH Error Code	The Unit Has Overheated, Possibly Due To Grease Fire Or Excess Fuel.	Press the Power Button to turn the unit off, and allow grill to cool. Follow Care and Maintenance instructions. After maintenance, remove pellets, and confirm positioning of all component parts. Once cooled, press the Power Button to turn the unit on, then select desired temperature. If error code still displayed, contact Customer Care.
Err Error Code	Grill Probe wire not making connection.	Remove hopper access panel (see Electric Wire Diagram for diagram), and check for any damage to the Grill Probe wires. Ensure Grill Probe molex connectors are firmly connected, and connected correctly, to the Control Board.
noP Error Code	Bad Connection At Connection Port	Disconnect meat probe from connection port on the Control Board, and reconnect. Ensure the meat probe adapter is firmly connected. Check for signs of damage to the adapter end. If still failed, call Customer Care for replacement part.
	Meat Probe Damaged	Check for signs of damage to the wires of the meat probe. If damaged, call Customer Care for replacement part.
	Faulty Control Board	Control Board needs to be replaced. Contact Customer Care for a replacement part.
Temperature on SMOKE is too high	"P" Setting is too LOW	Push the "P" SET button, and increase the "P" setting.
Appliance Will Not Achieve Or Maintain Stable Temperature	Insufficient Air Flow Through Burn Pot	Check Burn Pot for ash build-up or obstructions. Follow Care and Maintenance instructions for ash build-up. Check fan. Ensure it is working properly and air intake is not blocked. Follow Care and Maintenance instructions if dirty. Check auger motor to confirm operation, and ensure there is no blockage in the auger tube. Once all the above steps have been done, start the grill, set temperature to SMOKE and wait for 10 minutes. Check that the flame produced is bright and vibrant.
	Lack Of Fuel, Poor Fuel Quality, Obstruction In Feed System	Check hopper to check that fuel level is sufficient, and replenish if low. Should the quality of wood pellets be poor, or the length of the pellets too long, this may cause an obstruction in the feed system. Remove pellets and follow Care and Maintenance instructions.
	Grill Probe	Check status of Grill Probe. Follow Care and Maintenance instructions if dirty. Contact Customer Care for a replacement part if damaged.
Grill Produces Excess Or Discolored Smoke	Grease Build-Up	Follow Care and Maintenance instructions.
	Wood Pellet Quality	Remove moist wood pellets from hopper. Follow Care and Maintenance instructions to clean out. Replace with dry wood pellets.
	Burn Pot Is Blocked	Clear Burn Pot for moist wood pellets. Follow Auger priming Procedure.
	Insufficient Air Intake For Fan	Check fan. Ensure it is working properly and air intake is not blocked. Follow Care and Maintenance instructions if dirty.
Frequent Flare-Ups	Cooking Temperature	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.

ELECTRICAL WIRE DIAGRAM

The Digital Control Board system is an intricate and valuable piece of technology. For protection from power surges and electrical shorts, consult the wire diagram below to ensure your power source is sufficient for the operation of the unit.

PB – ELECTRIC REQUIREMENTS
110-120 V, 60 Hz, 250 W, 3-PRONG GROUNDED PLUG
NOTE: Electrical components, passed by product safety testing and certification services, comply with a testing tolerance of ± 5-10 percent.

LOCATE AND REMOVE THE FOUR SCREWS OF ACCESS PANEL ON UNDERSIDE OF UNIT

FUEL INPUT RATING:
1.73 LB/H (0.78 KG/H)

INDEX
W: WHITE
Y: YELLOW
P: PURPLE
R: RED
K: BLACK
G: GREEN
S: SILVER

SAFETY INFORMATION

MAJOR CAUSES OF APPLIANCE FIRES ARE A RESULT OF POOR MAINTENANCE AND A FAILURE TO MAINTAIN REQUIRED CLEARANCE TO COMBUSTIBLE MATERIALS. IT IS OF UTMOST IMPORTANCE THAT THIS PRODUCT BE USED ONLY IN ACCORDANCE WITH THE FOLLOWING INSTRUCTIONS.

Please read and understand this entire manual before attempting to assemble, operate, or install the product. This will ensure you receive the most enjoyable and trouble-free operation of your new hardwood pellet grill. We also advise you retain this manual for future reference.

DANGERS AND WARNINGS

You must contact your local home association, building or fire officials, or authority having jurisdiction, to obtain the necessary permits, mission or information on any installation restrictions, such as any grill being installed on a combustible surface, inspection requirements or even ability to use, in your area.

1. A minimum clearance of 305mm (12 inches) from combustible constructions to the sides of the grill, and 305mm (12 inches) from the back of the grill to combustible constructions must be maintained. Do not install appliance on combustible floors, or floors protected with combustible surfaces unless proper permits and permissions are obtained by authorities having jurisdiction. Do not use this appliance indoors or in an enclosed, unventilated area. This wood pellet appliance must not be placed under overhead combustible ceiling or overhang. Keep your grill in an area clear and free from combustible materials, gasoline and other flammable vapors and liquids.

Should a grease fire occur, turn the grill OFF and leave the lid closed until the fire is out. Unplug the power cord from the connected outlet. Do not throw water on the unit. Do not try to smother the fire. Use of an all-class (class ABC) approved fire extinguisher is valuable to keep on site. If an uncontrolled fire does occur, call the Fire Department.

2. Keep electrical supply cords and the fuel away from heated surfaces. Do not use your grill in the rain or around any water source.
3. After a period of storage, or non-use, check the burn pot for obstructions, the hopper for foreign objects, and any air blockage around the fan intake, chimney, or rear barrel exhaust holes. Clean before use. Regular care and maintenance is required to prolong the lifespan of your unit. If the grill is stored outside during the rainy season or seasons of high humidity, care should be taken to ensure that water does not get into the hopper. When wet or exposed to high humidity, wood pellets will expand greatly, decompose, and may jam the feed system. Always disconnect the power, before performing any service or maintenance.

Always power off the appliance and allow the shut-down cycle to run. Unplug the appliance only once the shut-down cycle is complete, and/or before cleaning. Failure to follow this warning can cause damage, serious injury, fire, electric shock, or death.

Do not transport your grill while in use or while the grill is hot. Ensure the fire is completely out and that the grill is completely cool to the touch before moving.

4. It is recommended to use heat-resistant barbecue mitts or gloves when operating the grill. Do not use accessories not specified for use with this appliance. Do not put a barbecue cover or anything flammable in the storage space area under the barbecue.

Be aware of building combustible material, maintain the fire to avoid over-firing.

5. To prevent fingers, clothing or other objects from coming in contact with the auger feed system, the appliance is equipped with a metal safety screen, mounted to the interior of the hopper. This screen must not be removed unless directed by Customer Care or an authorized dealer.

This appliance is not recommended for children, persons with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they are under direct supervision or instruction by a person responsible for their safety.

6. Parts of the barbecue may be very hot, and serious injury may occur. Remove pots and pans while the operating appliance is unattended, to reduce the risk of fire. Keep young children and pets away while in use.
7. 
   Do not enlarge igniter holes or Burn Pots. Failure to follow this warning could lead to a fire hazard and bodily harm and will void your warranty.
8. Product may have sharp edges or points. Contact may result in injury. Handle with care.

DISPOSAL OF ASHES

Ashes should be placed in a metal container with a tight-fitting lid. The closed container of ashes should be placed on a noncombustible floor or on the ground, well away from all combustible materials, pending final disposal. When ashes are disposed by burial in soil, or otherwise locally dispersed, they should be retained in a closed container until all cinders have thoroughly cooled.

WOOD PELLET FUEL

This pellet cooking appliance is designed and approved for pelletized, all natural hardwood fuel only. Any other type of fuel burned in this appliance will void the warranty and safety listing. You must only use all natural hardwood pellets, designed for burning in pellet barbecue grills. Do not use fuel with additives. Hardwood pellets are highly susceptible to moisture and should always be stored in an airtight container. If you are storing your grill, without use, for an extended period, we recommend clearing all pellets from your grill's hopper and auger, to prevent jams. The pellet fuel mean heating value in 18569-20362 KJ/KG (8000 - 8770 BTU/LB), ash content < 1%.

Do not use spirit, petrol, gasoline, lighter-fluid or kerosene for lighting or refreshing a fire in your grill. Keep all such liquids well away from the appliance when in use.

At time of printing, there is no industry standard for barbecue wood pellets, although most pellet mills use the same standards to make wood pellets for domestic use. Further information can be found at www.pelletheat.org or the Pellet Fuel Institute.
Contact your local dealer on the quality of pellets in your area and for information on brand quality. As there is no control over the quality of pellets used, we assume no responsibility to damage caused by poor quality of fuel.

CREOSOTE

Creosote - formation and need for removal. When burning, it produces black smoke with a residue that is also black in color. When wood pellets are burned slowly, they produce tar and other organic vapors that combine with expelled moisture to form creosote. The creosote vapors condense in a relatively cool oven flue and exhaust hood of a slow-burning fire. As a result, creosote residue accumulates on the flue lining and exhaust hood. When ignited, this creosote makes an extremely hot fire.
The grease duct should be inspected at least twice a year to determine when the grease and/or creosote buildup has occurred.
When grease or creosote has accumulated, it should be removed to reduce the risk of fire.

CARBON MONOXIDE

"The silent killer"
Carbon monoxide is a colorless, odorless, tasteless gas produced by burning gas, wood, propane, charcoal or other fuel. Carbon monoxide reduces the blood's ability to carry oxygen. Low blood oxygen levels can result in headaches, dizziness, weakness, nausea, vomiting, sleepiness, confusion, loss of consciousness or death. Follow these guidelines to prevent this colorless, odorless gas from poisoning you, your family, or others:

• See a doctor if you or others develop cold or flu-like symptoms while cooking or in the vicinity of the appliance. Carbon monoxide poisoning, which can easily be mistaken for a cold or flu, is often detected too late.
• Alcohol consumption and drug use increase the effects of carbon monoxide poisoning.

Carbon monoxide is especially toxic to mother and child during pregnancy, infants, the elderly, smokers, and people with blood or circulatory system problems, such as anemia, or heart disease.

Dansons
8877 North Gainey Center Drive, Scottsdale, AZ, USA 85258

Customer Care
USA: (480) 923-9630
Canada (Toll-Free): 1-877-942-2246
www.pitboss-grills.com

WARRANTY

ORDERING REPLACEMENT PARTS
To order replacement parts, please contact your local Pit Boss dealer or visit our online store at: www.pitboss-grills.com

CONTACT CUSTOMER CARE
If you have any questions or problems, contact Customer Care.
USA: (480) 923-9630 | Canada (Toll Free): 1-877-942-2246

Documents / Resources

References

• Pit Boss Grills | Wood Pellet Grills | Flat Top Griddles | BBQ Smokers
• Pellet Fuels Institute

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Here you can download full pdf version of manual, it may contain additional safety instructions, warranty information, FCC rules, etc.

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