Kenmore 16657 - 3 Burner Grill User manual

Use and Care Guide
®
LiquidPropaneGasGrill withinfraredCooking System
Sears ModelNo. 4t5.t6657900
This Grill isfor Outdoor Use Only
•Read and follow all Safety, Assembly,
and Use and Care instructions in this
Guide before assemblingand cooking
with this grill.
•Failure to follow all instructions in this
Use and Care Guide may lead to fire or
explosion, which could result in property
damage, personal injuryor death.
• Safety
• Parts
• Use and Care
• Assembly
Assembly Questions?
Call t-800-241-7548
Tools needed for assembly:
Adjustable wrench (not provided)
Screwdriver (not provided)
7/16" Combinationwrench (not provided)
SAVETHESEINSTRUCTIONS!
Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A.
©2008Sears,RoebuckandCo., AllRightsReserved Printedin China Model464261709 80019155,02-23-09

ifyou smell gas:
1. Shut off gas to the appliance.
2. Extinguish any open flame.
3. Open lid.
4. if odor continues, keep away from the appliance
and immediately call your gas supplier or your
fire department.
1. Do not store or use gasoline or other
flammable liquids or vapors in the vicinity of
this or any other appliance.
2. An LP Tank not connected for use shall not
be stored in the vicinity of this or any other
appliance.
Call Grill Service Center For Help And Parts
If you havequestions or need assistance during assembly,
please call 1-800-241-7548. You wilt be speaking to a
representative ofthe grill manufacturerand not a Sears
employee. Toorder new parts call Sears at 1-800-4-MY-HOME®.
Product Record
IMPORTANT:Fillouttheproductrecordinformationbelow.
Model Number
Serial Number
Date Purchased
Seeratinglabelongrillforserialnumber.
To InstalledAssembler: Leave these instructionswith
consumer.
To Consumer: Keep this manual for future reference.
CAUT,o. /K
CALIFORNIA PROPOSiTiON 65
1. Combustion by-products produced when using
this product contain chemicals known to the State of
California to cause cancer, birth defects, and other
reproductive harm.
2. This product contains chemicals, including lead
and lead compounds, known to the State of
California to cause cancer, birth defects or other
reproductive harm.
Wash your hands after handling this product.
installation Safety Precautions
•Use grill, as purchased, only with LP (propane) gas and the
regulator/valve assembly supplied.
• Grill installation must conform with local codes, or in the
absence of local codes, with either the National Fuel Gas
Code,ANSI Z223.1/NFPA 54, Natural Gas and Propane
Installation Code, CSAB149.1, or Propane Storage and
Handling Code, B149.2, or the Standardfor Recreational
Vehicles,ANSI A 119.2/NFPA1192,and CSAZ240 RV Series,
Recreational VehicleCode, as applicable.
• All electrical accessories (such as rotisserie) must be
electrically grounded in accordance with local codes, or
National Electrical Code,ANSI / NFPA 70or Canadian
Electrical Code, CSA C22.1. Keep any electrical cords and/or
fuel supply hoses away from any hot surfaces.
• Grill is not for use in or on recreational vehicles and/or boats.
• This grill issafety certified for use inthe United States and/or
Canada only. Donot modify for use in any other location.
Modification wilt result in a safety hazard.
Safety Symbols
The symbols and boxes shown below explain what each heading
means. Read and follow all of the messages found throughout
the manual.
DANGER: Indicates an imminently hazardous situation
which, if notavoided, will result in death or serious injury,
,Some parts may contain sharp edges,
especially as noted in these instructions.
Wear protective gloves if necessary.
CAUTION
For residential use only. Do not use for commercial
cooking.
2,464261709
WARNING: Be alert to the possibility of serious bodily injury
if the instructions are not followed. Be sureto read and
carefully follow all of the messages.
CAUTION
CAUTION: Indicates a potentially hazardous situation which,
if notavoided, may result in minoror moderate injury,

ForYourSafety...................................... 2
GrillServiceCenter................................... 2
ProductRecordInformation............................ 2
SafetySymbols...................................... 2
InstallationSafetyPrecautions.......................... 2
KenmoreEliteGrillWarranty........................... 3
UseandCare.................................... 4-10
PartsList.......................................... 11
PartsDiagram...................................... 12
Assembly....................................... 13-23
Troubleshooting.................................. 24-26
RepairProtection Agreements
Congratulations on making a smart purchase. Your new
Kenmore® product is designed and manufactured for years of
dependable operation. But like all products, it may require repair
from time to time. That's when having a Repair Protection
Agreement cansave you money and aggravation.
Here's what the Repair Protection Agreement* includes:
[] Expert service by our 10,000professional repair specialists
[] Unlimited service and no charge for parts and labor on all
covered repairs
[] Product replacement up to $1500 if your covered product
can't be fixed
[] Discount of 10% from regular price of service and related
installed parts notcovered by the agreement; also, 10% off
regular price of preventive maintenance check
[] Fast help by phone - we call it Rapid Resolution -
phone support from a Sears representative.Think of us
as a "talkingowner's manual."
Once you purchase the Repair ProtectionAgreement, a
simple phone call is all that it takes for you to schedule service.
You can call anytime day or night, or schedule a service
appointment online.
The Repair ProtectionAgreement is a risk-free purchase. If
you cancel for any reason during the product warranty period,
wewilt provide a full refund. Or, a prorated refundanytime after
the product warranty period expires. Purchase your Repair
ProtectionAgreement today!
Some limitations and exclusions apply. For prices and
additional information in the U.S.A. call 1-800-827-6655.
*Coverage in Canada varies on some items. For full details
call Sears Canada at 1-800-361-6665.
Sears Installation Service
For Sears professional installation of home appliances, garage
door openers, water heaters, and other major home items, in the
U.S.A. or Canada call 1-800-4-MY-HOME®.
KENMORE GRILL WARRANTY
One Year Full Warranty on Kenmore Grill
If this grill fails due to a defect in material or workmanship
within one year from the date of purchase, call 1-800-4-MY-
HOME% arrange for free repair (or replacement if repair
proves impossible).
Ten-Year Limited Warranty on Burners
Forten years from the date of purchase, any burner that
ruststhrough wilt be replaced free of charge.After the first
yearfrom the date of purchase,you payfor labor ifyou wish
to have it installed.
All warranty coverage excludes ignitor batteries and grill part
paint loss, discoloration or surface rusting,which are either
expendable parts that can wear out from normal usewithin
thewarranty period, or are conditions that can be the result
of normal use, accident or improper maintenance.
All warranty coverage is void if this grill is ever used for
commercial or rental purposes.
All warranty coverage applies only if this grill is used in the
United States.
This warranty gives you specific legal rights, and you may
also have other rights which vary from state to state.
Sears, Roebuck and Co., Hoffman Estates, IL 60179
CONVERSION-READY
Easily converts from (LP) liquid
propane to (NG) natural gas
Contact I-8OO4-MY-HOME or
_parts to purchase
a natura_ gas conversion kff,
Request Part number 41&4584609
Dual FuerrMand SureFireTM are registered trademarks of
the W. C. Bradley Company and used, with permission,
by Sears Holding Corporation.All rights reserved.
464261709• 3

•NEVERstore a spare LP cylinder under or near the
appliance or in an enclosed area.
• Never fill a cylinder beyond 80% full.
• If the information in two points above is not
followed exactly, afire causing death or serious
injury may occur.
• An over filled or improperlystored cylinder isa
hazard due to possible gas release from the safety
relief valve. This could cause an intense fire with
risk of property damage, serious injury or death.
• If you see, smell or hear gas escaping, immediately
get away from the LP cylindedappliance and call
your fire department.
LP Tank Removal, Transport And Storage
• Turn OFF all control knobs and LP tank valve. Turn coupling
nut counterclockwise by hand only - do not use tools to
disconnect. Lift LP tank wire upward off of LP tank collar, then
lift LP tank up and off of support bracket. Installsafety cap onto
LP tank valve.Always use cap and strap supplied with valve.
Failure to use safety cap as directed may result in serious
personal injury and/or property damage.
LP Tank Valve,
SafetyCap
RetainerStrap
• A disconnected LP tank in storage or being transported must
have a safety cap installed (as shown). Do notstore an LPtank
in enclosed spaces such as a carport, garage, porch, covered
patio or other building. Never leavean LP tank inside a vehicle
which may become overheated bythe sun.
• Do not store an LPtank in an area where children play.
4,464261709
LP Tank
•The LP Tank used with your grill must meet the following
requirements:
•Use LP Tanksonly with these required measurements: 12"
(30.5cm) (diameter) x 18" (45.7 cm) (tall) with 20 lb. (9 kg.)
capacity maximum.
• LPTanks must be constructed and marked in accordancewith
specifications for LP Tanksof the U.S. Department of
Transportation (DOT) or for Canada, CAN/CSA-B339, tanks,
spheres and tubes for transportation of dangerous goods.
Transport Canada (TC). See LP Tank collarfor marking.
•LP Tank valve must have:
• Type 1 outlet compatiblewith
regulatoror grill.
• Safety reliefvalve.
• ULlisted Overfill Protection
Device (OPD). This OPD safety OPDHandWheel
feature is identified by a unique triangular hand wheel. Use
only LP Tanks equipped with this type of valve.
• LPTank must bearranged for vapor withdrawal and include
collar to protect LPTank valve.Always keep LP Tanks in
upright position during use, transit or storage.
LP Tank in upright position for vapor withdrawal
LP (Liquefied Petroleum Gas)
•LPgas is nontoxic, odorless and colorless when produced. For
Your Safety, LPgas has been given an odor (similar to rotten
cabbage) so that it can be smelled.
•LPgas is highly flammable and may ignite unexpectedly when
mixedwith air.
LP Tank Filling
•Use only licensed and experienced dealers.
•LPdealer must purge new tank before filling.
• Dealershould NEVER fill LP Tank more than 80% of LPTank
volume. Volume of propane in tank will vary by temperature.
• A frosty regulator indicates gas overfill. Immediately close LP
Tankvalve and call local LP gas dealer for assistance.
• Do not releaseliquid propane (LP) gas into the atmosphere.
This is a hazardous practice.
• Toremove gas from LPTank, contact an LP dealer or call a
local fire department for assistance. Check the telephone
directory under "Gas Companies" for nearest certified LP
dealers.

LP Tank Exchange
• Many retailers that sell grills offer you the option of replacing
your empty LP tank through an exchange service. Use only
those reputable exchange companiesthat inspect, precision fill,
test and certify their tanks. Exchange your tank only for an
OPB safety feature-equipped tank as described in the "LP
Tank" section of this manual.
• Always keep new and exchanged LP tanks in upright position
during use, transit or storage.
• Leak test new and exchanged LP tanks BEFORE
connecting to grill.
Connecting Regulator To The LP Tank
1. LP tank must be properly secured onto grill. (Refer to
assembly section.)
2. Turnall control knobs to the OFF position.
3. Turn LP tank OFF by turning OPD hand wheel clockwise to a
full stop.
4. Remove the protective capfrom LP tank valve.Always use
cap and strap supplied with valve.
LP Tank Leak Test
For your safety
•Leak test mustbe repeated each time LP tank isexchanged or
refilled.
* Do not smoke during leak test.
•Do not use an open flame to check for gas leaks.
•Grill must be leak tested outdoors in a well-ventilated area,
away from ignition sources such as gas fired or electrical
appliances. Duringleak test, keep grill away from open flames
or sparks.
• Use a clean paintbrush and a 50/50 mild soap and water
solution. Brush soapy solution onto areas indicated byarrows
in figure below. Leaks are indicated bygrowing bubbles.
If "growing" bubbles appear do not use or move the LP tank.
Contact an LP gas supplier or your fire department!
ADo not use household cleaning agents. Damage to gas
train components can result.
OPDHandWheel
j Type 1outlet with
threadon outside
Safety Relief Valve
/
Strapand Cap
Do not use a POL transport plug
(plastic part with external threads)!
It will defeat the safety feature of
the valve.
5. Hold regulator and insert nipple into LP
tank valve. Hand-tightenthe coupling
nut, holding regulator in a straight line
with LP tank valve so as not to cross-
thread the connection.
Nipplehasto be centered
intothe LPtankvalve.
464261709•5

Holdcoupling nut and regulator
asshown for properconnection
to LP tank valve.
Leak Testing Valves, Hose and Regulator
1. Turn all grill control knobs to OFF.
2. Be sure regulator istightly connected to LP tank.
3. Completely open LP tank valve by turning OPD hand wheel
counterclockwise. If you hear a rushing sound, turn gas off
immediately.There is a major leak at the connection. Correct
before proceeding by calling Sears for replacement parts at
1-800-4-MY-HOME®.
4. Brush soapy solution onto areas where bubbles are shown in
picture below:
6. Turnthe coupling nut clockwiseand tighten to a full stop. The
regulatorwill seal on the back-checkfeature in the LPtank
valve, resulting in some resistance.An additional one-half to
three-quarters turn is required to complete the
connection. Tighten by hand only - do not use tools.
NOTE:
If you cannot complete the connection, disconnect regulatorand
repeat steps 5 and 6. If you are still unable to completethe
connection, do not use this regulator!
A Neverremovethreaded
orificeatend of valve.
_z
• Do not insert any tool or foreign objects into the valve outlet
or safety reliefvalve. You may damage the valve and cause
a leak. Leaking propane may result in explosion, fire, severe
personal injury,or death..
• If a leak isdetected at any time, STOPand call the fire
department.
• If you cannotstop a gas leak, immediately close LP tank
valve and call LP gas supplier or your fire department!
5. If "growing" bubblesappear, there is a leak. Close LP tank
valve immediately and retighten connections. If leaks cannot
be stopped do not try to repair. Call Searsfor replacement
parts at 1-800-4-MY-HOME®.
6. Always close LP tank valve after performing leak test by
turning hand wheel clockwise.
• Never attemptto attach this grill to the self-contained LP gas
system of a camper trailer or motor home.
• Do notuse grill until leak-tested.
6,464261709

For Safe Use of Your Grill and to Avoid Serious
Injury:
•Do not letchildrenoperate or play near grill.
• Keepgrill area clear and freefrom materials that burn.
• Do not blockholes in sidesor back of grill.
• Check burnerflames regularly.
• Use grill only inwell-ventilated space. NEVERuse in
enclosedspace suchas carport, garage, porch,
covered patio,or under anoverhead structure of any
kind.
Do not use charcoal orceramic briquetsin a gasgrill.
(Unlessbriquets aresupplied with your grill.)
Usegrill at least 3ft. from any wall or surface.
Maintain 10ft. clearanceto objects that cancatchfire
or sourcesof ignition such as pilot lightsonwater
heaters,live electrical appliances,etc.
• Apartment Dwellers:
Checkwith managementto learnthe requirements
and fire codes for using an LPgas grill in your
apartmentcomplex.If allowed, useoutside on the
ground floorwith a three (3)foot clearance from walls
or rails. Donot useonor under balconies.
•NEVERattempt to light burner with lid closed.A
buildup of non-ignited gas inside a closed grill is
hazardous.
•Never operategrill with LP cylinderout of correct
position specified in assembly instructions.
•Always close LP cylinder valve and remove
coupling nut before moving LP cylinder from
specified operation position.
Safety Tips
A Beforeopening LP cylinder valve, check the coupling nutfor
tightness.
A When grill is not in use, turn off all control knobs and LP
cylinder valve.
,A, Never move grill while in operation or still hot.
A Use long-handled barbecue utensils and oven mitts to avoid
burnsand splatters.
,A, Maximum load for sideburner and side shelf is 10 Ibs.
A The grease tray must be inserted into grill and emptied after
each use. Do not remove grease tray until grill has
completely cooled.
A Clean grill often, preferably after each cookout. If a bristle
brush is used to clean any of the grill cooking surfaces,
ensure no loose bristles remain on cooking surfaces prior to
grilling. It is not recommendedto clean cooking surfaces
while grill is hot.
A If you notice grease or other hot material dripping from grill
onto valve, hoseor regulator, turn off gas supply at once.
Determinethe cause, correct it, then clean and inspect valve,
hoseand regulator before continuing. Perform a leak test.
A Keep ventilation openings in cylinder enclosure (grill cart) free
and clear of debris.
A Donot store objects or materials inside the grill cart
enclosure that would block the flow of combustion air to the
undersideof either the control panel or the firebox bowl.
A The regulator may make a humming or whistling noise during
operation. This will notaffect safety or use of grill.
,A, If you have a grill problem see the "Troubleshooting Section".
A If the regulator frosts, turn off grill and LP cylinder valve
immediately.This indicates a problemwith the cylinder and it
should not be used on any product. Return to supplier!
tAuT,oN
•Putting out grease fires by closing the lid is not possible.
Grills are well ventilated for safety reasons.
• Do not use water on a grease fire. Personal injury may
result. If a grease fire develops, turn knobs and LP
cylinder off.
• Do not leave grill unattended while preheating or burning
off food residue on HI. if grill has not been regularly
cleaned, a grease fire can occur that may damage the
product.
Main Burner ignitor Lighting
ADo not lean over grill while lighting.
1. Open lid during lighting.
2. Turn on gas Tank valve.
3. Push and turn any burner control knob to HI and
immediately press and hold ELECTRONIC IGNITION button.
4. If ignitiondoes NOT occur in 5 seconds, turn burner control
knob OFF, wait 5 minutes for gas to clear away,and repeat
the lighting procedure.
5. Repeat above steps to lighteach burner individually.
if ignition still does not occur, follow match-lighting
instructions.
464261709.7

Turn controls and gas source or tank OFF when not
in use. CAUTIo.
if ignition does NOT occur in 5 seconds, turn the burner
controls OFF, wait 5 minutes for gas to clear away and
repeat the lighting procedure. If the burner does not ignite
with the valve open, gas will continue to flow out of the
burner and could accidently ignite with risk of injury.
Main Burner Match-Lighting
ADo not lean over grill while lighting.
1. Turn OFF all burner control valves.
2. Open lid during lighting. Turn on gas at LP cylinder.
3. Light match, and place into lighting holefor desired burner to
light. The lighting holesare located at the front of the cooking
grates between the emitter plate mounting brackets.
4. Push in and turn control knobto HI ._ position for desired
burner to light. Be sure burner lights and stays lit.
5. If ignition does NOT occur in 5 seconds, turn the burner
Control knob off, wait 5 minutes for gas to clear away, and
repeatthe match lighting procedure.
6. Ignite remaining burners by repeating steps 3 through 5 for
each burner.
Side Burner Ignitor Lighting
Sideburner Match Lighting
1. Turn OFF all burner control valves.
2. Open the sideburner lid.
Turn on gas at LP cylinder.
3. Place lit match near burner.
4. Turn sideburner knob to HI_ .
Be sure burner lights and stays lit.
WARNING: Sideburner top cover must be open when
sideburner is in operation.
Before Your First Cookout
• Lightburners, check to make sure they are lit, close the lid and
warm up grill on HIGHfor 15 minutes. This curing of paint and
partswill produce an odor only on first lighting.
Burner Flame Check
• Lightburner, rotate knobs from HIGHto LOW.You should see
a smaller flame in LOW position than seen on HIGH.Always
check flame prior to each use. If only lowflame is seen refer to
"Sudden drop or low flame" in the Troubleshooting Section.
Hose Check
•Beforeeach use, check to see if hoses are cut, worn or kinked.
Replace damaged hoses before usinggrill. Use only
valve/hose/regulator specified in the Parts List.
Warning:
Top cover must be open
when side burner(s) is in
operation.
,& Do not lean over grill while lighting.
1. Open lid during lighting.
2. Turn ON gas tank valve.
3. Push and turn sideburner control knobto_1:: HI and
immediately press and hold ELECTRONIC IGNITION button.
4. If ignitiondoes NOT occur in 5 seconds, turn burner control
knob OFF,wait 5 minutes for gas to clear away, and repeatthe
lighting procedure.
5. Repeat above steps to light each burner individually.
Normal
Hose
Turning Grill Off
Kinked
Hose
• Turn all knobs to OFF position.Turn LPtank off byturning
OPD hand wheel clockwise to a full stop.
Ignitor Check
• Turn gas off at LP tank. Push and turn burner control to _ .
"Clicking" should beheard and sparking seen each time
between collector box or burner and electrodes. See
"Troubleshooting" if no click or spark occurs.
Valve Check
•Important: Makesure gas is off at LP tank before checking
valves. Knobslock in OFF position. Tocheck valves, first
push in knobs and release, and knobs should spring back. If
knobs do not spring back, replace valve assembly before using
grill. Turn knobs to LO position then turn backto OFF position.
Valves should turn smoothly.
8. 464261709

General Grill Cleaning
•Do not mistake brown or black accumulation of grease and
smoke for paint. Interiorsof gas grills are notpainted at the
factory (and should never be painted). Apply a strong solution
of detergent and water or use a grill cleanerwith scrub brush
on insides of grill lid and bottom. Rinse and allow to completely
air dry. Do not apply a caustic grill/oven cleaner to painted
surfaces.
• Plastic parts: Wash with warm soapy water and wipe dry.
,&. Do not use citrisol, abrasive cleaners, degreasers or a
concentrated grill cleaner on plastic parts. Damage to and
failure of parts can result.
•Porcelain surfaces: Because of glass-like composition, most
residuecan be wiped away with baking soda/water solution or
specially formulated cleaner. Use nonabrasive scouring powder
for stubborn stains.
•Painted surfaces: Wash with milddetergent or nonabrasive
cleaner and warm soapy water.Wipe dry with a soft
nonabrasive cloth.
•Stainless steel surfaces: To maintain your grill's high quality
appearance, wash with mild detergent and warm soapy water
and wipe drywith a soft cloth after each use. Baked-on grease
deposits may require the useof an abrasive plastic cleaning
pad.Use only in direction of brushed finish to avoid damage.
Donot use abrasive pad on areas with graphics.
• Cooking surfaces: If a bristle brush is usedto cleanany of
the grill cooking surfaces, ensure no loose bristles remain on
cooking surfaces prior to grilling. It isnot recommendedto
clean cooking surfaces while grill is hot.
Storing Your Grill
•Clean cooking grates.
•Store in dry location.
•When LP cylinder isconnected to grill, store outdoors in a well-
ventilated space and out of reach of children.
•Cover grill ifstored outdoors. Choose from a variety of grill
covers offered by Sears or other qualified dealers.
•Store grill indoors ONLY if LP cylinder isturned off and
disconnected, removed from grill and stored outdoors.
•When removing grill from storage, follow "Cleaning the Burner
Assembly" instructions beforestarting grill.
CAUTION
/SPIDER ALERT!
If you notice that your grill isgetting hard tolight or thatthe
flame isn't asstrong asit should be, takethe time to checkand
clean theventuri's.
CONTROLPANEL SPIDERWEBS
INSIDE TUBE
BURNER
Insomeareasofthecountry,spidersor smallinsectshavebeen
knowntocreate"flashback"problems.Thespidersspinwebs,build
nestsand layeggsin thegrill'sburnertube(s)obstructingtheflowof
gastotheburner.Thebacked-upgascanigniteinthetubebehind
thecontrolpanel.Thisisknownasaflashbackand itcandamage
yourgrillandevencauseinjury.
Topreventflashbacksandensuregoodperformancetheburner
assemblyshouldbe removedfromthegrillandcleanedbeforeuse
wheneverthegrillhasbeenidleforan extendedperiod.
464261709•9

Cleaning the Burner Assembly
Follow these instructions to clean and/or replace parts of burner
assembly or if you have trouble igniting grill.
1. Turn gas off at control knobs and LP cylinder,
2. Remove cooking grates and flame tamers.
3. Remove hitch pins and carryover tubes from rear of burners.
4. Remove Hitch pinto disengage burner from bracket on
firebox.
5. Detach electrode from burner with a flat screw driver by
pressing the electrode clamp out of the burner through the
notch on the clamp. Electrode should remain in firebox.
6. Carefully lift each burner up and away from valve openings.
We suggest three ways to clean the burner tubes. Use the one
easiest for you.
(A) Bend a stiff wire (a light weight coat hanger works well)
into a small hook. Run the hook through each burner
tube several times.
(B) Usea narrow bottle brushwith a flexible handle (do not
use a brass wire brush), run the brush through each
burner tube several times.
(C) Wear eye protection: Use an air hose to force air into
the burner tube and out the burner ports. Check each
port to make sureair comes out each hole.
7. Wire brush entire outer surface of burner to remove food
residue and dirt.
8. Clean any blocked ports with a stiff wire such as an open
paper clip.
9. Check burner for damage, due to normal wear and corrosion
some holes may become enlarged. Ifany large cracks or
holes are found replace burner.
VERY IMPORTANT: Burner tubes must reengage valve
openings. See illustrations at right.
10. Attach electrode to burner.
11. Carefully replace burners.
12. Attach burners to brackets on firebox.
13. Reposition carryover tubes and attach to
burners. Replace flame tamers and
cooking grates. Correct
burner-to-valve
engagement
........................burner
10 •464261709
Food Safety
Food safety isa very important part of enjoying the outdoor
cooking experience. To keep foodsafe from harmful bacteria,
follow these four basic steps:
Clean: Wash hands, utensils, and surfaces with hot soapy water
before and after handling raw meat and poultry.
Separate: Separate raw meats and poultry from ready-to-eat
foods to avoid cross contamination. Use a clean platter and
utensils when removing cooked foods.
Cook: Cook meat and poultry thoroughly to kilt bacteria. Use a
food thermometer to ensure proper internal foodtemperatures.
Chill: Refrigerate prepared foods and leftovers promptly.
For more information call: USDA Meatand Poultry Notline at
1-800-535-4555 (in Washington, DC [phone], 10:00 am-
4:00 pm EST).
How To Tell If Meat Is Grilled Thoroughly
• Meat and poultry cooked on a grill often browns very fast on the
outside. Use a meat thermometer to be sure food has reached
a safe internal temperature, and cut into food to check for
visual signs of doneness.
•Whole poultry should reach 165° F.Juices should run clear and
flesh should not be pink.
•Hamburgers madeof any ground meat or poultry should reach
160° F, and be brown in the middle with no pinkjuices. Beef,
veal and lamb steaks, roasts and chops can be cooked to 145°
F.All cuts of pork should reach 160° F.
•NEVER partially grill meat or poultry and finish cooking later.
Cook food completely to destroy harmful bacteria.
•When reheating takeout foods or fully cooked meats like hot
dogs, grill to 165° F,or until steaming hot.
WARNING: Toensure that it is safe to eat, food must be cooked
to the minimum internal temperatures listed in the table below.
USDA* Safe Minimum Internal Temperatures
Fish 145°F
Pork 160°F
Egg Dishes 160°F
Steaks and Roasts of Beef,
Veal or Lamb 145°F
Ground Beef, Veal or Lamb 160°F
Whole Poultry (Turkey,
Chicken, Duck, etc.) 165°F
Ground or Pieces Poultry 165°F
(Chicken Breast,etc.)
*United States Department of A( ricutture

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2 CASTER, LOCKING
2 CASTER_ FIXED
1 BOTTOM SHELF
TANK SCREW, F/BOTTOM
1SHELF
1 CART LEFT SIDE PANEL
GROMMET, F/REGULATOR
1HOLE
1 CART RIGHT SIDE PANEL
1 CART LOWER BACK PANEL
1 TOP LID_OUTER
1 INNER LINER_ F/TOP LID
1 HANDLE F/TOP LID
RECTANGULAR BUMPER, F/
2TOP LID
2 RUBBER BUMPER_ F/LID
1 LOGO PLATE
1 HARDWARE F/TOP LID
1 FIREBOX
1 MATCH HOLDER
3 MAIN BURNER
ELECTRODE W/
3 WIRE/COLLECTOR, F/MAIN
BURNER
CARRYOVER TUBE W/
20 2 80017669
COTTER PIN
HOSE VALVE REGULATOR
21 1 ASSY 80018375
22 1 MAIN CONTROL PANEL 80019215
23 4 BEZEL, F/CONTROL KNOB 80018318
24 4 CONTROL KNOB 80019164
25 1 CART UPPER BACK PANEL 80007473
26 1 RIGHT SIDE SHELF 80007487
27 1 FASCIA, F/RIGHT SIDE SHELF 80017684
28 1 LEFT SIDE SHELF F/S/B 80007482
29 1 FASClA_ F/LEFT SIDE SHELF 80019216
30 1 DRIP PAN_F/SB 80017677
31 1 LID, F/SB 80008182
TEMPERATURE GAUGE, UFC
32 3 80007563
MOUNTED
33 1 SIDEBURNER 80017653
34 1 ELECTRODE, F/SB 80017680
ELECTRODE WIRE, F/
35 1 80018307
SIDEBURNER
13
14
15
16
17
18
19
80000268
80004093
80007452
80006484
80007454
80004157
80019167
80007458
80019160
80019217
80009953
80006983
80006625
80010544
80017678
80007720
80006654
80017579
80007512
36 1 GRATE, F/SB 80006640
37 1 FRONT BRACE 80007568
38 1 HEAT SHIELD, F/TANK 80007503
39 1 LEFT RAIL, F/GREASE TRAY 80007501
40 1 RIGHT RAIL, F/GREASE TRAY 80007502
41 1 LEFT DOOR, NO HANDLE 80017687
42 2 DOOR HANDLE 80009974
43 1 RIGHT DOOR, NO HANDLE 80017688
44 1 BUTTON CAP, F/El MODULE 80018347
ELECTRONIC IGNITION
45 1 80018343
MODULE
46 1 HEAT SHIELD, F/El MODULE 80015536
47 1 IGNITER SWITCH MODULE 80018315
48 3 HEAT DIFFUSER 80003332
49 3 COOKING GRATE 80018619
50 1 WARMING RACK 80007505
51 1 GREASE TRAY 80018309
Not Pictured:
... 2 DOOR MAGNET 80008850
... 1 HARDWARE PACK 80019169
... 1 CASTER WRENCH 80000283
... 1 ASSEMBLY MANUAL, ENGLISH 80019155
... 1 ASSEMBLY MANUAL, SPANISH 80019156
Ifyou are missing hardwareor have damaged parts,
please call 1-800-241-7548for replacement.
464261709.11

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12,464261709

Attach the two locking casters at the rear of the bottom shelf
and the two fixed casters at thefront and tighten with the caster wrench provided.
Fixed caster
Lockingcaster--______
Bottom
Attach side panels to bottom shelf usingthree
1/4-20x1/2" screws, 7ram lock washers, and
7ram flat washers per panel.
IMPORTANT: Panel with large hole must
be on left side of bottom shelf.
l/4-20xl/2"Screw 1/4-20x1/2"screw
Qty.6
O7mm lock washer 7ram
Qty.6 7ram
7mmfiat washer
Qty.6
Leftsidepanel
(with largehole)
Makesuresidepanels
are pushedasfar to the
rearof bottom shelfas
possiblebeforefully
tightening screws.
Right sidepanel
464261709.13

Place lower back panel between side
panels at rear of bottom shelf. Secure
lower back panel to side panels using four
1/4-20x1/2" screws, 7ram lock washers,
and 7ram flat washers. Lowerbackpanel 1/4-20×1/2"screw
7ramlock washer
l/4-20xl/2"Screw 7ramflat washer
Qty.4
7mmlock washer
Qty.4
7mm flat washer
Qty.4
This step requires two people
to lift and position grill head
onto cart. Carefully lower the grill
head onto the cart, aligning slots at
bottomof grill head with posts on
cart side panels. Make sure the
regulator hose is hanging outside
the cart. Grill head must face open
side of cart.
Grill head
Regulatorhose
14.464261709

Onbackofgrill,placeupperbackpanelbetweensidepanelsand abovefowerbackpanel
Secureupperbackpanelin lowerholes,usingonet/4-20x114" screw,7ramIockwasher,and7ramfiatwasheroneachside
Do notfully tighten screws until side shelf installation is completein later steps,
0 ©
7mmLockwasher 7mmfiatwasher
Qty.2 Qtyo2
114-20x1½"screw
Qty.2
Upperbackpanel
Insertflangeon rightsideshelfintosideshelfbracketsonsideof firebox
AttachrightsideshelfusingthreeI/4"-20x3/4"screws,7ramlockwashers,7ramflatwashers,tl4" nuts,shownAo
Attachrearof shelfusingoneI/4-20x1%"screw,7ramlockwasher,and7ramfiat washerinlowerhole,shownBo
Attachfrontofshelfandfasciausingone#8x3/8"self-tappingscrewandlarge fiatwasher,shownCo
Attachfrontofshelfandfasciausingone114"-20x3/4"screw,7ramlockwasher,7ramfiat washerand114"nut,shownDIG
ll4-20x3i4"Screw
Qtyo4
1i4-20xlW'screw
_'y.1
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7ramlockwasher 7mmfiatwasher
#8x3f8" Qty.5 _q/,5
seINappingscrew
Qty.I
lock
washer screw
1/4"_t largefiatwasher
QtyA Qty.1
:i:?
wesher
panel
washer
114-20x314"
screw
7ram 454261709o15

Insertflange on left sideburner shelf into side shelf brackets on side of firebox.
Attach left sideburner shelf using three 1/4-20x3/4" screws, 7ram lock washers, 7ram flat washers, 1/4" nuts, shown A.
Attach rear of shelf using one l/4-20xllA '' screw, 7ram lock washer,and 7ram flat washer in lower hole, shown D.
Attach front of shelf and fascia using one #8x3/8" self-tapping screw and large flat washer, shown C.
Under main control panel, attach front of shelf and fascia using one 1/4-20x3/4" screw, 7ram lock washer, 7ram flat
washer and 1/4" nut, shown DIE.
Now you may fully tighten lower screws on upper back panel.
l/4-20x3/4"Screw #8×3/8"
Qty.4 self-tappingscrew Flange
into
1/4-20x1W'screw _'Y"
Qty. 1 1/4-20xlI/2"
screw
7ramlock washer 7ramflat washer 1/4"nut
Qty.5 Qty.5 Qty.4
largeflat washer
Qty.1
Fascia,left sideburnershelf
7mmlock
washer
Back of main control
1/4-20x3/4"
screw
16.464261709

First, removethetwo screws and lock washersfactory attachedto the sideburner valvebracket,.Positionsideburner
valvebracketbeneathsidebumershelffasciaso thatvalvestemcomesthroughlargercenterholeinfascia Aligntheholes
onvalvebracketwithleftandrightholesonfascia Secureusinglockwashersandscrewsthatwereremovedfrombracket
Next,placesideburnerbezelovervalvestemonfrontsideoffascia Alignsmallholesonbezelwithupperandlowerholeson
lascia,paNngsure°OFF°isF_thetP,S.Attachusingtwo#8-32x318"screwsand4ramlockwashersPresssidebumer
controlknobontovalvestern
Note: Use left and right
holeson fascia to
attachvalve bracket
ScrewsandWashers
removedfromvalvebracket
.... •,!,_:T" ::::::::::::::::::::::::::::
S deb,,,,,er
i;:::: va,vob,ooket
_ 8-32x3f8"screw
Qty.2
O4ramlockwasher
Qty.2
Note: Use upper and lower
holes on fascia toattach bezel
Controlknob #8-32x318"screw
l
: _
Pulloutthethreeknobsfromcontrolpanel Inserttemperaturegaugestemintothebiggerholeaboveknobbezel,shownA
Makesurethegaugeispushedin asfarasitwillgo,thenpushthegaugedownwarduntilitclipsintothepanel,asshown
in B/C Re-installthethreeknobs gaugestern
i
Knob

InsertsideburnerburnerintoleftshelfThestudonbottomofburnerfitsintorearsmallholein sideburnerdrippanon
shelf,shownA,Secureburnerto sidebumerdrip panwithoneWingnut,shownB Makesureburnertubeengages
sidebumervalve,shownC
Wingnut Sidebumerburner
G_' Wingnut
PP_
Sidebumer drippan
Undersidebumershelf,attachsidebumerignitorwiretoelectrode,shownA Placesidebumergrateontosideburnershelf,
aligninggratelegswithholesinshelf,shownB,
Sidebumer IgnitorWire
Sic
18°4E.426_709

Insertfront brace under control panel and between cart side panels. Make sure door hinge pins are on thetop side and
facing the front. Secure using two l/4-20xllA '' screws, 7ram lock washers, and 7ram flat washers on each side.
1/4-20×11/2"screw
Qty.4
7ramLockwasher 7ramflat washer
Qty.4 Qty.4
7ramflat 7ramlock 1/4-20×11/2"
washer washer screw
Inside of cart, insert rear shield tab into left slot on upper of lower back panel. Insert left and rightgrease tray rails into slots
beneath grease tray opening in upper back panel, shown A. Attach front shield tabs under front brace and attach right and
left rails under front bracewith three #8x3/8" self-tapping screws, shown B.
Tankheatshield
Note:somepartsomitted
forclarityofillustration
#8x3/8"self-tappingscrew
Qty.3
Greasetrayopening
464261709.19

Insert hinge pin on bottom of doors into hole in bottom shelf. Press upper hinge pin in front brace, align hinge hole on top of
door, and release hinge pin into door.
doo_
I
i!i!,i_i,i!iiiiiiii_i,liiiiiiiiiliiiii!,i!_iiiii]liJiliiii_
Hingepin
on bottom
of door
Release the cap and nutfrom electronic ignition module. Attach electronic ignition module and heat shield to the cart right
side panel with the nutand cap, shown A.
Connect each of the wires from the main burner electrodes, and sideburner electrode into the back of the Electronic Ignition
Module. Total (4) connections.
Connect the two wires [(a) and (b)] from the switch wiring harness into the backof the Electronic Ignition Module.
Total (2) connections.
NOTE: Switchterminals are larger than electrode terminals and should only be installed in location shown as (a), (b).
Nut Cap
20.464261709