Kenmore 415.16115 User manual

Assembly Instructions/UseandCareManual
LiquidPropaneGasGrill
Model No. 415.16115 and 640-122390-115
ThisGrillisFor
Outdoor UseOnly
®
• Read this manual before cooking on
grill. Failure to follow all
manufacturer's instructions could
result in fire or e×plosion which could
cause property damage, personal
injury or death.
-Combustion by-products produced
when using this product contain
chemicals known to the State of
California to cause cancer, birth
defects, or other reproductive harm.
CAUTION
- Read and follow all Safety
Statements, Assembly instructions
and Use & Care Directions before
attempting to assemble and cook.
•Some parts may contain sharp edges,
especially as noted in these
instructions. Wear protective gloves
if necessary.
• Parts
• Assembly
• Safety Rules
• Use and Care
• Troubleshooting
•EspaSol
Assembly Questions?
Call 1-800-241-7548
Parts Ordering:
Call 1-800-4-MY-HOME ®
To InstallerlAssembler: Leave
these instructions with
consumer,
To Consumer: Keep this
manual for future reference.
Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A.
@2006Sears,Roebuckand Co.,All RightsReserved Printedin China 464321607and464321407°80009281,11-01-06

ifyou smell gas:
1. Shut off gas to the appliance.
2. Extinguish any open flame.
3. Open lid.
4. Ifodor continues, keep away from the
appliance and immediatelycall 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 cylinder 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
Ifyou havequestionsor needassistanceduring assembly,
pleasecall 1-800-241-7548.Youwill be speakingto a
representativeof thegrill manufacturerand nota Sears
employee.Toordernew parts call Searsat 1-800-4-MY-HOME®.
Product Record
iMPORTANT:Filloutthe productrecord informationbelow.
Model Number
Serial Number See ratinglabel on grill for serial number.
Date Purchased
Safety Symbols
The symbolsand boxesshown belowexplainwhat eachheading
means.Readandfollow all ofthe messagesfound throughout
the manual.
DANGER: Indicatesan imminentlyhazardoussituation
which, if not avoided,will result in death or serious injury.
WARNING: Be alertto the possibilityof serious bodily injury
ifthe instructionsare notfollowed.Be sure to read and
carefullyfollow all of the messages.
CAUTION
CAUTION: Indicatesa potentiallyhazardous situationwhich,
ifnot avoided, may resultin minoror moderate injury.
Installation Safety Precautions
• Use grill, as purchased,only with LP (propane)gas and the
regulator/valveassembly supplied.
• Grill installationmustconformwith localcodes,or in their
absence of localcodes,with either the NationalFuel Gas
Code,ANSI Z223.1/NFPA 54, Natural Gasand Propane
Installation Code, CSAB149.1,or Propane Storageand
Handling Code,B149.2, or the Standardfor Recreational
Vehicles,ANSlA 119.2/NFPA1192,and CSAZ240RV Series,
Recreational VehicleCode,as applicable.
,All electricalaccessories(such as rotisserie) mustbe
electrically groundedin accordancewith local codes,or
National ElectricalCode,ANSl/ NFPA70. Keepany electrical
cords and/orfuel supply hosesawayfrom any hot surfaces.
,Grill isnotfor usein or on recreationalvehiclesand/orboats.
,This grill issafety certifiedfor use in the UnitedStatesonly. Do
not modifyfor use in anyother location.Modificationwill result
in a safety hazard.
CAUTION
For residential useonly. Do not use for commercial
cooking.
2•464321607and464321407

ForYour Safety...................................... 2
Grill Service Center................................... 2
Product Record Information ............................ 2
SafetySymbols...................................... 2
InstallationSafetyPrecautions.......................... 2
KenmoreGrill Warranty ............................... 3
Use and Care..................................... 4-11
Parts List.......................................... 12
Parts Diagram...................................... 13
Assembly ....................................... 14-23
Troubleshooting.................................. 24-26
Repair Protection Agreements
Congratulationson makinga smartpumhase.Your new
Kenmore®product isdesignedand manufacturedfor years of
dependableoperation. Butlike allproducts, it may requirerepair
from time to time.That's when havinga Repair Protection
Agreementcan save you moneyand aggravation.
Purchasea RepairProtectionAgreementnow and protect
yourselffrom unexpectedhassleand expense.
Here'swhat's includedin theAgreement:
[] Expert service by our 12,000professionalrepairspecialists
Unlimited service and no charge for partsand labor on all
coveredrepairs
[] Product replacement if yourcovered product can't befixed
[] Discount of 10%from regular priceof serviceand service-
relatedparts notcovered by theagreement;also, 10%off
regularpriceof preventivemaintenancecheck
[] Fast help by phone - phone supportfrom a Sears
technicianon productsrequiring in-homerepair,plus
convenientrepair scheduling
Onceyou purchasetheAgreement,a simple phonecall is all that
it takesfor youto scheduleservice. Youcan call anytimedayor
night, or schedulea serviceappointmentonline.
Sears hasover 12,000professionalrepair specialists,who have
access toover4.5 millionquality parts and accessories.That's
the kindof professionalismyou cancount on to help prolong the
lifeof your new purchasefor yearsto come. Purchaseyour
RepairProtectionAgreement today!
Some limitationsand exclusions apply.
For pricesand additional informationcall 1-800-827-6655.
SearsInstallationService
For Searsprofessionalinstallationof homeappliances,garage
door openers,water heaters,and othermajorhome items, in the
U.S.A. call 1-800-4-MY-HOME®
One-YearFullWarrantyon KenmoreGrill
Ifthisgrillfailsduetoadefectinmaterialorworkmanshipwithin
oneyearfromthedateofpurchase,call1-800-4-MY-HOME®to
arrangeforfreerepair(orreplacementifrepairprovesimpossible).
Five-Year LimitedWarranty on Stainless Steel Burners
For five years from the date of purchase, any stainless steel burner
that ruststhrough will be replacedfree ofcharge. After the first
year from the date of purchase, you payfor labor if you wish to
have it installed.
All warranty coverage excludes ignitor batteriesand grill part paint
loss, discoloration or rusting, which are either expendableparts
that canwear out from normal usewithin the warranty period, or
are conditions that can be the result of normal use, accidentor
improper maintenance.
Allwarrantycoverageisvoidifthisgrilliseverusedforcommercial
or rentalpurposes.
Allwarrantycoverageappliesonlyifthisgrillisusedin theUnited
States.
Thiswarrantygivesyouspecificlegalrights,andyoumayhave
otherrightswhichvaryfromstatetostate.
Sears, Roebuck and Co., Hoffman Estates, IL 60179
464321607and464321407•3

LP Tank
• NEVERstore a spare LP tank under or near grill or in
enclosed areas
hi, _ _Siii_ i_
• Never fill the cylinderbeyond 80% full,
• An overfilled or improperlystoredtank is a hazard due
to possiblegas release from the safety relief valve.
• If you see, smell or hear escaping gas, immediatelyget
away from the LP tank/grill and call your fire
department.
• If the above is not followed exactly, a fire causing
death or serious injury may occur.
•The LP tank used with your grill must meet the following
requirements:
• Use LP tanks only with theserequired measurements:12"
(30.5cm)(diameter) x 18" (45.7cm) (tall)with 20 Ib. (9 kg.)
capacity maximum.
, LP tanks mustbe constructedand marked in accordancewith
specificationsfor LP tank ofthe U.S.Departmentof
Transportation(DOT).See LP tank collarfor marking.
• LP tank valve must have:
, Type 1 outlet compatiblewith
regulatoror grill.
, Safety reliefvalve.
, UL listed OverfillProtection OPDHandWheel
Device (OPD).This OPDsafety
feature is identifiedby a unique triangularhand wheel. Use
only LP tanks equipped with this type of valve.
, LP tank must be arrangedfor vaporwithdrawaland include
collarto protect LP tank valve.
LP (Liquefied Petroleum Gas)
• LP gas is nontoxic,odorless and colorlesswhen produced. For
Your Safety, LP gas hasbeen givenan odor (similarto rotten
cabbage)so that it can be smelled.
• LP gas is highlyflammable and may igniteunexpectedlywhen
mixedwith air.
LP Tank Removal, Transport And Storage
,TurnOFF all control knobs and LP tank valve.Turncoupling
nut counterclockwiseby handonly - do notusetools to
disconnect.Lift LP tank wire upwardoff of LPtank collar, then
lift LP tank up and off of support bracket. Installsafety caponto
LP tank valve.Alwaysuse capand strap suppliedwith valve.
Failure to use safety cap as directed may result in serious
personalinjury andlor propertydamage.
LPTankValve
Salty Cap
Retainer Strap
, A disconnectedLP tank in storage or being transported must
havea safety capinstalled (asshown). Donot storean LP tank
in enclosedspaces such as a carport,garage, porch,covered
patioor otherbuilding.Never leavean LPtank insidea vehicle
which may becomeoverheated bythe sun.
, Do notstore an LPtank in an areawhere childrenplay.
4•464321607and464321407
LP Tank Filling
• Use only licensedand experienced dealers.
• LP dealer must purge tank beforefilling.
• Dealershould NEVERfill LP tank morethan 80% of LP tank
volume.Volumeof propane intank will vary by temperature.
• A frosty regulatorindicatesgas overfill.Immediatelyclose LP
tank valve and call localLP gas dealerfor assistance.
, Do not releaseliquidpropane(LP) gas intothe atmosphere.
This is a hazardouspractice.
, Toremovegas from LP tank,contact an LPdealer or call a
localfire departmentfor assistance.Checkthe telephone
directoryunder "Gas Companies"for nearestcertified LP
dealers.

LP Tank Exchange
, Many retailersthat sell grillsoffer you theoption of replacing
yourempty LP tank throughan exchange service.Use only
those reputableexchangecompaniesthat inspect, precisionfill,
test and certifytheir cylinders. Exchange your tank only for
an OPDsafety feature-equipped tank as described in the
"LP Tank" section of this manual,
• Alwayskeep newand exchanged LP tanksin upright position
during use, transitor storage.
, Leak test new and exchanged LP tanks BEFORE
connecting to grill.
Connecting Regulator To The LP Tank
1. LP tank mustbe properlysecured onto grill.(Refer to
assemblysection.)
2. Turnall control knobsto the OFF position.
3. TurnLP tank OFF byturning OPDhand wheelclockwiseto a
ful! stop.
4. Removethe protectivecapfrom LPtank valve.Always use
capand strap suppliedwith valve.
LP Tank Leak Test
For your safety
• Leaktest mustbe repeatedeach time LP tank is exchangedor
refilled.
• Do not smokeduring leak test.
• Do notuse an openflame tocheck forgas leaks.
• Grill must be leaktestedoutdoors in a well-ventilatedarea,
awayfrom ignitionsources such as gas fired or electrical
appliances.During leaktest, keepgrill away from openflames
or sparks.
, Use a clean paintbrushand a 50/50 mildsoap andwater
solution.Brushsoapy solution ontoareas indicated byarrows
in figure below.Leaks are indicated bygrowingbubbles.
If"growing"bubblesappear do notuse or move the LPtank.
Contact an LP gassupplieror yourfire department!
,L Do not use householdcleaning agents. Damageto gas
traincomponentscan result.
Type 1outlet with
thread on outside
Safety Relief Valve
Strap and Cap
Do not use a POL transport plug
(plastic part with external threads)!
It will defeat the safety feature of
the valve.
5. Holdregulatorand insert nipple into LP
tank valve.Hand-tightenthecoupling
nut, holding regulatorin a straightline
with LPtank valveso as notto cross-
threadthe connection.
Nipplehasto becentered
intotheLPtank valve.
464321607and464321407•5

Hold coupling nut and regulator
as shown for proper connection
to LP tank valve.
Leak Testing Valves, Hose and Regulator
1. Turn all grill control knobs to OFF.
2. Be sureregulator istightlyconnectedto LP tank.
3. Completelyopen LP tank valve byturning OPDhand wheel
counterclockwise,Ifyou hear a rushing sound,turn gasoff
immediately,Thereis a major leakatthe connection, Correct
before proceeding bycalling Searsfor replacementpartsat
1-800-4-MY-HOME®.
4. Brushsoapy solutiononto areaswhere bubblesare shown in
picture below:
6. Turnthe coupling nutclockwiseand tightento a full stop. The
regulatorwill seal on the back-checkfeature in the LP tank
valve, resulting in some resistance.An additional one-half to
three-quarters turn is requiredto complete the
connection, Tighten by hand only - do not use tools,
NOTE:
Ifyou cannotcompletethe connection, disconnectregulatorand
repeatsteps 5 and 6. If you are still unable tocompletethe
connection,do not use this regulator!
,Do notinsertany toolor foreign objectsinto thevalve outlet
or safety reliefvalve. Youmay damagethevalve and cause
a leak. Leaking propanemay result in explosion,fire, severe
personalinjury,or death..
,If a leakis detectedat anytime, STOPand callthe fire
department.
,If you cannot stop a gas leak, immediatelyclose LPtank
valve and call LPgas supplieror your fire department!
,ANeverremovethreaded
orificeatend ofvalve.
\
5. if "growing" bubblesappear,thereis a leak. Close LP tank
valve immediatelyand retightenconnections.If leaks cannot
be stopped do not try to repair, CallSearsfor replacement
partsat 1-SO0-4-iVIY-HOME®.
6. Always close LP tank valve after performingleak testby
turninghand wheelclockwise.
,Never attemptto attachthis grillto theself-containedLP gas
systemof a camper traileror motor home.
,Do notuse grill until leak-tested.
6• 464321607and464321407

For Safe Use Of Your Grill And To Avoid Serious
injury:
• Do not let children operateor playnear grill.
• Keep grill area clearand free from materialsthat burn.
• Do not block holes in bottom or back of grill.
• Check burnerflamesregularly.
• Use grill only in well-ventilatedspace.NEVER usein
enclosedspace such as carport,garage, porch,covered
patio, or under an overheadstructure dany kind.
• Do notuse charcoalor ceramicbriquets in a gas grill.
(Unlessbriquets are suppliedwith yourgrill.)
• Use grill at least 3ft. from any wall or surface. Maintain
10 ft. clearanceto objectsthatcan catchfire or sourcesof
ignitionsuch as pilot lightson water heaters, live electrical
appliances,etc.
•Apartment Dwellers:
Checkwith managementto learn therequirementsand fire
codes for usingan LP gas grill in yourapartmentcomplex. If
allowed, useoutside on the groundfloorwith a three (3)foot
clearancefrom walls or rails. Donot useon or under
balconies.
• NEVERattempt to light burner with lid closed. A buildup
of non-ignited gas inside a closed grill is hazardous.
• Never operate grill with LP tank out of correct position
specified in assembly instructions.
• Always close LP tank valve and remove coupling nut
before moving LP tank from specified operation
position.
Safety Tips
Beforeopening LP tank valve,check the coupling nut for
tightness.
A Whengrill isnot in use, turn offall control knobs and LP tank
valve.
A Never move grill whilein operationor still hot.
,_Use long-handledbarbecue utensilsand ovenmitts to avoid
burns and splatters.
,_Maximum loadfor shelves is 10 Ibs.
A Do not usea cooking pot largerthan 9" on grid.
A The greasecup must be attachedto greasecup clipand
emptied after eachuse. Donot removegreasecup untilgrill
has completelycooled.
,= If younotice greaseor other hot materialdrippingfrom grill
onto valve,hoseor regulator,turnoff gas supply atonce.
,_Determinethe cause,correct it,then cleanand inspectvalve,
hose and regulatorbeforecontinuing.Performa leaktest.
,_The regulatormay make a hummingor whistling noiseduring
operation.This will not affectsafety or useof grill.
A If youhave a grill problemsee the "TroubleshootingSection".
ifthe regulatorfrosts, turn off grill and LP tank valve
immediately.This indicatesaproblemwith the tank and it
should not be used on any product. Return to supplier!
464321607and464321407• 7

Ignitor Lighting
A Do not lean over grill while lighting.
1.Open lid during lighting,
2. Toignite, turn IGNITIONBURNER knobto_ _.
3. Pushand hold ELECTRONICIGNITION button.
4. If ignitiondoes NOToccur in 5 seconds,turn the burner
control off,wait 5 minutes, and repeatthe lightingprocedure.
5. Igniteother burnersbyturning knobto _.
6. If ignitordoes notwork,wait 5 minutes,then follow match
lightinginstructions.
CAUTION
If burner does not light, turn knobs to OFF,wait 5
minutes, and try again. Always close valve during the 5
minute waiting period. Ifthe burner does not ignite with
the valve open, gas will continue to flow out of the burner
and could accidentally ignitewith risk of injury.
Match-Lighting
,A Do not lean over grill whilelighting.
1.Open lid during lighting.
2. Placematchinto matchholder (hangingfrom side of cart).
Lightmatch, placeinto lightinghole on rightside offirebox.
3. Pushin and turn left knobto HIGH position. Be sure burner
lightsand stays lit.
4. Lightotherburners bypushing knobin and turningto _ HIGH
position.
mc.uTio.
• 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 injurymay
result. If a grease fire develops, turn knobs and LP tank
off.
•Do not leave grill unattended while preheating or
burning off food residue on high. If gril! has not been
regularly cleaned, a grease fire can occur that may
damage the product.Follow instructions on General
Grill Cleaning and Cleaning The Burner Assembly to
preventgrease fires.
Before Your First Cookout
,Light burners,checkto make sure they are lit, close the lid and
warm up grill on HIGHfor 15 minutes.This curing dpaint and
parts will producean odor onlyon first lighting.
Burner Flame Check
,Light burner,rotateknobs from HIGHto LOW.Youshould see
a smaller flame in LOWpositionthan seenon HIGH.Always
checkflame priorto each use. If only lowflame is seenreferto
"Sudden drop or lowflame" in the TroubleshootingSection.
Hose Check
•Beforeeach use, checkto see ifhoses are cut,worn or kinked.
Replace damagedhoses before usinggrill. Use only
valve/hose/regulatorspecified in the PartsList.
Normal
Hose Kinked
Hose
8• 464321607and 464321407

Turning GrillOff
, Turnall knobsto OFF position.TurnLP tank off by turning
OPD handwheel clockwisetoa fullstop.
Ignitor Check
• Turn gas off at LP tank. Press and hold ignitorbutton. "Click"
shouldbe heardand spark seen eachtime between collector
box or burner and electrodes.See "Troubleshooting"if no click
or spark.
Valve Check
•important:Makesure gas is off at LP tank before checking
valves. Knobslock in OFF position.Tocheck valves,first
push in knobsand release,knobs shouldspring back. If knobs
do not spring back, replacevalve assemblybefore usinggrill.
Turnknobs to LO positionthen turnback to OFF position.
Valvesshouldturn smoothly.
General Grill Cleaning
,Keep theoutside of your grilllookingnew bycleaningit oncea
monthwith warm soapand water or a non-abrasivecleaner. If
you don't have a grill cover,wipeoffdust and grime before
startingyour grill.
,Coatingthe cooking gridswith spray-oncooking oil will keepthe
foodfrom sticking and make clean up easier.After cooking,
scrape thegrates with a long handled,brasswire bristle brush.
,Check insidethegrill bottom for grease build up and clean
often,especiallyafter cooking fatty meat.
, Do notmistake brownor blackaccumulationof grease and
smokefor paint. Apply a strong solution ddetergentand water
or usea grill cleanerwith scrub brushon insidesof grill lid and
bottom. Rinseand allowto completelyair dry. Do not apply a
caustic gril!/oven cleaner to painted surfaces.
• Plated wire grates: Wash grates with concentratedgrill
cleaneror usesoapand water solution. Dry thoroughlyand
store indoors betweencookouts.
, Plastic parts: Washwith warm soapywater andwipe dry.
A Do not usecitrisol, abrasivecleaners,degreasersor a
concentratedgrill cleaneron plasticparts.Damage to and
failureof parts can result.
• Porcelain grates: Becauseof glass-likecomposition,most
residuecan be wipedaway with baking soda/watersolutionor
speciallyformulatedcleaner.Use non-abrasivescouring
powderfor stubbornstains.
m m
cAuT,o.
/SPIDER ALERT! -"
SPIDERANDWEBS,=o_ J,
INSIDEBURNERTUBE _'_*_:
If you notice that your grill is getting hard to light or that the
flame isn't as strong as it should be, take the time to check and
clean the burner's,
I,
...............................t
CONTROLPANEL. SPIDERWEBS
INSIDETUBE
Insomeareasofthecountry,spidersor smallinsectshavebeen
knowntocreate"flashback"problems.Thespidersspinwebs,build
nestsandlayeggsinthegrill'sburnertube(s)obstructingtheflowof
gastotheburner.Thebacked-upgascanigniteinthetubebehind
thecontrolpanel.Thisisknownasaflashbackanditcandamage
yourgrillandevencauseinjury.
Topreventflashbacksandensuregoodperformancetheburner
assemblyshouldberemovedfromthegrillandcleanedbeforeuse
wheneverthegrillhasbeenidleforanextendedperiod.
\ 1'
464321607and464321407•9

Cleaning the Burner Assembly
Followthese instructionsto clean and/orreplaceparts of burner
assemblyor ifyou havetrouble ignitinggrill
1 Turn gas off at control knobs and LP cylinder.
2. Removecookinggrates and heat tents.
3. Removescrewsand flame carryovertubes from rear of
burners.
4. Removescrewand washersto disengageburnerfrom
bracketonfirebox.
5. Removescrewsto detach electrodefrom burner.Electrode
should remainin firebox.
6. Carefullylift eachburner up and away from valve openings.
Wesuggest threewaysto clean theburner tubes.Use the one
easiestfor you.
(A) Bend a stiff wire (a lightweight coat hangerworks well)
intoa small hook. Runthe hookthrougheach burner
tubeseveral times.
(B) Use a narrow bottlebrushwith a flexible handle (do not
usea brasswire brush),run the brushthrougheach
burner tubeseveral times.
(C) Wear eye protection: Use an air hosetoforce air into
the burnertube and out theburnerports. Checkeach
port tomake sure air comesout each hole.
7. Wire brushentire outersurfaceof burner to removefood
residueand dirt.
8. Cleanany blockedports with a stiff wire such asan open
paperclip.
9. Checkburnerfor damage, due to normalwearand corrosion
some holesmay becomeenlarged. If anylarge cracks or
holesare found replaceburner.
VERYIMPORTANT: Burner tubes must re-engage valve
openings. See illustrationsat right, Correct
10. Attach electrodeto burner, burner-to-valve
11. Carefullyreplaceburners, engagement ,
12. Attach burnersto bracketson firebox.
13. Repositionflame carryover tubes and attach _
to burners.Replace heattentsand __
cooking grates. ,,_
Storing Your Grill
,Cleancooking grates.
,Store in dry location.
,When LPtank isconnectedto grill, storeoutdoors in well-
ventilatedspace and out of reachof children.
,Cover grill if stored outdoors.
,Storegrill indoorsONLYif LPtank is turnedoffand
disconnected,removedfrom grill and stored outdoors.
,When removinggrill from storagefollow "CleaningBurner
Assembly"instructionsbeforestartinggrill.
Food Safety
Foodsafety isa very importantpartof enjoyingthe outdoor
cooking experience.Tokeepfood safe from harmful bacteria,
follow these four basicsteps:
Clean: Wash hands, utensils,and surfaces with hot soapywater
beforeand after handlingraw meat and poultry.
Separate: Separaterawmeatsand poultryfrom ready-to-eat
foods to avoidcrosscontamination.Use a clean platter and
utensilswhen removingcooked foods.
Cook: Cook meatand poultry thoroughlyto kill bacteria.Use a
thermometerto ensureproper internalfood temperatures.
Chill: Refrigerateprepared foods and leftovers promptly.
For more information call: USDA Meatand Poultry Hotline at
1-800-535-4555(in Washington, DC [phone], 10:00am-
4:00 pm EST).
How To Tell If Meat is Grilled Thoroughly
•Meat and poultry cooked on a grill often browns veryfast on the
outside. Usea meatthermometer to besure food hasreached
a safe internaltemperature,and cut intofood to checkfor
visual signs of doneness.
• Whole poultryshould reach180° F; breasts, 170° F.Juices
should runclear and flesh shouldnot be pink.
• Hamburgersmadeof any groundmeat or poultryshould reach
160° F,and be brown inthe middle with no pinkjuices. Beef,
veal and lambsteaks, roastsand chops can becooked to 145°
F.All cuts of porkshouldreach 160° F.
• NEVER partially grill meat or poultryand finish cooking later.
Cook foodcompletely to destroyharmful bacteria.
• When reheatingtakeoutfoods orfully cooked meatslike hot
dogs, grill to 165° F,or untilsteaming hot.
10•464321607and464321407

indirect Cooking
Poultry and large cutsof meat cook slowlyto perfectionon
thegrill byindirect heat. Theheatfrom selectedburners
circulatesgently throughoutthe grill, cookingmeat or poultry
withoutthe touch ofa directflame. This methodgreatly reduces
flare-upswhen cookingextra fatty cuts because thereis no direct
flame to ignitethefats and juices that dripduring cooking.
indirect Cooking instructions
,Always cookwith the lid closed.
oDueto weatherconditions, cookingtimes may vary.During
coldand windy conditionsthetemperaturesetting may need
to be increasedto insuresufficientcooking temperatures
1 Burner Cooking
Cook with direct or indirect heat,
Best for smaller meals or foods.
Consumes less fuel.
2Burner Cooking
Greatindirectcookingon low.
Produces slow, even heating.
Ideal for slow roasting and baking.
464321607and464321407•11

@y__ ................ Part #
1 1 Right LegAssembly .......... 80009068
2 1 Match Lighter w/Chain ........ 80000274
3 1 LeftLegAssembly ........... 80009069
4 1 Tank Exclusion Wire .......... 80008616
5 1 Bottom Shelf ................ 80009035
6 1 TankThumbscrew ............ 80006484
7 4 1/4-20x1-1/2" Screw ........... HMS02520150CPNSTSS
8 12 1/4-20 Flange Nuts ........... HFN02520MNSS
9 1 Upper Front Panels .......... 80009038
10 1 Lower Front Panels .......... 80011105
11 2 Wheels .................... 80009727
12 1 Axle Rod ................... 80009036
13 1 Hitch Pin ................... 80003610
14 1 8ram Fiat Washer .......... 80008091
15 2 Leg Extenders ............... 80008596
16 1 Firebox .................... 80009059
17 1 Control Panel ............... 80009060
18 1 Valve/Hose/Regulator ......... 80009067
19 1 Ignitor Module............... 80009062
20 3 Bezels..................... 80009030
21 3 Control Knobs............... 80009030
22 3 Main Burners ............... 80009027
23 1 Main Burners Electrode ...... 80009029
24 2 Flame Carry-Over Tubes ...... 80009028
K_y _y Description ................ Part #
25 1 Top Lid ................... 80009061
26 1 Temperature Gauge .......... 80009025
27 1 Logo Plate ................. 80009024
28 12 1/4-20x1/2"Screw ........... HMS02520050CPNSTSS
29 8 7 mm Fiber Washers ......... HFWM7PRSTSS
30 4 7ram Lock Washers .......... HSWM7RHSPSS
31 1 Right Side Shelf ............. 80009063
32 1 Right Fascia ................ 80009064
33 1 Left Side Shelf .............. 80009065
34 1 Left Fascia ................ 80009066
35 12 #8x3/8" Self-Tap Screw ....... HMS01632038PPNBD
36 3 Heat Tents.................. 80008530
37 3 Cooking Grates.............. 80008531
38 1 Grill@NightTMLightHandle Assy. 70001074
39 2 #10-24x3/4" Thumbscrew ...... 4080132
40 1 Swing Away ................ 80008532
41 1 Grease Cup Clip............. 80000271
42 1 Grease Cup ................ 80000270
43 2 Spacer ................... 80009743
44 4 7ram Fiat Washer .......... HFWM7RHSPSS
12•464321607and464321407

®
464321607and464321407• 13

DTank Exclusion Wire
Place legs as shown (A). Left leg assembly has large holes on ends of legs. Hook tank exclusion
wire into right and left leg assemblies (B).
A
TankExclusionWire
LeftLegAssembly
haslargeholesonendsof
RightLegnoholes
onendsof leg
14•464321607and464321407

Bottom Shelf to Legs
"Attach bottom shelf to right and left legassemblies with (4) 1/4.20x1.1/2" screws and 1/4.20 flange nuts
@
1/4-20FlangeNuts
Qty:4
©
1/4-20X1-1/2"Screw
Qty:4
464321607and464321407•15

Front Panels
• Attach lowerfront panel to lower half ofcart with (4)#8x3/8" self=tapscrews.
• Slide slot in upper front panel onto tank exclusion wire and attach to upper half of cart
with (4)#8×3/8" self-tap screws,
#8x3/8" Self-Tap Screw
Qty: 8
LowerFront Panel
Back of cart
\Upper FrontPane
16•464321607and464321407

DWheelsand Leg Extenders to Cart
" Turn assembly upside down,
*insertaxle rod intowheel, legs, spacersandotherwheel. Attach with (1) _8flat washerand hitch pin.
* Pushleg extenders into right legs.
@ ©
Spacer HitchPin
Qty:2 Qty:1 (_
8ramFiatWasher
Qty:1
LegExtenders
AxleR,ed /Wheat
"Cone" side of wheelagainst leg
464321607and464321407°17

Grill Headto Cart
•Standcartupright.
"Thissteprequirestwo peopleto lift andposition grill headontocart.
" Carefullylowerthe grillheadontothecart.Makesurethe regulatorhoseishangingoutsidethe cart.Attachwith (4)
1/4-20x1/2"screws,7ramfiat washers,7ramlockwashers.
®
GrillHead 1/4-20xl/2"Screw
Qty:4
©
@ ®
7mmFlatWasher 7mmLockWasher
Qty:4 Qty:4
18• 464321607and464321407

Rightand LeftSideShelves
"Hooksidewall ofshelf oversupport bracketsonside offirebox (A).
• insidefirebox insert(4)fiber washersand (4)1/4-20x1/2"screws asshown(B).
• Attachshelf using(2)flange nutsoneachside.(C). (_)
•Repeatthesamestepsfor left shelf. 1/4-20FlangeNuts
Qty: 8
®
7ram Fiber Washers
Qty: 8
®
1/4-20xl/2" Screw
Qty:8
RightSideShelf
B29 28
Back of Cart
D RightFascia
"Attachfasciatofireboxwith(2)#8x3/8"self-tapscrew
" Repeatthesamesteptoattachleftfascia.
®
#8x3/8"Self-TapScrew
Qty:4
RightFascia
35
464321607and464321407•19

Heat Tents
•Place heattents over burners by inserting tabs into slots in front of firebox.
Opposite ends of heattents reston pins in back of firebox.
Pin
Cooking Grate
" Place cooking grates onto grate rests.
CookingGrate
20. 464321607 and464321407