Kenmore 415.165059 User manual

Use and Care Guide
®
LiquidPropaneGasGrill
KenmoreModelNo.415.16505900
Kmart itemNo.640-t 75289tt5
This Grill isfor OutdoorUseOnly
•Read and follow all Safety, Assembly,
and Use and Care instructionsin this
Guide before assembling and 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
AssemblyQuestions.'?
Callt-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 464722309•464722509• 80017881• 11-24-08

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 manufacturer and not a Sears
employee. Toorder new parts call Sears at 1-800-4-MY-HOME®.
Product Record
IMPORTANT:Fillouttheproductrecordinformationbelow.
Model Number
Serial Number Seeratinglabelongrillforserialnumber.
Date Purchased
CALIFORNIA PROPOSITION65
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. A conversion kit mustbe
purchased for use with naturalgas.
•Grill installation must conform with local codes, or in their
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.
• This grill issafety certified for use in the 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.
To InstalledAssembler: Leave these instructionswith
consumer.
To Consumer: Keep this manual for future reference.
CAUT,o. /K
,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.
DANGER: Indicatesan imminentlyhazardous situation
which, if not avoided,will result in death or serious injury.
WARNING: Indicatesan potentiallyhazardous situation
which, if not avoided, could result in death or serious injury.
CAUTION
CAUTION: Indicatesa potentially hazardoussituationor
unsafe practicewhich, if notavoided, may result in minor
or moderateinjury.
2,464722309,464722509

For Your Safety...................................... 2
Grill Service Center................................... 2
Product Record Information ............................ 2
Safety Symbols...................................... 2
Installation Safety Precautions .......................... 2
Kenmore Elite Grill Warranty ........................... 3
Use and Care .................................... 4-10
Parts List .......................................... 11
Parts Diagram...................................... 12
Assembly ....................................... 13-24
Troubleshooting.................................. 25-27
Repair Protection Agreements
Congratulations on making a smart purchase. Your new
Kenmore®productisdesigned 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.
Purchase a Repair ProtectionAgreement now and protect
yourself from unexpected hassle and expense.
Here's what the Repair ProtectionAgreement* includes:
171 Expert service by our 10,000 professional repair specialists
[] Unlimited service and no charge for parts and labor on all
covered repairs
[] Product replacement up to $1500 ifyour covered product
can't be fixed
[] Discount of 10% from regular price of service and related
installed parts not covered by the agreement; also, 10% off
regular priceof preventive maintenance check
[] Fast help by phone -we call it Rapid Resolution-
phone support from a Sears representative.Think of us
as a "talking owner's manual."
Once you purchase the Repair ProtectionAgreement, a simple
phone call isall that it takes for you to schedule service. You can
call anytime day or night, or schedule a service appointment
online.
The Repair ProtectionAgreement isa risk-free purchase. Ifyou
cancel for any reason duringthe product warranty period, we will
provide a full refund. Or, a prorated refund anytime after the
product warranty period expires. Purchase your Repair
ProtectionAgreement today!
Some limitations and exclusions apply.
For prices and additional information call 1-800-827-6655.
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. 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).
Three-Year Limited Warranty on Burners
Forthree 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 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 legalrights, and you may
also have other rights which vary from state to state.
Sears, Roebuck and Co., Hoffman Estates, IL 60179
464722309,464722509,3

LP Tank
•NEVERstore aspare 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 handonly - 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 andstrap supplied with valve.
Failure to use safety cap as directed may result in serious
personal injury and/or property damage.
LP Tank Valve
Salty Cap
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.
4,464722309,464722509
*The LP tank used with your grill must meet the following
requirements:
*Use LP tanks only 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 markedin accordance with
specifications for LP tank of the U.S. Department of
Transportation (DOT). See LP tank collar for marking.
*LPtank valve must have:
,Type 1 outlet compatible with
regulatoror grill.
,Safety reliefvalve.
,UL listed Overfill Protection OPDHandWheel
Device (OPD). This OPD safety
feature is identified by a unique triangular hand wheel. Use
only LP tanks equipped with this type of valve.
•LPtank must be arranged for vapor withdrawal and include
collar to protect LP tank valve.
LP cylinder 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 flammableand may ignite unexpectedly when
mixedwith air.
LP Tank Filling
*Useonly licensed and experienced dealers.
*LPdealer must purge tank before filling.
*Dealer should NEVER fill LP tank more than 80% of LP tank
volume. Volume of propane in tank will vary by temperature.
*Afrosty regulator indicates gas overfill. Immediatelyclose LP
tank valve and call local LP gas dealer for assistance.
,Do not releaseliquid propane (LP) gas into the atmosphere.
This is a hazardous practice.
,To remove gas from LP tank, 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 cylinders. Exchange your tank only for
an OPD safety feature-equipped tank as described inthe
"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.Turn all control knobs to the OFF position.
3.Turn LP tank OFF byturning OPD hand wheel clockwiseto a
full stop.
4.Remove the protective cap from LP tank valve.Always use
cap and strap supplied with valve.
LP Tank Leak Test
For your safety
•Leak test must be repeated each time LPtank isexchanged or
refilled.
*Do notsmoke during leak test.
*Do notuse an openflame 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 regulatorand 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.
464722309.464722509.5

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 handwheel
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 areaswhere bubbles are shown in
picture below:
6.Turn the coupling nut clockwiseand tighten to a full stop. The
regulatorwill seal onthe back-checkfeature inthe LP tank
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 arestill unable to completethe
connection, do not use this regulator!
A Neverremovethreaded
orifice atend of valve.
Do not insertany tool or foreignobject intothe valve
outlet or safety relief valve. You may damagethe valve
and cause a leak. Leaking propane mayresult in
explosion,fire, severepersonal injury,or death.
5.If "growing" bubbles appear, 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.
Outdoorgas appliance is not intendedto be installed
in or on a boat.
Outdoorgas appliance is not intendedto be installed
in or on an RV.
. Never attemptto attach this grill to theself-contained
LPgas system of a campertrailer or motorhome.
. Do not use grill until leak-tested.
. If a leak is detectedat any time, STOPand callthe fire
department.
. If you cannotstop a gas leak,immediately close
LPcylindervalve and call LPgas supplieror yourfire
department!
6,464722309,464722509

zL zL
For Safe Use Of Your Grill And To Avoid Serious
Injury:
*Do notlet children operate or play near grill.
•Keep grill area clear and free from materialsthat burn.
•Do notblock holes in bottom or back of grill.
•Check burner flames regularly.
•Use grill only inwell-ventilated space. NEVER use in
enclosed space such as carport, garage, porch, covered
patio, or under an overhead structure of any kind.
•Do notuse charcoal or ceramic briquets in a gas grill.
(Unless briquets are supplied with your grill.)
•Use grillat least 3ft. from any wall or surface. Maintain
10 ft. clearance to objects thatcan catch fire or sources of
ignitionsuch as pilot lights on water heaters, live electrical
appliances, etc.
•Apartment Dwellers:
Check with management to learn the requirements and fire
codes for using an LP gas grill in your apartment complex. If
allowed, use outside on the ground floorwith a three (3) foot
clearance from walls or rails. Donot use on or under
balconies.
•NEVER attempt 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
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 If the outdoor cooking gas appliance is not in use, the gas
must be turned off at the supply cylinder. Storage of an
outdoor cooking gas appliance indoorsis permissible only if
the cylinder is disconnected and removed from the appliance.
,& Never move grill while in operation or still hot.
,& Use long-handled barbecue utensils and oven mitts to avoid
burnsand splatters.
,& Maximum load for side shelves is 10 Ibs.
,& The grease cup must be inserted into grease clip and
emptied after each use. Do not remove grease cup until grill
has completely cooled.
,& Clean grill often, preferably after each cookout. If a bristle
brush is used to clean any of the grill cookingsurfaces,
ensure no loose bristles remain on cooking surfaces prior to
grilling. Itis not recommendedto clean cookingsurfaces
while grill is hot.
,& 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.
,& The regulator may make a humming or whistling noiseduring
operation. This will notaffect safety or use of grill.
,& Onlyuse the pressure regulator and hose assembly supplied
with this grill. Replacement pressure regulator and hose
assemblies must be specified or supplied by Char-Broil, LLC.
,& If you have a grill problem see the "Troubleshooting Section".
,& If the regulator frosts, turn off grill and LP cylinder valve
immediately.This indicatesa problemwith the cylinder and it
should notbe used on any product. Return to supplier!
CAUTION
Putting out grease fires by closing the lid is not
possible. Grills are well ventilated for safety
reasons.
Do not use water ona 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.
464722309,464722509,7

Main burner ignitor Lighting
ADo not lean over grill while lighting.
1. Open lid during lighting.
2. TurnON valve from source or tank.
3. Push and turn Ignition Burner control knob to _ HI and
immediately press and hold Electronic Ignition button.
4. If ignition does NOT occur in 5 seconds, turn Left Burner
control knob OFF, wait 5 minutes, and repeat the lighting
instructions.
5. ToLight Main Burner,turn controlknob to HI.
If ignitor does not work, follow match lighting instructions.
After Lighting: Turn knobs to HI position for 15 minutesto pre-
heat grill.Then turn knob to desired setting for cooking.
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, if the burner does not ignite with
the valve open, gas will continue to flow out of the burner
and could accidentally ignite with risk of injury.
Match-Lighting
A Do not lean over grill while lighting.
1. Open lidduring lighting.
2. Place match into match holder (hanging from side of cart).
3. Push in and turn left knobto ,,¢ HI position. Be sure burner
lights and stays lit.
4. Light right burner by pushing knob in and turning to_ HI
position.
Sideburner Ignitor Lighting
,A,Donot leanovergrill whilelighting,
1.Open lidor coverfor Side Burnerduring lighting.
2. TurnON valvefrom sourceor tank.
3. Push and turn Side Burnercontrolknob to,C. HI and
immediatelypress and hold Electronic Ignitionbutton.
4. Ifignition does NOToccur in 5 seconds,turn Side Burner
controlknob OFF, wait 5 minutes, and repeatthe lighting
instructions.
Ifignitordoesnotwork,followmatchlightinginstructions.
AfterLighting:TurnknobstoHI positionforwarm-up.
Sideburner Match Lighting
1. Turn OFF all burner control valves.
2. Open sideburner lid(if equipped).
Turn on gas at LP cylinder.
3.Place lit match near burner.
4.Turn sideburner knobto
,,¢ HI. Be sure burner
lights and stays lit.
Before Your First Cookout
•Light burners, check to make sure they are lit, close the lid and
warm up grill on HIGHfor 15 minutes. This curing of paint and
partswilt produce an odor only on first lighting.
Burner Flame Check
•Light burner, rotateknobs 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 using grill. Use only
valve/hose/regulator specified in the Parts List.
Normal Kinked
Hose Hose
CAUTION
•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 grill has not been
regularly cleaned, a grease fire can occur that may
damage the product. Follow instructionson General
Grill Cleaning and Cleaning The Burner Assembly to
prevent grease fires.
8,464722309 o464722509

Turning Grill Off
•Turn all knobs to OFF position.Turn LP tank off byturning
OPD handwheel clockwise to a full stop.
Ignitor Check
•Turn gas off at LP tank. Press and hold ignitor button. "Click"
should be heard and spark seen each time between collector
box or burner and electrodes. See "Troubleshooting" if no click
or spark.
Valve Check
•important: Make sure gas is off at LP tank before checking
valves. Knobs lock in OFF position. Tocheck valves, first
push in knobs and release, knobs should spring back. If knobs
do not spring back, replace valve assembly before using grill.
Turn knobs to LO position then turn back to OFF position.
Valves should turn smoothly.
General Grill Cleaning
•Keepthe outside of your grill looking new by cleaning it once a
month with warm soap and water or a non-abrasive cleaner. If
you don't havea grill cover, wipe off dust and grime before
starting your grill.
• Coating the cooking gridswith spray-on cooking oil will keep the
food from sticking and make clean up easier.After cooking,
scrape the grates with a long handled, brass wire bristle brush.
•Check inside the grill bottom for grease build upand clean
often, especially after cooking fatty meat.
•Do not mistake brown or black accumulation of grease and
smoke for paint. Apply a strong solution of detergent and water
or use a grill cleanerwith scrub brush on insides of grill lidand
bottom. Rinse and allow to completely air dry. Do not apply a
caustic grill/oven cleanerto painted surfaces.
•Plated wire grates: Wash grates with concentrated grill
cleaner or use soap and water solution. Dry thoroughly and
store indoors between cookouts.
• Plastic parts: Wash with warm soapy water and wipe dry.
,A. Do not use citrisol, abrasive cleaners, degreasers or a
concentrated grill cleaner on plastic parts. Damage to and
failure of parts can result.
•Porcelain grates: Because of glass-like composition, most
residue can be wiped away with baking soda/water solution or
specially formulated cleaner. Use non-abrasive scouring
powder for stubborn stains.
•Painted surfaces: Wash with mild detergent or nonabrasive
cleaner and warm soapy water.Wipe dry with a soft
nonabrasive cloth.
•Stainless steel surfaces: Tomaintain your grill's high quality
appearance, wash with mild detergent and warm soapy water
and wipe drywith a soft cloth after each use. Baked-ongrease
deposits may require the use of an abrasive plastic cleaning
pad. Use only in direction of brushed finish toavoid damage.
Do not use abrasive pad on areas with graphics.
• Cooking surfaces: If a bristle brush isused to cleanany 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.
cAuT,o.
SPIDER ALERT!
GAS COLLECTOR
VALVE AIR VENTURI
SHUTTER
Ifyou notice thatyour gri// is getting hard to light or that the
flame isn't asstrong as itshou/d be,take the time to checkand
dean theventuri's.
LIFTOUT
BURNERASSEMBLY
REMOVE
BURNER
CLIPS
CLEANOUT SPIDER WEBS
VENTUR] INSIBEVENTURI
Insomeareasofthecountry,spidersor smallinsectshavebeen
knowntocreate"flashback"problems.Thespidersspinwebs,build
nestsandlayeggsin thegrill'sventuritube(s)obstructingtheflowof
gastotheburner.Thebacked-upgascanignitein theventuribehind
thecontrolpanel.Thisis knownasa flashbackanditcandamage
yourgrilland evencauseinjury.
Topreventflashbacksandensuregoodperformancetheburnerand
venturiassemblyshouldberemovedfromthegrilland cleaned
beforeusewheneverthegrillhasbeenidleforanextendedperiod.
,,. j
Storing Your Grill
• Clean cooking grates.
• Store indry location.
• When LP tank is connected to grill, store outdoors in well-
ventilated space and out of reachof children.
• Cover grill ifstored outdoors.
• Store grill indoors ONLYif LP tank is turned off and
disconnected, removed from grill and stored outdoors.
• When removing grill from storage follow "CleaningBurner
Assembly" instructions before starting grill.
464722309,464722509.9

Cleaning the Burner Assembly
Follow these instructions to clean and/or replace parts of burner
assembly or if you have trouble ignitinggrill.
1. Turn gas off at control knobs and LP cylinder.
2. Remove cooking grate and heattent.
3. Under grill remove grease cup, disconnect ignitorwire from
burner.
4. Inside grill remove burner assembly (A), clean ceramic
portion of electrode with rubbing alcohol and a swab.
5. Clean outside of burnerwith soap and water. Lay burner
upside down on flat surface, insert garden hose to force
water through tubes. Make sure water comes out of all
burner holes. Open clogged holes with a thinwire. Shake
out excess water and examine holes. Due to normal wear
and corrosion some holes may become enlarged. Ifany
large cracks or holesare found replace burner.
6. If grill is to be stored, coat burner lightly with cooking oil.
Wrap in protective cover to keep insects out.
7. If notstoring grill after cleaning, replace burner intogrill
bottom.
VERY IMPORTANT: Burner tubes must re-engage valve
openings. See illustration (A).
8. Reattach ignitorwire to electrode.
9. Reposition heat tent and cooking grate. Reattach clean
grease cup to grease clip.
10. Before cooking again on grill, perform a "Leak Test'and
"Burner Flame Check".
Correctburner-to-valveengagement
A
BurnerTube
Valve
13
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
beforeand after handling raw meatand 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 kill bacteria. Use a
thermometer to ensure proper internalfood temperatures.
Chill: Refrigerate prepared foods and leftovers promptly.
For more information call: USDA Meatand Poultry Hotline 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 middlewith 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 ofAc ricutture
10,464722309 °464722509

1 2 UPPER SUPPORT, F/ LEGS 80009811
2 1 LEG (WHEEL), LEFT, FRONT, 80009831
CURVED
3 1 LEG (WHEEL), LEFT, BACK, 80009830
STRAIGHT
4 1 SIDE BRACE F/TANK 80009815
RETAINER BRACKET
5 2 BRACKET, TANK SUPPORT 80009834
6 1 LEG, RIGHT, FRONT, CURVED 80009819
7 1 LEG, RIGHT, BACK, STRAIGHT 80009822
8 2 LEG EXTENDER, PLASTIC 80009820
9 1 FRONT PANEL MAGNET 80018416
10 1 UPPER FRONT PANEL, 80017873
FOLDING
11 1 LOWER FRONT PANEL 80018420
12 1 TOP BRACE, F/ FOLDING 80018422
PANEL
13 2 BACK BRACE 80009833
14 2 TANK EXCLUSION WIRE 80017474
15 2 WHEEL 80010191
16 1 AXLE ROD 80009835
17 1 CONTROL PANEL, MAIN 80017872
18 1 SUPPORT, FIREBOX, LEFT 80009838
19 1 SUPPORT, FIREBOX, RIGHT 80009839
20 1 VALVE\HOSE\REGULATOR 80018095
ASSY
21 1 ELECTRONIC IGNITION 80014484
MODULE
22 1 BUTTON, F/ ELECTRONIC 80014444
IGNITION MODULE
23 1 HEAT SHIELD, F/ELECTRONIC 80014458
IGNITION MODULE
24 1 HEAT SHIELD, F/TANK 80009837
25 1 RETAINER, TANK 80007961
26 1 FRONT PANEL HANDLE 80017878
27 1 CONDIMENT BASKET 80017877
28 1 BURNER, MAIN 80017864
29 1 COLLECTOR/ ELECTRODE 80012227
ASSY
30 1 FIREBOX 80017862
31 3 CONTROL KNOB 80000035
32 1 MOUNTING BRACKET, F/ 80017921
PLASTIC SIDE SHELF, BACK
33 1 MOUNTING BRACKET, F/ 80017920
PLASTIC SIDE SHELF, FRONT
34 1 RIGHT SIDE SHELF 80012073
35 1 MOUNTING BRACKET, F/SB 80009809
SHELF, BACK
36 1 MOUNTING BRACKET, F/SB 80009810
SHELF, FRONT
37 1 LEFT SIDE SHELF F/SB 80017870
38 1 MATCH HOLDER 80004320
39 1 DRIP PAN, F/SB 80006246
40 1 SIDEBURNER 80013817
41 1 ELECTRODE W/WIRE, F/ 80017658
SIDEBURNER
42 1 BURNER CLIP F/SIDE BURNER 80011110
43 1 LID, F/SIDEBURNER 80013818
44 1 SIDEBURNER GRATE 80009728
45 2 HINGE, LOWER, F/TOP LID 80009944
46 1 HANDLE, F/TOP LID 80009845
47 2 HINGE, UPPER, F/TOP LID 80010091
48 1 TOP LID 80017867
49 1 LOGO PLATE 80018437
50 1 HEAT DIFFUSER 80017876
51 1 COOKING GRATE 80009841
52 1 SWINGAWAY GRID 80009825
53 1 CLIP, F/GREASE CUP 80000271
54 1 GREASE CUP 80000270
NOT Pictured
... 1 HARDWARE PACK 80017880
... 1 ASSEMBLY MANUAL, ENGLISH 80017881
... 1 ASSEMBLY MANUAL, SPANISH 80018593
If you are missing hardware or have damaged parts,
please call 1-800-241-7548for replacement.
464722309°464722509oll

47
52
46
43
39
30,,,,__
25,._
36
15
14
38,,_
_,2
24
23
31
11
12°464722309°464722509
\

f
g Left Leg
i Placeoneupperlegasshown. NOTE:Leftfrontandleftbacklegsdonothavelegextenders.Infront,attachupperleg,side
braceandleftfrontleg(curve)with#10-24x1-1/4"screw and#10-24flange nut.Tighten screws. Inback,attachupperleg,side
braceandleftbackleg(straight)with #10-24x1-1/4"screwand#10-24flange nut. Donottighten.
i Attachsupportbracketinsecondholefrombottomof legwith hingepinsandhitchpins(A).
Upper Leg
Hitch Pin
Qty.2
Hinge Pin ,SideBrace
Qty.2 Left Back Leg _ /"
/
(Straight) :: /
\
Hitch Pin
i
/
/
i
/#10-24x1-1/4"
Machine Screw
Qty.2
Srac/ et
Hinge Pin
Front Leg
(Curve)
#10-24
Flange Nut
Qty.2
Right Leg
i Placeotherupperlegasshown.Attachupperlegand rightfrontleg(curve)with#10-24x1-1/4"screw and#10-24flange nut.
Tighten screws.
i Attachsupportbracketwith#10-24x1-1/4"screws and#10-24flange nuts.
Per Leg
Right Back Leg
(Straight)
\
Leg Extender
°rt Brac/ et Right Front Leg
(Curve) #10-24x1-1/4"
Machine Screw
Qty.3
#10-24
Flange Nut
Qty. 3
464722309,464722509,13

Upper and lower Front Panel and Top brace
j Layfront legs down on thefloor. Fit upper front panel between legs.Attach with 2" hinge pins and hitch pins.
iAttach lower front panel with #10-24x2" machine screws and #10-24 flange nuts.
Attach top brace with #10-24x2" machine screws and #10-24 flange nuts.
#10-24
Flange Nut
Qty. 8
Right leg
HitchQty.Pin2 assem_ Left leg
assembly
#10-24x2"
Machine Screw 2" Hinge Pin
Qty.8 Qty.2
#10-24x2"
Machine Screw
/
Hitch Pin
f
LowerFront Panel
Topbrace
Pin
2" Hinge Pin
#10-24x2"
Machine Screw
Back Brace to Cart
Removepreviouslyattachedscrewsandnutssecuringtheupperlegandsidebraceasnotedbelow.Attachupperandlowerback
braceswith#10-24x1-1/4"screws and#10-24flange nuts.
BackBrace
#10-24x1-1/4"
Machine Screw
Qty.7
(One re-used) Note:
Removepreviously installed
screw and nut from location
shown to attach upper back brace.
#10-24
Flange Nut
Qty.7
(One re-used) BackBrace
#10-24x1-1/4"
MachineScrew
14°464722309°464722509

Tank Exclusion
Hank tank exclusion wiresonto lower front panel brackets,attach other ends to back bracewith #8-32X3/8" sheet metal
screws.
#8-32X3/8"
Sheet Metal Screw
Qty.2
BackBrace
Wheels
Turnassemblyupsidedown.
i_ Insertaxlerodthroughwheel, legsand otherwheel. Attachwith awheel bushingand hitchpin.
Axle Rod Wheel
Hitch Pin Wheel Bushing
Qty.1 Qty.1
"Cone" side ofwheel against leg
./
Wheel Wheel Bu:
Hitch Pin
/
/
464722309°464722509,15

Control Paneland Firebox Support
_] Standcart upright.
In front, fit control panel between left and right legs. Insert#10-24x2" machine screws to hold panel in place. Place upper
firebox supports onto screws makingsure angle side is facingthe front and attachwith # 10-24 flange nuts.
In back, attach upper firebox support with #10-24x2" machine screws and # 10-24 flange nuts.
AngleEdge
Control panel
#10-24x2"
MachineScrew
f
f
#10-24x2"
MachineScrew
Qty.8
Left firebox
support
#10-24
FlangeNut
Qty.8
Valve/Hose/Regulator and Ignitor
Attach valve/hose/regulator assembly to control panel using #10-24xl/2" machine screws.
_ Remove ignitor cap and plastic hex nut from Electronic Ignition Module assembly. Insert module into the opening on
control panel and attach with the removed hex nut. PlaceAAA battery into module slot with positiveend (+) facing
outward. Screw ignitor caponto module.
...............Button
#10-24xl/2"
Machine Screw
Qty.2 Valve/Hose/Regulator
Assembly ............
16,464722309 °464722509

Heat Shield
Attachheatshieldwith #10-24xl/2" machinescrewsand #10-24flange nuts.
Tank Retainer
Inserttank retainerintosidebraceandsecurewith #10-24x3/8" wing screw.
#10-24xl/2"
Machine Screw
Qty.2
#10-24
Flange Nut
Qty.2
eatshield
#10-24x3/8"
Wing Screw
Qty.1
...........#10-24x3/8"
Wing Screw
Tank retainer......
Front Panel Handleand Condiment basket
Attachfront panel handletoupper frontpanel using#10-24flange nuts(A).
Attachcondiment baskettoupperfront panelasshown ( B).
#10-24
A Flange Nut
Qty.2
Front panel
handle
i
i
i
B
Condiment................
basket
464722309,464722509,17

Burner and Firebox and Control Knobs
Placeburner assembly into firebox. Fasten the burner assembly to the firebox using 5x15 fiberwashers and#10-24xl/2"
machine screws (A).
i Inside firebox, insert heat diffuser supports with 5x15 fiberwashers to firebox through sides of firebox, then securewith
#10-24 flange nuts on outside offirebox (A).
Place firebox on cart. Makesure burner tubes are correctly engaged with valves. If burner is not level from left to right,
adjust the two screws attaching valve to control panel.Attach ignitor wire to ignitor( B ).
ii Attach firebox with #10-24x2" machine screws, 5x15 fiber washers and #10-24 flange nuts ( C ).
Push control knobs onto valve stems ( C ).
ABurner assembly Firebox
j" #10-24 5xl 5
Flange Nut FiberWasher
Qty.8 Qty.10
@
\
\Heat diffuser
support
Heat shield
for Tank
#10-24Xl/2" Heat diffuser Support
Machine Screw Qty.4
Qty.6
Valve...........
Control Knob
Makesure the burner tubes are located
underneath Heat Shield
C
18,464722309 °464722509

Right Side Shelf and Side Burner Support Shelf
I ] Attach mounting brackets to Right SideShelf with #8-32x3/8" sheet metal screws and side shelf bushings (A). Note: Do
not overtighten the screws.
Insert mountingbrackets intoSide Burner Shelf Support, and secure with #10-24x1/2" machine screws (B).
;_]Attach Right SideShelf and Side Burner Support Shelf to front of legwith 1/4"-20x1/2" machine screws. Back of leg with
114"-20x1-114"machine screws and 1/4"-20 flange nuts.
AB
Side Shelf Bushing Mounting Bracket
e-.\.
i SideShelfSupport
!"
#8-32X3/8"
Sheet Metal Screw
Qty.4
Side Shelf Bushing
Qty.4 C
1/4"-20
Flange Nut
Qty.4
#10-24Xl/2"
Machine Screw
Qty.4
1/4"-20x1-1/4"
Machine Screw
Qty.4
1/4"-20xl/2"
Machine Screw
Qty.4
464722309°464722509o19

Sideburner
[ Attach sideburner valve with #8-32x3/8" machine screws.Attach sideburner panwith #8-32x3/8" sheet metal screws and
5x9 fiber washers (A).
Placesideburner intoshelf (B). Make sure valve is insidesidebumer tube (C).Attach sideburner with #8-32 wing nut and
5x9 fiber washer (B).
Hook burner clipto sideburner tube and around manifold.Attach sideburner ignitorwire. (C)
i_ Attach sidebumer lid to back of shelf with #10-24x1/2" machine screws and #10-24 flange nuts. Press control knobonto
valve stem and sideburner grate onto shelf. (D)
#8-32X3/8" #8-32
Machine Screw Wing Nut #10-24Xl/2" #10-24 5x9 Sideburner Clip
Qty.2 Qty.1 MachineQty.4ScrewFlangeQty.4Nut FiberQty.4Washer Qty.1
!'
#8-32X3/8"
Sheet Metal Screw
Qty.3
#8-32x3'8"
5x9 Sheet Metal Screw
J
Fiber Washer,,[. A 5
Sidebumer..................,J,
B
Correctly assembled burner-to-valve engagement
D
CSideburner..........,v
Lid
Sidebumer Grate
"%
SicteburnerValve
Sideburner Clip Control
20,464722309,464722509