Kenmore 920.16201 User manual

Assembly Instructions
Liquid Propane Gas Grill
FLAVOR
Models: 920.16201, 920.16203
EngineeringCodes:KCKt1645- KCK11625
No Tools Required
/'_ CAUTION:
Assemblerllnstallerleavetheseinstructions
withthe consumer.
Consumer/Userreadall theseinstructions
and keepthem ina safe placeforfuture
reference.
•Easy Assembly Instructions
•Important Warranty Information
• Safety and Maintenance Tips
/_WARNING:
Units not equipped with a side burner
CANNOT BE converted to a Side
Burner unit. If a conversion is attempted
the warranty will be voidr
114122420209
Sears, RoebuckandCo.,Hoffman Estates,IL 60179U.S.A.

Table of Contents Page
Hazard Statements ............... 2
Hardware ...................... 2
Product Packaging ............... 3
Assembly Instructions .......... 4-13
Parts Diagram ................. 14
Parts List ..................... 15
Before Use Information ........... 15
Service Numbers ........ Back Cover
Hazard Statements
//_ WARNING:
The edges of sheet metal parts can cause
injury if not handled with care.
USE EXTREME CAUTION!
,_k WARNING:
Combustion by-products produced when
using this product contains chemicals
known to the State of California to cause
cancer, birth defects, or other reproductive
harm.
Z_ WARNING:
To ensure proper gas flow, burner control
valves must be "OFF" before opening the
gas cylinder valve.
//_ WARNING:
Units not equipped with a side burner
CANNOT BE converted to aSide Burner
unit. If a conversion is attempted the
warranty will be void!
/'_ IMPORTANT:
Your grill may not have all the parts
shown. Please refer to the back of these
instructions for a listing of parts for your
specific model of grill.
11412242 (rig. 2)
Hardware
Frame
Front Basket
Assembly for
Model
920.16203
Front
Handle
Assembly
DU
(10)
(32500198)
1/4-20X 2"
CarriageBolt
DM
(2)
(32500197)
10-24x I 3/4
CarriageBolt
Frame
Assembly
Z) (10)
(32500179) (00402371)
10-24x3/4 114-20
CarriageBolt StarWasher
MR
Grill Lid
Grill Lid and Burner
Assembly
NO
132300112)
Hinge Pin T(00402507)
HairPin
Frame Front Handle
Assembly and Front Basket
Assembly
DZ
(10) (4)
(32700101) (32700132)
114-20 t0-24
Wing Nut WingNut

Carton Contents
Note: not all parts are shown in
illustration.
Model920.16201
1AssemblyInstruction
Useand Care Manual
HardwarePackage(seepage2, Hardware)
IgniterPackage
LargeHardwarePackage
FrameKitBox
BaseAssembly
ControlPanelAssembly
HeatShield
BottomCasting
TopCasting
Burner
Handle
HeatTent
CookingGrid
BottomWarmingRack
FrontBasket
CyfinderWire
2-SplashShields
2 Sidetables
2-BasketEndCaps(left and Right)
Model920.16203
1-AssemblyInstruction
Useand CareManual
HardwarePackage(seepage2, Hardware)
IgniterPackage
LargeHardwarePackage
FrameKitBox
SideBurnerKit Box
BaseAssembly
ControlPanelAssembly
HeatShield
BottomCasting
TopCasting
Burner
SideBurner
Handle
HeatTent
CookingGrid
BottomWarmingRack
TopWarmingRack
FrontBasket
Side Basket
CylinderWire
Sidetables
2-SplashShields
2-BasketEndCaps(leftandRight)
FrameKit
Top
for model
920.16201)
11412242 (Pg, 3)

Assembly instructions
I MPORTANT: Duringassembly,referto PartsDiagramand PartsListson pages14and 15.
Step 1
Open the Frame Kit,
Remove Legs (4 and 13), 2 carriage bolts (DU) and 2wing nuts (CP).
Locate the Base Assembly (1), Bottom
Casting (42) and Grease Can Wire nmiddleholes
(49) for assembly in this step.
1a-Insert Legs (4 and 13) and
align middle holes, Figure 1.
Ib-Lower legs at the same
time onto the Base Assembly
(t). Snap into place, Figure 2.
Correct Incorrect
1 C- Place the Iocator pins on the
Bottom Casting (42) into the
alignment holes on the legs.
Secure with 2 carriage bolts (DU),
2star washers and 2 wing nuts
(CP), Figure 3.
1d-Placethe Grease Can Wire (49)
into the Bottom Casting, Figure 4.
Note: Grease can not included.
Use an ordinary soup can.
Locatorpins
3
•!•!
|
4
11412242 (Pg.4)

Step 1
DU
ld !
DU 42
i
CP
4
13
lc
11412242 (Pg 5)

Step 2
Remove the remaining parts from the Frame Kit: 4 Side Supports (11), 8carriage
bolts (DU), and 8 wing nuts (CP).
Locate 1 or 2 Sidetable(s) (9), Control Panel (25), 2 Control Knobs (32), and Side
Burner Kit, if needed, for assembly in this step.
2a-insert 2 Side Supports (11)
inside the Sidetable (9) until the
tabs on the Sidetable snap into
the notches, Figure 1.
2b-Loosely attach the
Sidetable assembly to the
leg with 3 carriage bolt
(DU), 3 star washers and
3 wingnuts (CP), Figure 2.
2C-If the grill has two side tables,
repeat steps 2a and 2b.
If the grill has a side burner, attach
the 2remaining Side Supports
(11) as described in 2b. Assemble
the side burner components per
the assembly instructions located
in the side burner kit.
2
DU
CP
_P
ID w
IMPORTANT:Model920.16201cannot
be convertedtoa SideBurnerunit.If a
conversionis attemptedthewarrantywill
be void!
2d-Remove the 4 wingnuts (CP), 4
star washers (MR) and 4 carriage
bolts (DU) from the back legs
and side supports. Place the Back
Brace (10) inside the two back legs
and secure with the carriage bolts,
star washers and wingnuts, Figure 3.
11412242 (Pg 6)
of grill

Step 2
2a
2e-Slide the Control Panel
Assembly (25) over the
front legs. Place the
notch on the Control
Panel between the leg
and head of the carriage
bolt. Secure the top hole
to the legs with 2
carriage bolts (DU), 2
star washers (MR) and 2
wing nuts (CP). Place
the 2 Control Knobs
(32) onto the valve
stems, Figure 4.
11
2c
25
11412242(Pg. 7)

IN.p3
Locate the Burner (43),Heat Shield (47a), Collector Box (44), 2 Splash Shields (45),
Igniter package, Top Casting (55), Handle (58), Nameplate (56), Heat Tent (61), and
Cooking Grid (63).
3a.Place the Heat Shield (47a) over
the valve offices, Figure 1.
Note: The Heat Shield slides
onto the Valve. The Burner will
hold the Heat Shield in place.
3b- Clip the Collector Box (44) into
place on the Burner (43). The
Notch fits over the burner edge,
Figure 2.
3C-Set the 2 Splash Shields (45) over
the two oval holes in the Bottom
Casting. Place the Burner into the
bottom casting, aligning the Venturi
Tubes over the valves. Secure
burner with 2 hair pins (WO), Figure
Backview 2
Important: Position the Burner
Venturi Tubes over the valve
orifices. The orifices must be
visible through the venturi tube's
air openings.
11412242 (Pg 8)
3
43 x

3d-Push the Main Burner Wire (26b)
onto the back of the Push Button Igniter
(26). Snap the Igniter into the Control Panel,
Figure 4.
The main Burner wire attaches to the
main burner electrode; see figure A.
The Electrode Tip is located on the Burner
assembled in the bottom casting; see figure B.
For the Side Burner igniter use assembly
instructions found in the Side Burner Kit.
26b
4
26
Test the Igniter:
(See Use and Care Manual)
If the spark does not appear:
- Check the wire connection to the Igniter.
- Check the Collector Box electrode installation
to the main burner.
3e-Snap the Nameplate (56) into the Top
Casting (55).
Attach the Handle (58) to the Top Casting
with 2 screws (SB) and 2 wing nuts (DZ),
Figure 5.
3f- Attach the Top Casting assembly to
the Bottom Casting with the 2 clevis
pins (VE) and 2 hair pins (WO). Place
the Heat Tent (61) and
Cooking Grid(s) (63)
into the Bottom
Casting, Figure 6. 55
Z_ CAUTION: This
grill is equipped with a
Heat Tent, DO NOT
use Lava rock or
ceramic briquettes.
558
6
VE
11412242 (Pg. 9)

8telp 4
Locate Warming Rack(s) (65 and 66), and 1 Side Basket (80, for model 16203).
4a-Place the Warming Rack (65) into the Top Casting first, then lower and insert the
pivot wires into the Bottom Casting. To center the rack, slightly bend the pivot
wires to adjust for a tight fit.
Model 920.16201]
4a-Place the Warming Rack (65) into the Top Casting first, then lower and insert the
pivot wires into the Bottom Casting. Place the Top Warming Rack (66) into the
Top Casting first, then lower and insert the pivot wires into the bottom warming rack.
Model 920.16203
11412242(Pg. 10)

4b-Model 16203 only: Insert the Side Basket (80) into the left legs.
11412242 (Pg. 11)

Stops
Locate Front Basket (22), Basket End Caps (22a and 22b) and Cylinder Wire (78).
5a-Assemble the Front Basket; see figures 1 thru 3.
l-Insert wire hook of the Front Basket 2-Rotate the basket end cap up and
(22) into Basket End Cap (22a) lower insert other wire. Repeat for (22b).
hole, and rotate to secure wire hook in See Figure 3.
hole. See Figures 1 and 2.
3
5b-Attach the Basket Assembly to the front legs with 2 screws (DV) and 2 wing nuts
(DZ). Slide both Basket End Caps (22a and 22b) under Control Panel. Note: On
Model 16203; Fit the front basket over the side basket wire foot, Figure 4.
11412242 (Pg 12)

5C-Assemble the Cylinder Wire (78) as shown in steps 1-3.
1. Insert the Cylinder Wire into the right legs, Figure 1.
2. Rotate the wire as shown in Figure 2 until it fits over the Cylinder collar.
3. Attach the Type 1 Nipple to the Cylinder, see Figure 3.
Back view
Right end
The Outlet Valve must
face the grill front.
IMPORTANT! To ensure proper gas flow,
burner control valves must be "off"
before opening the gas cylinder valve.
L_ WARNING:
During assembly of grill and when attaching or
replacing the LP gas cylinder, ensure that the gas
supply hose is free of kinks and/or damage and is at
least 3" away from hot surfaces such as the grill
casting.
11412242(Pg. 13)

r_
22a
11 11\_\_! t
27
32
26
Parts Diagram
42
lO
56
16
58
65
55

Supplemental Instruction Sheet - pn 11441011
Please disregard Pg 15 of your manual - Refer to this supplemental sheet for all part number info.
i_920.16201
920.16263
Key Qty
1 1
2 2
3 1
42
9 2
10 1
11 4
13 2
16 2
17 2
22 t
22a I
22b 1
25 1
26b 1
32 2
42 1
43 1
44 1
45 2
47a 1
49 1
55 1
1
1
85 1
78 1
The Top warming rack
(66) and side Basket
(80) are only available Key Qty
on Model 920.16203 26 1
._ • Your grill may not g7 1
63 1
have all the parts 66 1
shown. Please refer 80 1
to the partslistsfor
_, your specific model
of grill
U1
PadNumber
30262007
30250126
01230180
11330126
30260128
0121055701
11330125
11030127
30220117
00400251
38220133
30263001
30263002
04572045
36200175
30230207
3412021901
14410212S
14150707
0125O182
01250181
38340139
3411032801
15120128
30230228
01280169
38110172
38320119
Description
FullBase
TubePlugs
Axle
Left Legs
Tabteside
BackBrace
Side Supports
RightLegs
Wheels
Hub Caps
FrontBasket
Left BasketEnd Cap
Right Basket End Cap
ControlBox
Main BurnerWire 10"
ControlKnobs
Bottom Casting
Burner
CollecterBoxAssembly
Splash Shields
Heat Shield
GreaseCup Wire
GOllLid
Nameplate
Handle
HeatTent
WarmingRack, Bottom
CylinderWire
Pad Number
920.16201
00404437
35170189S
04160109
Pad Number
920,16203
00404438
35170193S
3817013773
38110163
38220134
Description
Igniter
HVRAssembly
CookingGrid(s)
WarmingRack,Top
SideBasket
Before Using Your Grill
Read Owner's Use and Care Manual:
For properf)llingand purgingof the cylinder
_] For leaktestingall gassupply connections
1_ For correct grill lighting instructions
For use and storage of the grill and cylinder
._WARNING! The edges of sheet
metal parts can cause injury if not
handled with care. Use extreme
caution[
/_WARNING! When leak testing:
DO NOT smoke,
DO NOT use fire to test for leaks.
Z_ DANGER:
To avoid the possibility of an
explosion, never store a spare LP
gas supply cylinder under the grill
body nor inside grill enclosure.Refer
to the Use and Care manual.
._ IMPORTANT:
Be sure to tighten up all hardware
(screws, nuts, r
least once a
year or each • .
grilling season.
'. _4 I U se and Care
, Manual

_7
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11412242 (Pg. 16)