Kenmore D02 M90221 User manual

Use & Care Guide
Model: D02 M90221
Kenmore
Natural Gas Grill
P/N G651-001-160801
Model 466225712 • Dec-21-11
®/MD
™
/MC
Sears Canada Inc.
Toronto, ON., M5B 2C3
www.sears.ca

Product Record
IMPORTANT: Fill out the product record information below.
CAUTION
For residential use only. Do not use for commercial
cooking.
DANGER
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 not avoided, will result in death or serious injury.
WARNING
WARNING: Be alert to the possibility of serious bodily injury
if the instructions are not followed. Be sure to read and
carefully follow all of the messages.
CAUTION
CAUTION: Indicates a potentially hazardous situation which,
if not avoided, may result in minor or moderate injury.
Model Number
Serial Number
Date Purchased
See rating label on grill for serial number.
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.
WARNING
DANGER
If you 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.
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, CSA B149.1, or Propane Storage and
Handling Code, B149.2, or the Standard for Recreational
Vehicles, ANSI A 119.2/NFPA 1192, and CSA Z240 RV Series,
Recreational Vehicle Code, as applicable.
• All electrical accessories (such as a rotisserie) must be
electrically grounded in accordance with local codes, or
National Electrical Code, ANSI / NFPA 70 or 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 is safety certified for use in the United States and/or
Canada only. Do not modify for use in any other location.
Modification will result in a safety hazard.
WARNING
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.
To Installer/Assembler: Leave these instructions with
consumer.
To Consumer: Keep this manual for future reference.
Call the Grill Information Center for Help and Parts
Missing Parts? Assembly Questions?
Before returning grill to store, call 1-800-241-7548
Some parts may contain sharp edges, especially
as noted in these instructions.
Wear protective gloves if necessary.
CAUTION
Operation Problems?
Printed in China
© 2011 Sears Canada Inc.
2 • 466225712

Table of Contents
For Your Safety......................................2
..............................2
Product Record Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Symbols......................................2
Installation Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . 2-4
Kenmore Grill Warranty..............................3
Grilling Guide.....................................5-8
Use and Care.....................................9-14
Parts List...........................................15
Parts Diagram......................................16
Assembly.......................................17-26
Troubleshooting.................................27-29
Grill Information Center
WARRANTY
KENMORE GRILL WARRANTY
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
Canada.
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 1-800-241-
7548 to arrange for free repair parts (or replacement if repair
proves impossible).
One-Year Limited Warranty on Burners
For one year from the date of purchase, any burner that
rusts through will be replaced free of charge.
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 use within
the warranty period, or are conditions that can be the result
of normal use, accident or improper maintenance.
Toronto, ON., M5B 2C3
Sears Canada Inc.
466225712 • 3
• Read and follow all Safety, Assembly,
and Use and Care Instructions in 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 injury or death.
WARNING
This Grill is for Outdoor Use Only
Tools needed for assembly:
Adjustable wrench (not provided)
Screwdriver (not provided)
7/16" Combination wrench (not provided)

WARNING CAUTION
Using pots larger than 6 quarts in capacity could
exceed weight limit of the
side burner shelf
resulting in failure
of grill cart
components.
or side shelf,
NOTE: DO NOT over tighten screws and washers that
come into contact with porcelain coated surfaces.
Over tightening may cause the porcelain coating to
crack and break, resulting in exposed metal that will
be prone to rust.
Natural Gas Connections and Service Regulators
Above 1/2 psi.
Prior to 1998, all residual gas service regulators were
set with an outlet pressure of 7 inches water column.
In the 1998 edition of NFPA 54, the National Fuel Gas
Code, a change was made allowing service regulators
of 2 and 5 psi.
With this change it was also required that an in line
regulator be connected between the service regulator
and the appliance regulator if the 2 or 5 psi system is
used. This additional regulator is not supplied with the
product.
It is possible for a consumer, making the connection
themselves, or a plumber, not checking, to tap into a 2
or 5 psi line. If a pressure of 2 psi or greater is supplied
to the appliance regulator on certain grills it will shut
down and not deliver any gas to the grill. Other
concerns are the quick disconnect socket and hose
which are only rated to 1/2 psi.
If the quick disconnect socket, hose, and grill are
properly connected and still not getting gas, delivery
pressure needs to be verified. If pressure is greater than
1/2 psi, make sure that an in line regulator is present.
Once the grill has been over-pressured, the regulator
may or may not have been damaged. The best
practice is to replace the regulator.
Do not attempt to repair or alter the hose/qucik
disconnect for any “assumed” defect. Any
modification to this assembly will void your
warranty and create the risk of a gas leak and fire.
Use only authorized replacement parts supplied by
manufacturer.
4 • 466225712

First Time Use
Read your Assembly Manual and ensure the grill is put
together properly. Remove all Point-of-Purchase advertising
material from all grill surfaces before first use. We
recommend operating your grill on its highest setting for 15-
20 minutes prior to your first use. This aids in removing the
oils used during manufacturing.
Lava Rock / Briquettes
This gas grill has been designed, engineered, and tested to
be used with flame tamers or heat distribution plates to
provide more even heating, improve the cleaning process,
and reduce flare-ups. The addition of after market lava
rocks, charcoal, or briquettes of any type will cause poor
combustion and increase the likelihood of a grease fire, and
is not recommended. Using briquettes, lava rock, or
charcoal in this grill will void your warranty. For extra
smoke flavor, we recommend using a smoker box with wood
chips.
Temperature - Convective Grills ONLY.
The temperature gauge in the hood of your new grill
measures air temperature. The air temperature inside your
grill will never be as hot as the temperature at the cooking
surface.
Pre-Heating Your Grill
Just like your home oven, your grill should be pre-heated to
provide optimum performance. Pre-heat the grill on high for
10-15 minutes – longer if weather conditions require. Please
refer to the lighting instructions inside the Product Guide if
you have questions about how to light your grill. A match-
light chain and hole is provided for your convenience.
GRILLING GUIDE – Getting Started
466225712 • 5

Outdoor grilling is really quite simple. You'll succeed with
burgers, dogs, or steaks usually on your very first try. With
experience, you will learn how to work with your grill,
creating more imaginative meals all the time. This
knowledge makes up the art of grilling. Before you start
grilling, organize your food according to cooking technique
and required cooking time, and optimize the use of your
grilling area.
Direct Cooking
Direct cooking involves grilling your meat directly over high
heat. It is perfect for searing steaks, chops, and other
smaller pieces of meat and vegetables that quickly make
their way to the table.
Indirect Cooking
Indirect cooking utilizes select burners to circulate heat
throughout the grill, without direct contact between the
meat and the flame. The meat is placed over the burner
that is 'off'. This method is generally used to slow cook
large cuts of meat and poultry. A pan can be placed
underneath the meat to catch grease and food drippings,
and helps minimize clean-up.
Rotisserie Cooking
Rotisserie cooking is best for 'round' meat, such as large
roasts, whole poultry, and pork. It generally requires an
accessory motor and spit rod that allows the meat to be
turned at a constant speed. Rotisserie cooking is best done
in front of a special rotisserie burner, or utilizing an indirect
cooking burner arrangement. A pan can be placed
underneath the meat to catch grease and food drippings,
and helps minimize clean-up.
Food Safety
Food safety is a very important part of enjoying the
outdoor cooking experience. To keep food safe from
harmful bacteria, follow these four basic steps:
Clean: Wash hands, utensils, and surfaces with hot soapy
water before and after handling raw meat.
Separate: Separate raw meats 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 internal food
temperatures.
Chill: Refrigerate prepared foods and leftovers promptly.
GRILLING GUIDE – Grilling 101
6 • 466225712

466225712 • 7
Cooking on your new grill is a hands-on experience, and it
is recommended to remain outside with your grill while
cooking. Grilling can be affected by many external
conditions. In cold weather, you will need more heat to
reach an ideal cooking temperature, and grilling may take
longer. The meat's internal temperature and thickness can
also affect cooking times. Cold and thicker meats will take
longer to cook.
Internal Meat Temperatures
Meat cooked on a grill often browns very fast on the
outside. Therefore, use a meat thermometer to ensure it has
reached safe internal temperatures.
Sauces
Sauces containing sugars and fats can cause flare-ups, and
your food may burn. In general, apply these sauces during
the final 10 minutes of cooking. Keep in mind, use of
excessive sauces or glazes will also require extra cleaning
afterwards.
Marinades and Rubs
To enhance the flavor of grilled foods, a liquid marinade or
dry rub can be used prior to cooking. Meat can be either
soaked or injected with liquid marinade up to 24 hours
prior to grilling. Dry rubs can be applied directly to the
meat immediately before grilling.
GRILLING GUIDE – Tips & Tricks Wood Chips
For extra smoke flavor when grilling, try adding wood
chips. Soak the chips in water for approximately 30
minutes before adding to a smoke box or pan. Place smoke
box or pan on top of the cooking grate above the flame.
Turn grill on high until the wood starts to smoke. Reduce
heat to desired temperature for cooking, and place food on
cooking grate as desired. Close lid to retain more smoke.
Hardwood varieties that work particularly well with grilled
foods include Alder, Apple, Cherry, Grapevines, Hickory,
Mesquite, Oak, Rosemary and Sassafras.
Skewers
Metal skewers should be flat, with long handles. Round
skewers allow food to roll when turned, so it may not cook
as evenly. Use metal skewers when cooking meat kabobs.
Wooden skewers should be soaked in water for an hour
before use, and are best used for quick cooking foods such
as vegetables and fruits.
Utensils
Use tongs or a spatula to handle the food instead of a fork,
and don't turn the food too
often. Piercing the food
with a fork will release
juices that you want in
the meat, and may
cause flare-ups.
Food Temperature
Beef, veal and lamb (pieces and whole cuts) -
medium-rare 63°C (145°F)
Beef, veal and lamb (pieces and whole cuts) -
medium 71°C (160°F)
Beef, veal and lamb (pieces and whole cuts) -
well done 77°C (170°F
Pork (pieces and whole cuts) 71°C (160°F)
Poultry (e.g. chicken, turkey, duck) - pieces 74°C (165°F)
Poultry - whole 85°C (185°F)
Ground meat and meat mixtures (e.g.
burgers, sausages, meatballs, meatloaf,
casseroles)- beef, veal, lamb and pork 71°C (160°F)
Ground meat and meat mixtures - poultry 74°C (165°F)
Egg dishes 74°C (165°F)
Others (hot dogs, stuffing and leftovers) 74°C (165°F)
Canadian Food Inspection Agency
Recommended Internal cooking tempeaures

GRILLING GUIDE – Cleaning Your Grill Cooking surfaces: 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 recommended to
clean cooking surfaces while grill is hot.
Storing Your Grill
• Clean cooking grates.
• Store grill in dry location.
• When LP cylinder is connected to grill, store outdoors in a
well ventilated space and out of reach of children.
• Cover grill if stored outdoors. Choose from a variety of
grill covers offered by manufacturer.
• Store grill indoors ONLY if LP cylinder is turned off,
disconnected, and removed from grill. Never store LP
cylinder indoors.
• When removing grill from storage, follow the 'Cleaning
the Burner Assembly' instructions in the Use and Care
section of the Product Guide.
Critters
Spiders like to make their homes in the venturi tubes of
grills. These must be inspected and cleaned regularly to
ensure there are no blockages. Refer to the Use and Care
portion of this Product Guide for complete information.
Why Clean?
We've all heard the saying, “an ounce of prevention is
worth a pound of cure.” This is great advice when it comes
to keeping your grill clean.
Routine Care
Periodic cleaning of this grill is necessary,
as grill fires can occur when grease and
food debris collect in the bottom of the grill.
After each use, remove any remaining
food particles from the cooking grate and
inside of the grill using a grill brush. Do
this after the grill has cooled down, yet is
still warm. It is much easier to clean food
particles while warmth is still present, than
after the food particles have completely
cooled and hardened. This grill is not
designed to be 'burned off' by closing the
lid and turning the burners on High for an
extended time. The excessive heat
generated can cause leftover grease to
catch fire, and can cause permanent
damage to your grill.
General Cleaning
Plastic parts: Wash with warm soapy water and wipe dry.
Do not use 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
residue can be wiped away with baking soda/water
solution or glass cleaner. Use non-abrasive scouring powder
for stubborn stains.
Painted surfaces: Wash with mild detergent or non-abrasive
cleaner and warm water. Wipe dry with a soft non-
abrasive cloth.
Stainless steel surfaces: Stainless steel can rust under certain
conditions. This can be caused by environmental conditions
such as chlorine or salt water, or improper
cleaning tools such as wire or steel
wool. It can also discolor due to heat,
chemicals, or grease build-up. To
maintain your grill's high quality
appearance, wash with mild detergent
and warm water, or use a stainless
steel grill cleaner. Baked-on grease
deposits may require the use of an
abrasive plastic cleaning pad. Use only
in direction of brushed finish to avoid
damage. Do not use abrasive pad on
areas with graphics.
8 • 466225712

Connecting Your Grill to the Natural Gas Source.
1. A professionally-installed shut-off valve between the
supply piping and the socket is recommended, but
not required, by the National Fuel Gas Code. Socket
connection must be made outdoors.
2. Coat the gas supply pipe nipple with gas resistant
pipe dope or approved teflon tape. Screw socket
onto gas supply pipe (house gas source) as shown in
Figure A below, and wrench-tighten.
Quick disconnect socket House piping
Figure A
3. Pull back the sleeve on the quick disconnect socket
and insert the unattached end of the gas hose into
the socket. Release the sleeve and continue pushing
the hose into the socket until the sleeve snaps into
the locked position. See Figure B.
Figure B
Gas hose Sleeve
4.When the quick disconnect socket and the gas hose
are connected, a valve in the socket opens
automatically to permit full gas flow. When the gas
hose is disconnected, the valve in the socket instantly
and positively shuts off the flow of gas. Because the
valve in the socket positively shuts off the flow of
gas, the grill can be disconnected from the gas
source by disconnecting the gas hose from the quick
disconnect socket. The socket should be left
attached to the gas source (house piping). Figure C,
below, shows properly connected hose and socket.
CAUTION
The quick disconnect socket should never be
connected to the grill. Direction of gas flow is
indicated on the socket.
Figure C
With proper assembly, the gas hose cannot be
removed without pushing the quick disconnect sleeve
back. To disconnect, push sleeve back and pull plug
out of sleeve (this automatically shuts off gas).
Please Note: Hose and assembly are C.S.A. listed for
natural gas, manufactured gas, mixed gas and for
liquefied petroleum and for LP Gas-Air mixtures on
basis of 0.64 specific gravity for 1000 BTU’s per
cubic foot of gas at 0.3 in. water column pressure
drop. Only ANSI Z21.54 approved hoses should be
used with this grill.
The appliance and its individual shut off valve must
be disconnected from the gas supply piping system
during any pressure testing on that system at test
pressures in excess of 1/2 psig (3.5kPa).
The appliance must be isolated from the gas supply
piping system by closing its individual manual shutoff
valve during any pressure testing of the gas supply
piping system at test pressures equal to or less than
1/2 psi (3.5kPa).
WARNING
Do not use hard metal piping of any kind to
connect this type of grill to natural gas source. Use
only hose specified by manufacturer. Using hard
metal piping or convoluted metal tubing is an
unsafe practice. Movement of the grill can cause
breakage of metal pipe.
WARNING
Do not use flexible gas hose supplied for Drop-in
Models.
This unit should be hard plumbed using components
that meet National Fuel Gas Code.
466225712 • 9

• NEVER store a spare LP cylinder under or near
the appliance or in an enclosed area.
• Never fill a cylinder beyond 80% full.
• An over filled or improperly stored cylinder is a
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
cylinder/appliance and call your fire department.
DANGER
USE AND CARE
• Outdoor gas appliance is not intended to be
installed in or on a boat.
• Outdoor gas appliance is not intended to be
installed in or on an RV.
• Never attempt to attach this grill to the self-contained
LP gas system of a camper trailer or motor home.
• Do not use grill until leak-tested.
• If a leak is detected at any time, STOP and call the
fire department.
• If you cannot stop a gas leak, immediately close
gas valve and call your fire department!
WARNING
NOTE: Sideburner
shelf fascia not
shown for clarity.
NOTE: Your grill
may NOT be
equipped with a
sideburner.
Safety Tips
When grill is not in use, turn off all control
knobs and gas source.
•
Leak Testing
1. Turn all grill control knobs to OFF.
2. Be sure gas hose is tightly connected to gas
source.
3. Completely open gas source. If you hear a rushing
sound, turn gas off immediately. There is a major
leak at the connection. Correct before proceeding.
4.Brush soapy solution onto area circled below.
5. If “growing” bubbles appear, there is a leak.
Close gas source immediately and tighten
connection. If leaks cannot be stopped do not
try to repair.
6.Always close gas source after performing leak
test.
10 • 466225712

WARNING
CAUTION
For Safe Use of Your Grill and to Avoid Serious
Injury:
• Do not let children operate or play near grill.
• Keep grill area clear and free from materials that
burn.
• Do not block holes in sides or back of grill.
• Check burner flames regularly.
• Use grill only in well-ventilated space. NEVER use
in enclosed space such as carport, garage, porch,
covered patio, or under an overhead structure of
any kind.
• Do not use charcoal or ceramic briquets in a gas
grill.
• Do not cover grates with aluminum foil or any
other material. This will block burner ventilation
and create a potentially dangerous condition
resulting in property damage and/or personal
injury.
• Use grill at least 3 ft. from any wall or surface.
Maintain 10 ft. clearance to objects that can catch
fire or sources of ignition such 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 floor with a three (3) foot clearance from
walls or rails. Do not 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 cylinder out 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
s When grill is not in use, turn off all control knobs
and LP cylinder valve.
s Never move grill while in operation or still hot.
s Use long-handled barbecue utensils and oven mitts
to avoid burns and splatters.
s Maximum load for sideburner and side shelf is 10
lbs.
s The grease tray or cup must be installed during
use and emptied after each use. Do not remove
grease tray or cup until grill has completely cooled.
s 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
recommended to clean cooking surfaces while grill
is hot.
s If you notice grease or other hot material dripping
from grill onto valve or gas hose, turn off gas
supply at once. Determine the cause, correct it, then
clean and inspect valve, hose and regulator before
continuing. Perform a leak test.
s Keep ventilation openings in cylinder enclosure
(grill cart) free and clear of debris.
s Do not store objects or materials inside the grill
cart enclosure that would block the flow of
combustion air to the underside of either the
control panel or the firebox bowl.
s If you have a grill problem see the "Troubleshooting
Section".
• 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. Follow instructions
on General Grill Cleaning and Cleaning The
Burner Assembly to prevent grease fires.
466225712 • 11

CAUTION
If ignition does NOT occur in 5 seconds, turn the
burner controls OFF, wait 5 minutes 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.
Turn controls and gas source when not in use.
WARNING
Ignitor Lighting
s Do not lean over grill while lighting.
1. Turn OFF gas burner control valves.
2. Turn ON gas at tank or source.
3. Open lid during lighting.
4. To ignite, push and turn IGNITION BURNER knob
to HIGH.
5. Push and hold ELECTRONIC IGNITION button until
the burner lights.
6. If ignition does NOT occur in 5 seconds, turn the
burner controls OFF, wait 5 minutes and repeat the
lighting procedure.
7. To ignite remaining burners, turn knob to the HI
position starting with the burners closest to
IGNITION BURNER first. If ignitor does not work,
follow match lighting instructions.
8. For grills equipped with ELECTRONIC IGNITION
at each burner:
Repeat steps 4 through 6 to light each burner.
9. Once each burner has ignited, turn knobs to
desired setting.
Match-Lighting
s Do not lean over grill while lighting.
1. Open lid. Turn ON gas at tank or source.
2. Place match into match holder (hanging from left
side panel of grill). Light match; then light burner
by placing match through the match light hole on
left side of grill.
3. Push in and turn far left burner knob to the HIGH
position. Be sure burner lights and stays lit.
4. Light adjacent burners in sequence by pushing
knobs in and turning to the HIGH position.
SEAR Burner Ignitor Lighting
s Do not lean over grill while lighting.
1. Turn OFF gas burner control valves.
2. Turn ON gas at tank or source.
3. Open lid during lighting.
4. To ignite, push and turn SEAR burner knob to HGHI.
5. Push and hold ELECTRONIC IGNITION button until
the burner lights.
6. If ignition does NOT occur in 5 seconds, turn the
burner controls OFF, wait 5 minutes and repeat the
lighting procedure.
SEAR Burner Match-Lighting
s Do not lean over grill while lighting.
1. Open lid. Turn ON gas at tank or source.
2. Place match into match holder (hanging from right
side panel of grill). Light match; then light burner
by placing match through the match light hole on
right side of grill.
3. Push in and turn SEAR burner knob to the HIGH
position. Be sure burner lights and stays lit.
NOTE: Your grill may NOT be equipped with a
Sideburner!
Sideburner Ignitor Lighting
s Do not lean over grill while lighting.
1. Open sideburner lid. Turn ON gas at tank or source.
2. Turn sideburner knob to the HGHI position, push
and hold ELECTRONIC IGNITOR button.
3. If sideburner does NOT light within 5 seconds, turn
knob to OFF, wait 5 minutes, then repeat lighting
procedure.
Sideburner Match Lighting
1. Open sideburner lid. Turn
ON gas at source.
2. Place lit match near burner.
3. Turn sideburner knob to the
HIGH position. Be sure
burner lights and stays lit.
12 • 466225712

HI
LOW
Burner Flame Check
• Remove cooking grates and heat diffusers. Light
burners, rotate knobs from HIGH to LOW. You should
see a smaller flame in LOW position than seen on
HIGH. Perform burner flame check on sideburner,
also. Always check flame prior to each use. If only
low flame is seen refer to "Sudden drop or low
flame" in the Troubleshooting Section.
Turning Grill Off
• Turn all knobs to the OFF position. Turn LP cylinder
OFF by turning hand-wheel clockwise to a full stop
or turn of NG source.
Ignitor Check
• Turn gas off at LP cylinder or source. Press and hold
electronic ignitor button. "Click" should be heard
and spark seen each time between each collector
box or burner and electrode. See "Troubleshooting"
if no click or spark.
Valve Check
• Important: Make sure gas is off at LP cylinder or
source before checking valves. Knobs lock in OFF
position. To check 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 LOW position then turn back to
OFF position. Valves should turn smoothly.
Hose Check
• Before each use, check to see if hoses are cut or
worn or kinked. Replace damaged hoses before
using grill. Use only valve/hose/regulator specified
by manufacturer.
General Grill Cleaning
• Do not mistake brown or black accumulation of
grease and smoke for paint. Interiors of gas grills
are not painted at the factory (and should never be
painted). Apply a strong solution of detergent and
water or use a grill cleaner with 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 residue can be wiped away with
baking soda/water solution or specially formulated
cleaner. Use nonabrasive 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: To maintain your grill’s high
quality appearance, wash with mild detergent and
warm soapy water and wipe dry with a soft cloth
after each use. Baked-on grease deposits may
require the use of an abrasive plastic cleaning pad.
Use only in direction of brushed finish to avoid
damage. Do not use abrasive pad on areas with
graphics.
• Cooking surfaces: 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 recommended to clean cooking surfaces
while grill is hot.
466225712 • 13

4. Detach electrode from burner.
NOTE: Removal/Detachment method will depend
on the burner configuration. See different
configurations in illustrations below.
5. 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) Use a narrow bottle brush with 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 sure air comes
out each hole.
6. Wire brush entire outer surface of burner to remove
food residue and dirt.
7. Clean any blocked ports with a stiff wire such as an
open paper clip.
8. Check burner for damage, due to normal wear and
corrosion some holes may become enlarged. If any
large cracks or holes are found replace burner.
VERY IMPORTANT: Burner tubes must reengage
valve openings. See illustrations at right.
9. Attach electrode to burner.
10. Carefully replace burners.
11. Attach burners to brackets on firebox.
12. Reposition carryover
tubes and attach to
burners. Replace heat
diffusers and cooking
grates.
Firebox
Carryover tube
Firebox
burner
bracket
Electrode
Correct
burner-to-valve
engagement
Remove screws
Firebox
Carryover tube
Firebox burner
bracket
Pry off electrode
with a flat blade
screwdriver
Electrode
CAUTION
SPIDER ALERT!
VALVE
CONTROL PANEL SPIDER WEBS
INSIDE VENTURI TUBE
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 tubes.
BURNER
SPIDER AND WEBS
INSIDE BURNER TUBE
Important: Always ensure that the venturi burner tubes are clean. A
venturi burner tube has a narrow area in which spiders tend to build
nests.
Spiders or small insects have been known to create “flashback”
problems. The spiders spin webs, build nests and lay eggs in the
grill’s venturi tube(s) obstructing the flow of gas to the burner.
The backed-up gas can ignite in the burner tube behind the
control panel. This is known as a flashback and it can damage
your grill and even cause injury.
To prevent flashbacks and ensure good performance the burner
and venturi tube assembly should be removed from the grill
and cleaned before use whenever the grill has been idle for an
extended period.
Storing Your Grill
• Clean cooking grates.
• Store in dry location.
• Cover grill if stored outdoors. Choose from a variety
of grill covers offered by manufacturers.
• When removing grill from storage, follow “Cleaning
the Burner Assembly” instructions before starting
grill.
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 heat diffusers.
3. Remove carryover tubes and burners.
14 • 466225712

466225712 • 15
PARTS LIST
NOTE: Some grill parts shown in the assembly steps may differ slightly in appearance from
those on your particular grill model. However, the method of assembly remains the same.
To order replacement parts after using grill,
call 1-800-241-7548.
Key Qty Description Part #
1 1
BOTTOM SHELF G651-0036-W1
2 1 LEFT SIDE CART PANEL G651-2200-W1
3 1 RIGHT SIDE CART PANEL G651-2300-W1
4 2 MATCH HOLDER G401-0079-W1
5 1 LOWER BACK PANEL G651-7701-W1
6 2 MAGNET ASSEMBLY G439-0035-W1
7 1 FRONT DOOR BRACE G651-0600-W1
8 2 CASTER, LOCKING G350-0023-W1
9 2 CASTER, FIXED G350-0024-W1
10 4 CASTER SOCKET G408-0036-W1
11 1 WEIGHT BLOCK G651-0012-W1
12 1 TOP LID G651-4200-W1
13 1 LOGO PLATE F/ LID G528-0002-W2
14 1 TEMPERATURE GAUGE G430-0022-W1
15 1 BEZEL, F/ TEMPERATURE
GAUGE
G404-0034-W1
16 2 LID BUMPER, RECTANGLE G430-00B8-W1
17 2 LID BUMPER, ROUND G303-0038-W1
18 1 TOP LID HARDWARE G430-0024-W2
19 1 HANDLE, F/ LID G651-0008-W1
20 1 FIREBOX G651-0200-W2
21 5 MAIN BURNER-TUBE BURNER G651-4000-W1
22 1 MAIN BURNER-BAR BURNER G651-4100-W1
23 1 ELECTRODE, F/ TUBE BURNER G501-0010-W2
24 1 ELECTRODE, F/ BAR BURNER G651-5103-W1
25 4 CARRY OVER TUBE G501-0015-W1
26 1 CONTROL PANEL, MAIN G651-0035-W1
27 1 ELECTRONIC IGNITION
MODULE
G651-1300-W1
28 1 SHIELD, F/ ELECTRONIC
IGNITION MODULE
G308-0025-W1
29 1 HOSE VALVE REGULATOR
ASSEMBLY
G651-A700-W1
30 7 BEZEL F/ CONTROL KNOB G430-0027-W2
31 7 CONTROL KNOB G432-0010-W1
32 1 RIGHT SIDE SHELF G432-3600-W1
33 1 FASCIA, F/ RIGHT SHELF G651-7501-W1
34 1 LEFT SIDE SHELF F/ SB G432-3900-W1
35 1 DRIP PAN, F/ SB G651-0038-W1
Key Qty Description Part #
36 1
SIDEBURNER LID G651-0037-W1
37 1 CONTROL PANEL, F/ SB G651-A501-W1
38 1 SIDEBURNER G550-6300-W1
39 1 ELECTRODE, F/ SB G431-0034-W1
40 1 ELECTRODE WIRE, F/
SIDEBURNER
G602-0007-W1
41 1 SIDEBURNER VALVE CLIP G405-0019-W1
42 1 SIDEBURNER GRATE G430-0053-W1
43 1 LEFT DOOR G651-7801-W1
44 2 HANDLE, F/ DOOR G651-0006-W2
45 1 RIGHT DOOR G651-7901-W1
46 2 DOOR PIN, FIXED G401-0053-W1
47 2 DOOR PIN, SPRING G439-0036-W2
48 5 HEAT DIFFUSER G430-0005-W1
49 1 HEAT DIFFUSER, F/ BAR BURNER G651-0011-W1
50 4 COOKING GRATE G432-0002-W1
51 1 WARMING RACK G651-0017-W1
52 1 BUTTON, F/ IGNITION MODULE G409-0030-W1
53 1 GREASE TRAY G651-3900-W1
54 1 GREASE PAN G416-0015-W1
55 1 NATURAL GAS HOSE G501-0099-W1
NOT Pictured
… 1 CASTER PIN G350-0026-W1
… 1 PRODUCT MANUAL, ENGLISH G651-160801-W1
… 1 PRODUCT MANUAL, SPANISH G651-160802-W1
… 1 HARDWARE PACK G65116-B001-W1

PARTS DIAGRAM
XX
16 • 466225712
32
31
30
8
8
7
65
6
9
1
2
47
24
33
25 23
46
3
4
26
39
22
28
18
27
14
12
13
11
10
15
19
20
16
21
40
17
41
42
43
45
44
34
35
36
37
38
29
4
9
10
21 21 21 21
25 25 25
30 30 30 30 30
30
31 31 31 31 31
31
44
46
47
48 48 48 48 48
49
50 50 50 50
51
52
53
54
55

ASSEMBLY
•Place lower back panel between side panels as shown. Attach to left and right side panels with (4) #8x3/8” sheet metal
screws. Then attach to bottom shelf with (2) #8x3/8” sheet metal screws.
11
2
1/4-20
Flange Nut
Qty: 6
1/4-20x2-3/8"
Machine Screw
Qty: 6
Sheet Metal Screws
Qty. 6
#8x3/8"
Left Side Panel
Right Side Panel
Right Side Panel
Left Side Panel
Magnet Assembly
Lower Back Panel
For Front Door
Brace Assembly
Rear
Front
Bottom Shelf
Bottom Shelf
•Attach bottom shelf to left and right leg assemblies with 1/4-20x2-3/8” machine screws and 1/4-20 flange nuts. The
cut out hole for the LP cylinder should be on the left side.
466225712 • 17

3•Attach to left and right leg assemblies with
1/4-20 flange nuts.
Place front door brace as shown. 1/4-20x2-3/8" machine screws and
Front Door Brace
1/4-20
Flange Nut
Qty: 4
1/4-20x2-3/8"
Machine Screw
Qty: 4
18 • 466225712

Caster
Pin
4•
•Insert Caster Pin into the caster mounting plate to lock it in place, shown A. Spin the caster clockwise into the threads on
the bottom shelf until secure. Remove the Caster Pin and repeat for remaining casters. Make sure the two locking casters
are secured at the rear and the non-locking casters are secured at the front (B). After all 4 casters are secure remove the
Caster Pin and save for future maintenance.
• Stand cart upright.
• Attach weight block to bottom shelf with (2) 1/4-20x2” machine screws and 1/4-20 flange nuts (C).
Turn assembly upside down.
Caster Pin
1/4-20
Flange Nut
Qty: 2
1/4-20x2"
Machine Screw
Qty: 2
A
C
Rear
Locking Caster
Fixed Caster
Locking Caster
Fixed Caster
B
466225712 • 19

5•T
•Carefully lower the grill head onto the cart. Make sure the regulator hose is hanging outside the cart. Attach with
1/4-20x1/2” screws.
his step requires two people to lift and position grill head onto cart.
1/4-20x1/2" Screw
Qty: 4
Grill Head
20 • 466225712