Assembly Instructions/Useand Care Manual
LiquidPropaneGasGrill
Model No. 415.16109
This Grill is For
Outdoor Use Only
®
, 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
• Espahol
Assembly Questions?
Call 1=800=241=7548
Parts Ordering:
Call 1=800=4=MY=HOIVlE®
To InstalledAssembler: Leave
these instructions with
consumer.
To Consumer: Keep this
manual for future reference.
Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A.
(#2006 Sears, Roebuck and Co., All Rights Reserved Printed in China 464820907,80009273 *12-06-06
Ifyou smellgas:
1. Shut off gasto the appliance.
2. Extinguish any openflame.
3. Openlid.
4. If odor continues,keepawayfrom the
applianceand immediatelycall your gas
supplieror yourfire department.
1. Do notstoreor use gasolineor other
flammableliquidsorvaporsin the vicinityof
this or any otherappliance.
2. An LP cylindernotconnectedfor use shaftnot
bestoredin the vicinityof this or any other
appliance.
Carl Grifl Service Center For Help And Parts
If you have questions or need assistance during assembly,
please call 1.800.241.7548. Youwill be speaking to a
representative of the grill manufacturer and not a Sears
employee. To order new parts call Sears at 1-800-4-MY-HOME®.
ProductRecord
iMPORTANT:Fill out the productrecordinformationbelow.
Model Number
Serial Number
Seeratinglabel on grill for serialnumber.
Date Purchased
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: 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.
cAo.
CAUTION: indicates a potentially hazardous situation which,
if not avoided, may result in minor or moderate injury.
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 their
absence d 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, B 149.2, or the Standard for Recreational
Vehicles,ANSI A 119.2/NFPA1192, and CSA Z240 RV Series,
Recreational Vehicle Code, as applicable.
• All electrical accessories (such as rotisserie) must be
electrically grounded in accordance with local codes, or
National Electrical Code, ANSI/NFPA 70. 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 only. Do
not modify for use in any other location. Modification will result
in a safety hazard.
m m
cAuT,o.
For residential use only. Do not use for commercial
cooking.
2,464820907
For Your Safety ...................................... 2
Grill Service Center ................................... 2
Product Record Information ............................ 2
Safety Symbols ...................................... 2
Installation Safety Precautions .......................... 2
Kenmore Grill Warranty ............................... 3
Use and Care .................................... 4-10
Parts List .......................................... 11
Parts Diagram ...................................... 12
Assembly ....................................... 13-24
Troubleshooting .................................. 25-26
Repair Protection Agreements
Congratulations on making a smart purchase. Your new
Kenmore®product is designed and manufactured for years of
dependable operation. But like all products, it may require repair
from time to time. That's when having a Repair Protection
Agreement can save you money and aggravation.
Purchase a Repair Protection Agreement now and protect
yourself from unexpected hassle and expense.
Here's what's included inthe Agreement:
[] Expert service by our 12,000 professional repair specialists
[] Unlimited service and no charge for parts and labor on all
covered repairs
[] Product replacement if your covered product can't be fixed
[] Discount of 10%from regular price of service and service-
related parts not covered by the agreement; also, 10% off
regular price of preventive maintenance check
[] Fast help by phone- phone support from a Sears
technician on products requiring in-home repair, plus
convenient repair scheduling
Once you purchase the Agreement, a simple phone call is all that
it takes for you to schedule service. You can call anytime day or
night, or schedule a service appointment online.
Sears has over 12,000 professional repair specialists, who have
access to over 4.5 million quality parts and accessories. That's
the kind of professionalism you can count on to help prolong the
life of your new purchase for years to come. Purchase your
Repair Protection Agreement 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_'to arrange for free repair (or replacement if repair
proves impossible).
Two-Year Limited Warranty on Stainless Steel Burners
For two years from the date of purchase, any stainless steel
burner that rusts through will be replaced free of charge. After
the first year from the date of purchase, you pay for labor if
you 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 use within
the warranty 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 used for
commercial or rental purposes.
This warranty coverage applies only if this grill is used in the
United States.
This warranty gives you specific legal rights, and you may
have other rights which vary from state to state.
Sears, Roebuck and Co., Hoffman Estates, IL 60179
464820907.3
LP Tank
T
• NEVER store a spare LP tank underorneargrillorin
enclosed areas
Never fill the cylinder beyond 80% full.
• An overfllled or improperly stored tank is a hazard due
to possible gas release from the safety relief valve.
• if you see, smell or hear escaping gas, immediately get
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 these required measurements: 12"
(30.5cm) (diameter) x 18" (45.7 cm) (tall) with 20 lb. (9 kg.)
capacity maximum.
, LP tanks must be constructed and marked in accordance with
specifications for LP tank of the U.S. Department of
Transportation (DOT). See LP tank collar for marking.
• LP tank valve must have:
, Type I outlet compatible with
regulator or grill.
, Safety relief valve.
, UL listed Overfill Protection
OPD HandWheel
Device (OPD). This OPD safety
feature is identified by a unique triangular hand wheel. Use
only LP tanks equipped with this type of valve.
, LP tank must be arranged for vapor withdrawal and include
collar to protect LP tank valve.
LP (Liquefied Petroleum Gas)
• LP gas is nontoxic, odorless and colorless when produced. For
Your Safety, LP gas has been given an odor (similar to rotten
cabbage) so that it can be smelled.
• LP gas is highly flammable and may ignite unexpectedly when
mixed with air.
LP Tank Removal, Transport And Storage
, Turn OFF all control knobs and LP tank valve. Turn coupling
nut counterclockwise by hand only - do not use tools to
disconnect. Lift LP tank wire upward off of LPtank collar, then
lift LP tank up and off of support bracket. Install safety cap onto
LP tank valve. Always use cap and strap supplied with valve.
Failure to use safety cap as directed may result in serious
personal injury and/or property damage.
LP TankValve
Safety Cap
Retainer Strap
, A disconnected LP tank in storage or being transported must
have a safety cap installed (as shown). Do not store an LP tank
in enclosed spaces such as a carport, garage, porch, covered
patio or other building. Never leave an LP tank inside a vehicle
which may become overheated by the sun.
, Do not store an LP tank in an area where children play.
4 • 464820907
LP Tank Filling
Use only licensed and experienced dealers.
• LP dealer must purge tank before filling.
• Dealer should NEVERfill LP tank more than 80% of LP tank
volume. Volume of propane in tank will vary by temperature.
• A frosty regulator indicates gas overfill, immediately close LP
tank valve and call local LP gas dealer for assistance.
, Do not release liquid 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 LPtank through an exchange service. Use only
those reputable exchange companies that inspect, precision fill,
test and certify their cylinders. Exchange your tank only for
an OPD safety feature-equipped tank as described in the
"LP Tank" section of this manual,
Always keep new and exchanged LP tanks in upright position
during use, transit or storage.
, Leak test new and exchanged LP tanks BEFORE
connecting to grill.
Connecting Regulator To The LP Tank
1. LP tank must be properly secured onto grill. (Refer to
assembly section.)
2. Turn all control knobs to the OFF position.
3. Turn LP tank OFF by turning OPD hand wheel clockwise to a
full stop.
4. Remove the protective 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 LP tank is exchanged or
refilled.
Do not smoke during leak test.
Do not use an open flame to check for gas leaks.
Grill must be leak tested outdoors in a well-ventilated area,
away from ignition sources such as gas fired or electrical
appliances. During leak 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 by arrows
in figure below. Leaks are indicated by growing bubbles.
If "growing" bubbles appear do not use or move the LP tank.
Contact an LP gas supplier or your fire department!
A Do not use household cleaning agents. Damage to gas
train components can result.
Do not use a POL transport plug
(plastic part with external threads)!
It will defeat the safety feature of
the valve.
5. Hold regulator and insert nipple into LP
tank valve. Hand-tighten the coupling
nut, holding regulator in a straight line
with LP tank valve so as not to cross-
thread the connection.
Nipple has to be centered
intothe LPtank valve.
464820907 • 5
Hold coupling nut and regulator
as shownfor proper connection
to LP tank valve.
Leak Testing Valves, Hose and Regulator
1. Turn all grill control knobs to OFF.
2. Be sure regulator is tightly connected to LP tank.
3. Completely open LP tank valve by turning OPD hand wheel
counterclockwise. If you hear a rushing sound, turn gas off
immediately. There is a major leak at the connection. Correct
before proceeding by calling Sears for replacement parts at
1-800-4-MY-HONIE®.
4. Brush soapy solution onto areas where bubbles are shown in
picture below:
6. Turn the coupling nut clockwise and tighten to a full stop. The
regulator will seal on the back-check feature in the 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 regulator and
repeat steps 5 and 6. If you are still unable to complete the
connection, do not use this regulator!
. Do not insert any tool or foreign objects into the valve outlet
or safety relief valve. Youmay damage the valve and cause
a leak. Leaking propane may result in explosion, fire, severe
personal injury,or death..
. If a leak is detected at any time, STOP and call the fire
department.
. If you cannot stop a gas leak, immediately close LP tank
valve and call LP gas supplier or your fire department!
A Never remove threaded
orifice at end of valve.
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 Sears for replacement
parts at 1-800-4-MY-HOME®.
6. Always close LP tank valve after performing leak test by
turning hand wheel clockwise.
. 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.
6 • 464820907
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 bottom or back of grill.
Check burnerflames 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.
(Unless briquets are supplied with your grill.)
* Use grill at least 3 ft. from any wall or surface. Maintain
10ft. 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 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 Before opening LP tank valve, check the coupling nut for
tightness.
A When grill is not in use, turn off all control knobs and LP tank
valve.
A Never move grill while in operation or still hot.
A Use long-handled barbecue utensils and oven mitts to avoid
burns and splatters.
A Maximum load for shelves is 10 Ibs.
A Do not use a cooking pot larger than 9" on grid.
A The grease cup must be attached to grease cup clip and
emptied after each use. Do not remove grease cup until grill
has completely cooled.
A If you notice grease or other hot material dripping from grill
onto valve, hose or regulator, 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.
A The regulator may make a humming or whistling noise during
operation. This will not affect safety or use of grill.
A If you have a grill problem see the "Troubleshooting Section".
ff the regulator frosts, turn off grill and LP tank valve
immediately. This indicates a problem with the tank and it
should not be used on any product. Return to supplier!
464820907.7
ignitor Lighting
A Do not lean over grill while lighting.
1. Open lid during lighting.
2. To ignite, turn left knob to4 _ HIGH.
3. Push IGNITOR button rapidly.
4. If ignition does NOT occur in 5 seconds, turn the burner
controls off, wait 5 minutes, and repeat the lighting procedure.
5. Ignite right burner, turn knob to _.
6. If ignitor does not work, wait 5 minutes, then follow match
lighting instructions.
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 ignitewith risk of injury.
Match-Lighting
A Do not lean over grill while lighting.
1. Open lid during lighting.
2. Place match into match holder (hanging from side of cart).
3. Push in and turn left knob to _ _ HIGH position. Be sure
burner lights and stays lit.
4. Light right burner by pushing knob in and turning to ,i HIGH
position.
Sideburner ignitor Lighting
1. To ignite SIDEBURNER, turn knob to ..€ _ HIGH.
2. Push IGNITOR button rapidly.
3. If sideburner does NOT light in 5 seconds, turn knob to OFF,
wait 5 minutes, then repeat lighting procedure.
Sideburner Match Lighting
1. Turn on gas at LP tank.
2. Hold lit match to any port on the burner. Push in and turn
sideburner knob to._ _ HIGH. Be sure burner lights and
stays lit.
-- m
cAu'r,o.
* 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 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 instructions on General
Grill Cleaning and Cleaning The Burner Assembly to
prevent grease fires.
Before Your First Cookout
, Light burners, check to make sure they are lit, close the lid and
warm up grill on HIGH for 15 minutes. This curing of paint and
parts will produce an odor only on first lighting.
Burner Flame Check
, Light burner, rotate knobs from HIGH to LOW. You should see
a smaller flame in LOW position than seen on HIGH.Always
check flame prior to each use. If only low flame is seen refer to
"Sudden drop or low flame" in the Troubleshooting Section.
Hose Check
* Before each 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
8 • 464820907
Turning Grill Off
. Turn all knobs to OFF position. Turn LP tank off by turning
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. 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 LO position then turn back to OFF position.
Valves should turn smoothly.
General Grill Cleaning
, Keep the 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 have a grill cover, wipe off dust and grime before
starting your grill.
, Coating the cooking grids with 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 up and 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 cleaner with scrub brush on insides d grill lid and
bottom. Rinse and allow to completely air dry. Do not apply a
caustic grillloven cleaner to 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.
,& 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 bewiped away with baking soda/water solution or
specially formulated cleaner. Use non-abrasive scouring
powder for stubborn stains.
I1 ! c ,o. II !
SPIDER ALERT!
CONTROL PANEl
GAS COLLECTOR
BOX & IGNITOR
/
BURNER
SPIDER WEBS
INSIDEVENTURI
VALVE AIR VENTURI
SHUTTER
If you notice that yourgrill is getting hard to light or that the
flame isn't as strong as it should be, take the timeto check and
clean the venturi's.
LIFT OUT
BURNER ASSEMBLY
REMOVE
BURNER
CLIPS
J
CLEAN OUT SPIDERWEBS
VENTURI INSIDEVENTURI
Insome areasof thecountry,spidersor small insectshavebeen
knownto create "flashback"problems.Thespidersspinwebs,build
nestsand layeggsin thegrill'sventuritube(s)obstructingthe flowof
gas to the burner,The backed-upgas can ignitein the venturibehind
the controlpanel.Thisis knownas a flashbackandit can damage
your grill and evencauseinjury.
Topreventflashbacksand ensuregoodperformancethe burnerand
venturiassemblyshouldbe removedfrom the grillandcleaned
beforeusewheneverthe grillhas beenidle for an extendedperiod.
464820907,9
Cleaning the Burner Assembly
Follow these instructions to clean and/or replace parts of burner
assembly or if you have trouble igniting grill.
1. Turn gas off at control knobs and LP cylinder,
2. Remove cooking grate and heat tent.
3. Under grill remove grease cup, disconnect ignitor wire from
burner.
4. Inside grill remove burner assembly (A), clean ceramic
portion of electrode with rubbing alcohol and a swab.
5. Clean outside of burner with 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 thin wire. Shake
out excess water and examine holes. Due to normal wear
and corrosion some holes may become enlarged. If any
large cracks or holes are 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 not storing grill after cleaning, replace burner into grill
bottom.
VERY iMPORTANT: Burner tubes must re-engage valve
openings. See illustration (A).
8. Reattach ignitor wire 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".
Storing Your Grill
, Clean cooking grates.
, Store in dry location.
, When LP tank is connected to grill, store outdoors in well-
ventilated space and out of reach of children.
, Cover grill if stored outdoors.
, Store grill indoors ONLY if LP tank is turned offand
disconnected, removed from grill and stored outdoors.
, When removing grill from storage follow "Cleaning Burner
Assembly" instructions before starting grill.
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 and poultry.
Separate: Separate raw meats and poultry from ready-to-eat
foods to avoid cross contamination. Use a clean platter and
utensils when removing cooked foods.
Cook: Cook meat and poultry thoroughly to kill bacteria. Use a
thermometer to ensure proper internal food temperatures.
Chill: Refrigerate prepared foods and leftovers promptly.
For more information call: USDA Meat and Poultry Notline at
1-800-535-4555 (in Washington, DC (202) 720-3333, 10:00 am-
4:00 pm EST).
Correct burner-to-valve engagement
A
Burner Tube
Valve
How To Tell if Meat is Grilled Thoroughly
* Meat and poultry cooked on a grill often browns very fast on the
outside. Usea 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 180° F; breasts, 170° F.Juices
should run clear and flesh should not be pink.
, Hamburgers made of any ground meat or poultry should reach
160° F,and be brown in the middle with no pink juices. 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.
10. 464820907
_ Descri_ ................ Part#
1 1 UpperLeft Leg .............. 80010080
2 2 LowerLeft Leg .............. 80010079
3 12 #10-24x2"Screw ............ HMS19824200CPNBZC
4 50 #10-24Nut ................. HHNO1924MNBD
5 1 TankRetainerSideBrace...... 80010078
6 1 MatchHolderwithChain....... 80004320
7 1 TankRetainerBracket ........ 80010192
8 3 Wing NutScrew ............. 80008304
9 2 HingePin .................. 80003610
10 3 HitchPin .................... 80003661
11 1 UpperRight Leg............. 80010077
12 2 LowerRight Leg............. 80010078
13 2 TankSupportBracket......... 80010082
14 1 TankExclusionWire.......... 80009836
15 1 UpperPanel ................ 80012242
16 1 LowerPanel ................ 80012243
17 2 Axle Rod................... 80010088
18 1 Wheel ..................... 80010191
19 1 Wheel Bushing.............. 80009743
20 1 Leg Extender ............... 80009820
21 2 BackBrace................. 80012236
22 20 #10-24X1-1/4"Screw ......... HMS19824125CPNBZC
23 1 UpperFireboxSupport, Right.. 80010084
24 1 UpperFireboxSupport,Left.... 80010083
25 1 ControlPanel ............... 80012239
26 1 Valve/Hose/Regulator......... 80012235
27 1 Ignitor..................... 5156113
28 30 #10-24x1/2"Screw........... HMS19824050CPNBZC
29 1 HeatShield................. 80010068
30 1 BurnerAssembly............. 80012232
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
1
12
3
2
2
4
1
3
2
1
1
2
1
2
Description................ Part #
Firebox.................... 80012231
5 MM FiberWasher .......... HFWM51D90DFB
ControlKnob................ 80009706
SideburnerShelf............. 80012245
SideburnerPan.............. 80006246
SideburnerElectrode ......... 80011100
MountingBracket,Left ........ 80010074
MountingBracket,Right....... 80010073
#10x3/8"Self-TapScrew ...... HABO16038CBNNK
SideburnerAssembly ......... 80009732
WingNut................... HWN02520MNNK
BurnerClip ................. 4080132
SideburnerGrate ............ 80009728
SideburnerLidAssembly ...... 80010103
Side Shelf.................. 80012223
ToolHolder................. 80009154
Lid........................ 80012234
7MM FiberWasher........... HFWM7PRSTSS
Logo Plate ................. 80012215
TemperatureGauge .......... 80009025
LowerHinge ................ 80018090
Handle .................... 80012224
UpperHinge ................ 80010091
HeatTent .................. 80009898
CookingGrate............... 80009899
SwingAway ................ 80009888
CondimentBasket ........... 80010102
GreaseCup Clip............. 80005794
GreaseCup ................ 80000270
484820907.11
56
54
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43
4O
42
28
A
32
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36
22
29
4
30
28
A
53
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A
32 53 ,,j50
34
28
38
33
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3
14
25
28
4
32
45
23
37
38
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26
12,464820907
Left Leg
Place left upper leg as shown (A). NOTE: Lower left leg has two large holes at the bottom. In front, attach upper leg, tank
retainer bracket side brace and lower leg with #10-24x1-1/4" screw and #10-24 nut (B). In back, place screw #10-24x1-1/4"
screw and #10-24 nut. Do not tighten.
Attach tank support bracket in second hole from bottom of leg with a hinge pins and hitch pins.
Do not tighten
this screw and nut
untie step 4
B
Upper Left Leg
A
3
Lower Left Leg
4
Qty:2
Correctlyassembledleftleg
Qty:2
Front
Tank Support Bracket
Notchsto hold LP cylinder
10
Qty:2
9
Qty:2
464820907• 13
Right Leg
[] Placeright upper legas shown(A)=Attach upperleg and lowerlegwith#10-24×14/4"screwsand#10o24nuts (B)=
[] Attachsupport bracket with #10o24×1=1/4"screwsand#10o24nuts=
Front
\
Correctlyassembledrightleg
UpperRightLeg
A
4
\
4 3
Qty:4 Qty:4
SupportBracket
Do not tighten
this screwand nut
until step4
,,
, 3
I ,
LowerRight Leg
14,464820907
TankExclusionWire
[] Hooktank e×clusionwireintolegswithopeningfor LPcylinderon tank bracketside.
TankExclusionWire
TankBracket
Upperand Lower Panels
Lay front legs down on the floor°
[] Slideupperpanelwithholes for condimentbasket underlegs.Attachwith#10o24x2"screwsand nuts.
[] Fitlowerpanelaround tank exclusionwireand attach with #10-24x2"screwsand nuts.
Qty:8
O
4
Qty:8
464820907*15
19
Qty: 1
Wheels, Leg Extenders and Back Braces to Cart
Turn assembly upside down.
On both sides remove screws and nuts from tank retainer and support
brackets as shown, Attach back braces with #10-24x1-1/4" screws and
#10-24 nuts,
Insert axle rod into wheel, legs and other wheel, Attach with a wheel bushing
and hitch pin.
Push leg extenders into right legs.
LegExtenders
/
Axle Rod
Qty: 1
22
Qty:6
3
Qty:8
4
Qty:6
Wheel
"Cone" side of wheel against leg
BackBrace
10
22
Remove screws and nuts to attach brace
Control Panel and Upper Firebox Supports
Stand cart upright.
} in front, attach control panel with #10-24x2" screws, Place upper firebox supports onto screws and tighten
with #10-24 nuts,
in back legs, attach right and left upper firebox supports with #10-24x2" screws and #10-24 nuts,
Control Panel
O
4
Qty: 8
16,464820907
Valve/Hose/Regumatorand ignitor
Attachvalve/hose/regulatorassembly to control panel with #10-24×1/2"screws.
Attach ignitorto contrompanel using the stampednut that's provided.
Ignitor
28 ShortIgnitorWire
_--_.._ _ _ _, SideburnerIgnitor Wire
Stam
Valve/Hose/Regulator ',
28
Qty:2
HeatShield
Attachheatshieldwith #10-24xl/2"screwsand#10-24nuts.NOTE:Regulatorandhosecomeout by the heatshield.
Heat Shietd
4
Qty:2
28
Qty:2
464820907• 17
TankRetainer
[] inserttank retainerintobracketand securewith wingscrew.
Burner,FireboxandControlKnobs
Qty:l
[] Placeburnerassembly intofirebox (A).Fastenthe burnerassembly to the firebox using5ramfiber washersand
#8sheetmetalscrews,insert5ramfiber washerand #10-24xl-1/4" screwsintoeachsideof firebox, insidefirebox attach
#10-24nuts to screws.
[] Placefirebox onto upperfirebox supports.Makesureburnertubes are correctlyengaged(B). ifburner is not leveledfrom
left to right, adjust the two screwsattaching valveto controlpanel.Attachshort ignitorwireto ignitor(B).
[] Attachfirebox with#10-24x1-1/4"screws,5turnfiber washersand #10o24nuts (C).
[] Pushcontrolknobsontovalvestems(C).
A
39
Qty:2
32
Qty: 10
0
#10-24Nut
Qty:8
C ?
÷
#10-24x1-1/4"
Screw
qty: 8
Control
Knob
18. 464820907
28
Shelves
[] insertmountingbracketsintoshelf supportswith#10=24xl/2"screws(A).
[] Attachmounting bracketsto frontof legwith #10=24x1/2"screws=Backof leg with #10°24×1=1/4"screw
and#10-24nuts(B).
28
Qty: 12
O
39
Qty:4
A
Qty:4
ShelfSupport
MountingBracket
Shelf
28
39
464820907*19
Sideburner
Attach sideburner valve with #8x3/8" screws (A).
Place sideburner into shelf (B).
Press sideburner control knob onto valve stem and sideburner grate onto shelf (C).
Make sure valve is inside sideburner tube. Attach sideburner with a wing nut. Hook burner clip to sideburner tube and
around manifold. Attach sideburner ignitor wire (D).
Attach hinges to back of shelf with #10-24xl/2" screws and #10-24 nuts (E).
SldeburnerValve
A
Sideburner
B
C
SideburnerGrate
39
Qty:2
41t
Qty: 1
Correctlyassembledburner-to-valveengagement
Sldeburner Valve
SideburnerControlKnob
BurnerClip
SideburnerIgnitorWire
SideburnerLid
E
28
Qty:4
20 • 464820907
28
Qty:4
28
LowerHinges
[] Attachlowerhingesto backof firebox using #10°24xl/2" screws,5ramfiber washersand#10-24nuts=Thecenter
fiat portionof the hingeshouldbe at the bottom (see inset),
O
4
32 Qty:4
Qty:8 LowerHinge
32
28
Lid Handleand UpperHinges
[] Attachhandleto lidwith7rnmfiber washersand wing nuts=
[] Attachupperhinges to back of lid using#10°24x1/2"screws, 5ramfiber washersand#10-24nuts=Hingesshould
curvedownwardwhenproperlyinstalled.
Qty:4
41
Qty:2
Handle
47 4 I
Qty:8 Qty:4 _47
32
Qty:4
41
28
464820907=21
Lid
Place lid assembly onto firebox, aligning hinges. Hinges on lid fit inside hinges on firebox. Secure using two
hinge pins and hitch pins.
9
Qty: 2
10
Qty:2
HeatTent
Place heat tent into firebox.
Heat Tent
\
\
22,464820907
Cooking Grate
Placegrate intofirebox.
Cooking
Swing Away and Condiment Basket
insert ends of Swing Away pivot wire into holes in sides of grill lid. Insert ends of Swing Away leg wire into holes in sides
of firebox. NOTE: Pivot and leg wires, running side-to-side, should be under wires running front-to-back. If pivot and leg
wires are on top, Swing Away is installed upside-down.
Attach condiment basket to upper front panel as shown.
SwingAway
PivotWire
Leg Wire
Condiment Basket
464820907,23
Grease Cup Clip and Grease Cup
Hang grease cup clip from bottom of firebox and place grease cup into grease clip.
W c.uT,o.
Failureto installgrease cup clip and cup
will cause hot grease to drip from bottom
of grill with risk of fire or property damage.
GreaseCup Clip
GreaseCL
LP Tank
LP tank is sold separately. Useonly with an OPD (over-fill protection device) equipped LP tank. Fill and leak check before
attaching to grill and regulator.
Tankcollar opening must face to front of grill. Loosen wing nut from tank retainer bracket. Set bottom of tank onto
notches inthe tank bracket. Placetank retainer bracket onto tank collar and tighten the wing nut.
See Useand Caresection to correctly Leak Test and
perform the Burner FlameCheck.
m m
cAu'rlo.
• Failureto installtank correctly may allow gas hose to
bedamaged in operation, resulting in the risk of fire.
LPTank
24 • 464820907
Troubleshooting
EMERGENCIES: if a gas leak cannot be stopped, or a fire occurs due to gas leakage, call the fire department.
, Damagedhose. , Turnoff gasat LPtank. If hoseis cut orcracked,replaceGasleakingfrom
cracked/cut/burned valve/hose/regulator.SeeLPTankLeakTestandConnecting
hose. RegulatorToThe LPTank.
GasleakingfromLP , Mechanicalfailuredue to rustingor , Turnoff LPtankvalve.
tank. mishandling.
GasleakingfromLP , Failureof tank valve from mishandlingor , Turnoff LPtankvalve.ReturnLPtank to gassupplier.
tankvalve, mechanicalfailure.
Gasleakingbetween , Improperinstallation,connectionnot , Turnoff LP tankvalve.Removeregulatorfrom cylinderand visually
LPtankandregulator tight,failureof rubberseal. inspectrubbersealfor damage.SeeLPTankLeakTestand
connection. ConnectingRegulatorToTheLPTank.
Firecomingthrough , Fire inburnertubesectionof burnerdue ,Tum off controlknobsand LP tankvalve.Leavelid open to allow
controlpanel, to partialblockage, flamesto diedown.Afterfire is out andgrillis cold,removeburner
and inspectfor spidernestsor rust.SeeNaturalHazardandCleaning
The BurnerAssemblypages.
nil 0 * • •
, Toomuchgreasebuildupin burnerarea.
Greasefire or , Turnoff LP tank valve.Leavelid opento allowflamesto diedown.
continuousexcessive Aftercooling,cleanfood particlesand excessgreasefrom inside
flamesabovecooking fireboxarea,greasecup/pan/tray,andother surfaces.
surface.
GASISSUES:
, Tryingto lightwrongburner.
, Burnernotengagedwith controlvalve.
, Obstructionin burner.
Burner(s)will not light
usingignitor.
Continuedonnext
page.
, No gasflow.
, Vaporlockat couplingnut to LP tank.
, Couplingnutand LPtank valve notfully
connected.
ELECTRICALISSUES:
, Electrodecrackedor broken;"sparksat
crack."
, Electrodetip not in properposition.
, Wire and/orelectrodecoveredwith
cookingresidue.
, Wiresarelooseor disconnected.
, Wiresareshorting(sparking)between
ignitorand electrode.
, Seeinstructionson controlpanelandsectioninthe Useand Care.
, Makesurevalvesare positionedinsideof bumertubes.
, Ensureburnertubes are notobstructedwithspiderwebsorother
matter.Seecleaningsectionof Useand Care.
, Makesure LP tank is notempty.If LPtankis notempty,referto
"Suddendropin gasflow."
, Turnoff knobsand disconnectcouplingnutfrom LP tank.Reconnect
and retry.
, Turnthe couplingnutapproximatelyone-halfto three-quarters
additionalturnuntilsolid stop.Tightenby handonly- do not usetools.
, Replaceelectrode.
, Tip of electrodeshouldbepointingtowardporthole in burner.The
distanceshouldbe 1/8"to 3/16".Adjust if necessary.
, Cleanwireand/orelectrodewith rubbingalcoholandcleanswab.
, Reconnectwiresor replaceelectrode/wireassembly.
, Replaceignitorwire.
464820907,25
Troubleshooting(continued)
Burner(s)will not light
usingignitor.
Bumer(s)will not
matchlight.
Suddendropingas
flowor lowflame.
Flames blow out.
Flare-up.
Persistentgreasefire.
Flashback...
(firein burnertube(s)).
Unable to fill LP tank.
Oneburnerdoesnot
lightfrom other
burner(s).
, Push-buttonsticksat bottom..
, Sparkingbetweenignitorand electrode.
, See"GAS ISSUES:"on previouspage.
, Impropermethodof match-lighting.
, Outof gas.
, Excessflow valvetripped.
, Vaporlock at couplingnut/LPtank
connection.
, Highor gustingwinds.
, Lowon LPgas.
, Excessflow valvetripped.
, Greasebuildup.
, Excessivefat in meat.
, Excessivecookingtemperature.
, Greasetrappedbyfood builduparound
burnersystem.
, Burnerand/orburnertubesare blocked.
, Somedealershaveolderfill nozzles
withwornthreads.
, Greasebuildupor foodparticlesin
end(s)of carryovertube(s).
, Replaceignitor.
, Inspectwire insulationand properconnection.Replacewires if
insulationis broken.
, See"Match-Lighting"sectionof Useand Care.
, Checkfor gas inLPtank.
, Tumoff knobs,wait 30 secondsand lightgrill. If flamesare still low,
turnoff knobsand LPtank valve.Disconnectregulator.Reconnect
regulatorand leak-test.Turnon LP tank valve,wait30secondsand
thenlightgrill.
, Turnoff knobsand LP tank valve.Disconnectcouplingnutfrom
tank.Reconnectand retry.
, Turnfront of grill to facewindor increaseflame height.
, RefillLPtank.
, Referto "Suddendrop in gasflow"above.
, Cleanburnersand insideof grill/firebox.
, Trimfat frommeat beforegrilling.
, Adjust(lower)temperatureaccordingly.
, Turnknobsto OFF.Turngasoffat LPtank. Leavelid in positionand
letfire burnout.After grill cools,removeandcleanall parts.
, Tumknobsto OFF.Cleanbumerand/orburnertubes.See burner
cleaningsectionof UseandCare manual.
, Theworn nozzlesdon't haveenough"bite"to engagethevalve.Try
asecondLPdealer.
, Cleancarry-overtube(s)with wire brush.
26,464820907
Page
lank
Intentionally
464820907,27
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