Use and Care Guide
®
LiquidPropaneGas Grill withinfraredCooking System
Sears Model No. 4t5.t6657900
This Grill is for Outdoor Use Only
• 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.
• Safety
• Parts
• Use and Care
• Assembly
Assembly Questions?
Call t-800-241-7548
Tools needed for assembly:
Adjustable wrench (not provided)
Screwdriver (not provided)
7/16" Combination wrench (not provided)
SAVETHESEINSTRUCTIONS!
Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A.
©2008Sears,RoebuckandCo., All Rights Reserved Printedin China
Model464261709 80019155,02-23-09
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 have questions or need assistance during assembly,
please call 1-800-241-7548. You wilt 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®.
Product Record
IMPORTANT:Fillouttheproductrecordinformationbelow.
Model Number
Serial Number
Date Purchased
Seeratinglabel on grill for serialnumber.
To InstalledAssembler: Leave these instructions with
consumer.
To Consumer: Keep this manual for future reference.
CAUT,o. /K
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.
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/NFPA1192,and CSAZ240 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 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 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.
DANGER: Indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury,
, 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.
2,464261709
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,
ForYourSafety...................................... 2
GrillServiceCenter................................... 2
ProductRecordInformation............................ 2
SafetySymbols...................................... 2
InstallationSafetyPrecautions.......................... 2
KenmoreEliteGrillWarranty........................... 3
UseandCare.................................... 4-10
PartsList.......................................... 11
PartsDiagram...................................... 12
Assembly....................................... 13-23
Troubleshooting.................................. 24-26
RepairProtection 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.
Here's what the Repair Protection Agreement* includes:
[] 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 if your 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 price of 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 Protection 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.
The Repair Protection Agreement is a risk-free purchase. If
you cancel for any reason during the product warranty period,
we wilt provide a full refund. Or, a prorated refund anytime after
the product warranty period expires. Purchase your Repair
Protection Agreement today!
Some limitations and exclusions apply. For prices and
additional information in the U.S.A. call 1-800-827-6655.
*Coverage in Canada varies on some items. For full details
call Sears Canada at 1-800-361-6665.
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. or Canada 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).
Ten-Year Limited Warranty on Burners
For ten years from the date of purchase, any burner that
rusts through wilt 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 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.
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 legal rights, and you may
also have other rights which vary from state to state.
Sears, Roebuck and Co., Hoffman Estates, IL 60179
CONVERSION-READY
Easily converts from (LP) liquid
propane to (NG) natural gas
Contact I-8OO4-MY-HOME or
_parts to purchase
a natura_ gas conversion kff,
Request Part number 41&4584609
Dual FuerrMand SureFireTM are registered trademarks of
the W. C. Bradley Company and used, with permission,
by Sears Holding Corporation. All rights reserved.
464261709• 3
• NEVER store a spare 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, a fire causing death or serious
injury may occur.
• An over filled or improperlystored 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 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 hand only - 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. 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 Tank Valve,
Safety Cap
RetainerStrap
• A disconnected LP tank in storage or being transported must
have a safety cap installed (as shown). Do not store an LPtank
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 LPtank in an area where children play.
4,464261709
LP Tank
• 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 marked in accordance with
specifications for LP Tanks of the U.S. Department of
Transportation (DOT) or for Canada, CAN/CSA-B339, tanks,
spheres and tubes for transportation of dangerous goods.
Transport Canada (TC). See LP Tank collar for marking.
• LP Tank valve must have:
• Type 1 outlet compatible with
regulator or grill.
• Safety relief valve.
• UL listed Overfill Protection
Device (OPD). This OPD safety OPDHandWheel
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 LPTank valve. Always keep LP Tanks in
upright position during use, transit or storage.
LP Tank 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 flammable and may ignite unexpectedly when
mixedwith air.
LP Tank Filling
• Use only licensed and experienced dealers.
• LPdealer must purge new 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.
• A frosty regulator indicates gas overfill. Immediately close LP
Tankvalve 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 LP tank through an exchange service. Use only
those reputable exchange companies that inspect, precision fill,
test and certify their tanks. Exchange your tank only for an
OPB 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.
OPDHandWheel
j Type 1outlet with
thread on outside
Safety Relief Valve
/
Strap and Cap
Do not use a POL transport plug
(plastic part with external threads)!
It will defeat the safety feature of
the valve.
5. 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 LP tank valve.
464261709• 5
Hold coupling nut and regulator
as shown for properconnection
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-HOME®.
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!
A Never remove threaded
orificeat end of valve.
_z
• Do not insert any tool or foreign objects into the valve outlet
or safety relief valve. You may 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!
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.
6,464261709
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 burnerflames 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 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 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 managementto 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
A Before opening LP cylinder valve, check the coupling nut for
tightness.
A When grill is not in use, turn off all control knobs and LP
cylinder 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 sideburner and side shelf is 10 Ibs.
A The grease tray must be inserted into grill and emptied after
each use. Do not remove grease tray until grill has
completely cooled.
A 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.
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 Keep ventilation openings in cylinder enclosure (grill cart) free
and clear of debris.
A 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.
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".
A If the regulator frosts, turn off grill and LP cylinder valve
immediately. This indicates a problem with the cylinder and it
should not be used on any product. Return to supplier!
tAuT,oN
• 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.
Main Burner ignitor Lighting
A Do not lean over grill while lighting.
1. Open lid during lighting.
2. Turn on gas Tank valve.
3. Push and turn any burner control knob to HI and
immediately press and hold ELECTRONIC IGNITION button.
4. If ignition does NOT occur in 5 seconds, turn burner control
knob OFF, wait 5 minutes for gas to clear away, and repeat
the lighting procedure.
5. Repeat above steps to light each burner individually.
if ignition still does not occur, follow match-lighting
instructions.
464261709.7
Turn controls and gas source or tank OFF when not
in use.
CAUTIo.
if ignition does NOT occur in 5 seconds, turn the burner
controls OFF, wait 5 minutes for gas to clear away 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.
Main Burner Match-Lighting
A Do not lean over grill while lighting.
1. Turn OFF all burner control valves.
2. Open lid during lighting. Turn on gas at LP cylinder.
3. Light match, and place into lighting holefor desired burner to
light. The lighting holes are located at the front of the cooking
grates between the emitter plate mounting brackets.
4. Push in and turn control knob to HI ._ position for desired
burner to light. Be sure burner lights and stays lit.
5. If ignition does NOT occur in 5 seconds, turn the burner
Control knob off, wait 5 minutes for gas to clear away, and
repeat the match lighting procedure.
6. Ignite remaining burners by repeating steps 3 through 5 for
each burner.
Side Burner Ignitor Lighting
Sideburner Match Lighting
1. Turn OFF all burner control valves.
2. Open the sideburner lid.
Turn on gas at LP cylinder.
3. Place lit match near burner.
4. Turn sideburner knob to HI_ .
Be sure burner lights and stays lit.
WARNING: Sideburner top cover must be open when
sideburner is in operation.
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
partswill 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.
Warning:
Top cover must be open
when side burner(s) is in
operation.
,& Do not lean over grill while lighting.
1. Open lid during lighting.
2. Turn ON gas tank valve.
3. Push and turn sideburner control knob to _1:: HI and
immediately press and hold ELECTRONIC IGNITION button.
4. If ignition does NOT occur in 5 seconds, turn burner control
knob OFF,wait 5 minutes for gas to clear away, and repeat the
lighting procedure.
5. Repeat above steps to light each burner individually.
Normal
Hose
Turning Grill Off
Kinked
Hose
• Turn all knobs to OFF position. Turn LP tank off by turning
OPD hand wheel clockwise to a full stop.
Ignitor Check
• Turn gas off at LP tank. Push and turn burner control to _ .
"Clicking" should be heard and sparking seen each time
between collector box or burner and electrodes. See
"Troubleshooting" if no click or spark occurs.
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, and 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.
8. 464261709
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.
Storing Your Grill
•Clean cooking grates.
•Store 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 Sears or other qualified dealers.
•Store grill indoors ONLY if LP cylinder is turned off and
disconnected, removed from grill and stored outdoors.
•When removing grill from storage, follow "Cleaning the Burner
Assembly" instructions before starting grill.
CAUTION
/ SPIDER ALERT!
If you notice that your grill is getting hard tolight or thatthe
flame isn't as strong as it should be, take the time to check and
clean the venturi's.
CONTROLPANEL
SPIDERWEBS
INSIDE TUBE
BURNER
In someareasof the country,spidersor smallinsectshavebeen
knownto create"flashback"problems.The spidersspinwebs, build
nestsand layeggsin the grill'sburnertube(s)obstructingtheflowof
gasto the burner.Thebacked-upgascan igniteinthe tubebehind
thecontrolpanel.Thisis knownas a flashbackand it candamage
yourgrill and evencauseinjury.
Topreventflashbacksandensuregoodperformancethe burner
assemblyshouldbe removedfromthe grill and cleanedbeforeuse
wheneverthe grill has beenidle for an extendedperiod.
464261709• 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 grates and flame tamers.
3. Remove hitch pins and carryover tubes from rear of burners.
4. Remove Hitch pinto disengage burner from bracket on
firebox.
5. Detach electrode from burner with a flat screw driver by
pressing the electrode clamp out of the burner through the
notch on the clamp. Electrode should remain in firebox.
6. 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.
7. Wire brush entire outer surface of burner to remove food
residue and dirt.
8. Clean any blocked ports with a stiff wire such as an open
paper clip.
9. Check burner for damage, due to normal wear and corrosion
some holes may become enlarged. Ifany large cracks or
holes are found replace burner.
VERY IMPORTANT: Burner tubes must reengage valve
openings. See illustrations at right.
10. Attach electrode to burner.
11. Carefully replace burners.
12. Attach burners to brackets on firebox.
13. Reposition carryover tubes and attach to
burners. Replace flame tamers and
cooking grates.
Correct
burner-to-valve
engagement
........................burner
10 • 464261709
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 kilt bacteria. Use a
food 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).
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 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.
WARNING: To ensure 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 of A( ricutture
1
2
3
4
5
7
8
9
10
11
12
2 CASTER, LOCKING
2 CASTER_ FIXED
1 BOTTOM SHELF
TANK SCREW, F/BOTTOM
1
SHELF
1 CART LEFT SIDE PANEL
GROMMET, F/REGULATOR
1
HOLE
1 CART RIGHT SIDE PANEL
1 CART LOWER BACK PANEL
1 TOP LID_ OUTER
1 INNER LINER_ F/TOP LID
1 HANDLE F/TOP LID
RECTANGULAR BUMPER, F/
2
TOP LID
2 RUBBER BUMPER_ F/LID
1 LOGO PLATE
1 HARDWARE F/TOP LID
1 FIREBOX
1 MATCH HOLDER
3 MAIN BURNER
ELECTRODE W/
3 WIRE/COLLECTOR, F/MAIN
BURNER
CARRYOVER TUBE W/
20 2 80017669
COTTER PIN
HOSE VALVE REGULATOR
21 1 ASSY 80018375
22 1 MAIN CONTROL PANEL 80019215
23 4 BEZEL, F/CONTROL KNOB 80018318
24 4 CONTROL KNOB 80019164
25 1 CART UPPER BACK PANEL 80007473
26 1 RIGHT SIDE SHELF 80007487
27 1 FASCIA, F/RIGHT SIDE SHELF 80017684
28 1 LEFT SIDE SHELF F/S/B 80007482
29 1 FASClA_ F/LEFT SIDE SHELF 80019216
30 1 DRIP PAN_ F/SB 80017677
31 1 LID, F/SB 80008182
TEMPERATURE GAUGE, UFC
32 3 80007563
MOUNTED
33 1 SIDEBURNER 80017653
34 1 ELECTRODE, F/SB 80017680
ELECTRODE WIRE, F/
35 1 80018307
SIDEBURNER
13
14
15
16
17
18
19
80000268
80004093
80007452
80006484
80007454
80004157
80019167
80007458
80019160
80019217
80009953
80006983
80006625
80010544
80017678
80007720
80006654
80017579
80007512
36 1 GRATE, F/SB 80006640
37 1 FRONT BRACE 80007568
38 1 HEAT SHIELD, F/TANK 80007503
39 1 LEFT RAIL, F/GREASE TRAY 80007501
40 1 RIGHT RAIL, F/GREASE TRAY 80007502
41 1 LEFT DOOR, NO HANDLE 80017687
42 2 DOOR HANDLE 80009974
43 1 RIGHT DOOR, NO HANDLE 80017688
44 1 BUTTON CAP, F/El MODULE 80018347
ELECTRONIC IGNITION
45 1 80018343
MODULE
46 1 HEAT SHIELD, F/El MODULE 80015536
47 1 IGNITER SWITCH MODULE 80018315
48 3 HEAT DIFFUSER 80003332
49 3 COOKING GRATE 80018619
50 1 WARMING RACK 80007505
51 1 GREASE TRAY 80018309
Not Pictured:
... 2 DOOR MAGNET 80008850
... 1 HARDWARE PACK 80019169
... 1 CASTER WRENCH 80000283
... 1 ASSEMBLY MANUAL, ENGLISH 80019155
... 1 ASSEMBLY MANUAL, SPANISH 80019156
If you are missing hardware or have damaged parts,
please call 1-800-241-7548 for replacement.
464261709.11
I©
@
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.0
(9-----
12,464261709
Attach the two locking casters at the rear of the bottom shelf
and the two fixed casters at the front and tighten with the caster wrench provided.
Fixed caster
Lockingcaster--______
Bottom
Attach side panels to bottom shelf using three
1/4-20x1/2" screws, 7ram lock washers, and
7ram flat washers per panel.
IMPORTANT: Panel with large hole must
be on left side of bottom shelf.
l/4-20xl/2"Screw 1/4-20x1/2"screw
Qty.6
O7mm lock washer 7ram
Qty.6
7ram
7mmfiat washer
Qty.6
Leftside panel
(with largehole)
Makesureside panels
are pushedas far to the
rearof bottom shelfas
possiblebefore fully
tightening screws.
Right sidepanel
464261709.13
Place lower back panel between side
panels at rear of bottom shelf. Secure
lower back panel to side panels using four
1/4-20x1/2" screws, 7ram lock washers,
and 7ram flat washers.
Lowerbackpanel
1/4-20×1/2"screw
7ramlock washer
l/4-20xl/2"Screw
7ramflat washer
Qty.4
7mmlock washer
Qty.4
7mm flat washer
Qty.4
This step requires two people
to lift and position grill head
onto cart. Carefully lower the grill
head onto the cart, aligning slots at
bottom of grill head with posts on
cart side panels. Make sure the
regulator hose is hanging outside
the cart. Grill head must face open
side of cart.
Grill head
Regulatorhose
14.464261709
Onbackof grill, placeupperbackpanelbetweensidepanelsand abovefowerback panel
Secureupper backpanelin lowerholes,usingone t/4-20x114" screw,7ramIockwasher,and7ram fiatwasheroneachside
Do not fully tighten screws until side shelf installation is complete in later steps,
0 ©
7mmLockwasher 7mmfiatwasher
Qty.2 Qtyo2
114-20x1½"screw
Qty.2
Upperbackpanel
Insertflangeon rightsideshelfintosideshelf bracketson sideof firebox
Attachrightside shelfusingthreeI/4"-20x3/4"screws,7ram lockwashers,7ramflatwashers,tl4" nuts,shownAo
Attachrear of shelfusingone I/4-20x1%"screw,7ramlockwasher,and7ramfiat washerinlowerhole,shownBo
Attachfront of shelf and fasciausingone #8x3/8"self-tappingscrewandlarge fiat washer,shownCo
Attachfront of shelf and fasciausingone 114"-20x3/4"screw,7ramlockwasher,7ramfiat washerand114"nut,shownDIG
ll4-20x3i4"Screw
Qtyo4
1i4-20xlW'screw
_'y.1
0 ©
7ramlock washer 7mmfiatwasher
#8x3f8" Qty.5 _q/,5
seINappingscrew
Qty.I
lock
washer
screw
1/4"_t largefiatwasher
QtyA Qty.1
:i:?
wesher
panel
washer
114-20x314"
screw
7ram
454261709o15
Insert flange on left sideburner shelf into side shelf brackets on side of firebox.
Attach left sideburner shelf using three 1/4-20x3/4" screws, 7ram lock washers, 7ram flat washers, 1/4" nuts, shown A.
Attach rear of shelf using one l/4-20xllA '' screw, 7ram lock washer, and 7ram flat washer in lower hole, shown D.
Attach front of shelf and fascia using one #8x3/8" self-tapping screw and large flat washer, shown C.
Under main control panel, attach front of shelf and fascia using one 1/4-20x3/4" screw, 7ram lock washer, 7ram flat
washer and 1/4" nut, shown DIE.
Now you may fully tighten lower screws on upper back panel.
l/4-20x3/4"Screw #8×3/8"
Qty.4 self-tappingscrew Flange
into
1/4-20x1W'screw _'Y"
Qty. 1 1/4-20xlI/2"
screw
7ram lock washer 7ram flat washer 1/4" nut
Qty.5 Qty.5 Qty.4
largeflat washer
Qty.1
Fascia,left sideburnershelf
7mmlock
washer
Back of main control
1/4-20x3/4"
screw
16.464261709
First, removethe two screws and lock washersfactory attachedto the sideburner valvebracket,.Positionsideburner
valvebracketbeneathsidebumershelffasciaso that valvestemcomesthroughlargercenterhole infascia Alignthe holes
onvalvebracketwithleft and rightholeson fascia Secureusinglockwashersandscrewsthatwereremovedfrombracket
Next,placesideburnerbezelovervalve stemonfrontsideof fascia Alignsmall holesonbezelwith upperand lowerholeson
lascia,p aNngsure°OFF° isF_ thetP,S. Attachusingtwo#8-32x318"screwsand4ram lockwashers Press sidebumer
controlknobonto valvestern
Note: Use left and right
holes on fascia to
attach valve bracket
ScrewsandWashers
removedfromvalvebracket
.... •,!,_:T" ::::::::::::::::::::::::::::
S deb,,,,,er
i;:::: va,vob,ooket
_ 8-32x3f8"screw
Qty.2
O 4ramlock washer
Qty.2
Note: Use upper and lower
holes on fascia to attach bezel
Controlknob #8-32x318"screw
l
: _
Pullout thethreeknobsfromcontrolpanel Inserttemperaturegaugesteminto thebiggerholeaboveknobbezel,shownA
Makesurethe gaugeis pushedin asfar as it will go, thenpushthegaugedownwarduntilitclips intothe panel,as shown
in B/C Re-installthe threeknobs gaugestern
i
Knob
Insertsideburnerburnerinto left shelfThe stud on bottomof burnerfits into rearsmallholein sideburnerdrip pan on
shelf,shownA, Secureburnerto sidebumerdrip panwithoneWingnut,shownB Makesureburnertubeengages
sidebumervalve,shownC
Wingnut
Sidebumerburner
G
_' Wingnut
PP_
Sidebumer drip pan
Undersidebumershelf,attachsidebumerignitorwireto electrode,shownA Placesidebumergrateontosideburnershelf,
aligninggratelegswithholesin shelf,shownB,
Sidebumer IgnitorWire
Sic
18°4E.426_709
Insert front brace under control panel and between cart side panels. Make sure door hinge pins are on the top side and
facing the front. Secure using two l/4-20xllA '' screws, 7ram lock washers, and 7ram flat washers on each side.
1/4-20×11/2"screw
Qty.4
7ram Lockwasher 7ram flat washer
Qty.4 Qty.4
7ramflat 7ramlock 1/4-20×11/2"
washer washer screw
Inside of cart, insert rear shield tab into left slot on upper of lower back panel. Insert left and right grease tray rails into slots
beneath grease tray opening in upper back panel, shown A. Attach front shield tabs under front brace and attach right and
left rails under front brace with three #8x3/8" self-tapping screws, shown B.
Tankheatshield
Note:somepartsomitted
for clarityof illustration
#8x3/8"self-tappingscrew
Qty.3
Greasetrayopening
464261709.19
Insert hinge pin on bottom of doors into hole in bottom shelf. Press upper hinge pin in front brace, align hinge hole on top of
door, and release hinge pin into door.
doo_
I
i!i!,i_i,i!iiiiiiii_i,liiiiiiiiiliiiii!,i!_iiiii]liJiliiii_
Hingepin
on bottom
of door
Release the cap and nut from electronic ignition module. Attach electronic ignition module and heat shield to the cart right
side panel with the nut and cap, shown A.
Connect each of the wires from the main burner electrodes, and sideburner electrode into the back of the Electronic Ignition
Module. Total (4) connections.
Connect the two wires [(a) and (b)] from the switch wiring harness into the backof the Electronic Ignition Module.
Total (2) connections.
NOTE: Switchterminals are larger than electrode terminals and should only be installed in location shown as (a), (b).
Nut Cap
20.464261709
Install heat diffusers by sliding one end of each heat diffuser into slots at front of firebox and resting opposite end on pins in
back of firebox.
Heat diffuser
Place cooking grates onto the firebox as shown. Insert the two wire ends at rear of warming rack into holes in back of
firebox. Front wires of warming rack rest on sides of firebox.
Assembled
warming rack
Cooking grate
464261709.21
On back of grill, slide grease tray into opening in upper back panel.
m m
cAuTioN
Failure to install grease tray will
cause hot grease to drip from bottom
of grill with risk of fire or property
damage.
Greasetray
Unscrew electronic ignition cap on cart right side panel. Insert AA battery into ignitor, negative (=) end first. '
Replace the cap.
AA Battery
/
Electronic ignitionCap
22.464261709
LP CYLINDER IS SOLD SEPARATELY. Fill and leak check the cylinder before attaching to grill and regulator (see Use &
Care section). Once cylinder has been filled and leak checked, place cylinder into hole in bottom shelf. Make sure cylinder
valve is facing front of grill. Secure cylinder with cylinder screw under bottom shelf. Insert regulator through large hole in
left side panel. See Use & Care section of this manual to perform the "Burner Flame Check" and for
important safety instructions before using.
Always keep LP cylinders in upright positionduring
use, transport, and storage.
Regulator
CAUT,o./L
Cylinder valve must face to front of cart once
tank is attached. Failure to install cylinder
correctly may allow gas hose to be damaged
in operation, resulting in the risk of fire.
464261709.23
EMERGENCIES; if a gas leak cannot be stopped, or a fire occurs due to gas leakage, call the fire department.
Gasleakingfrom
cracked/cut/burned
hose.
Gasleakingfrom LP
cylinder.
Gasleakingfrom LP
cylindervalve.
Gasleakingbetween
LPcylinderand
regulatorconnection.
Firecomingthrough
controlpanel.
Greasefire or
continuousexcessive
flamesabovecooking
surface.
•Damagedhose.
•Mechanicalfailuredueto rustingor
mishandling.
• Failureof cylindervalvefrom
mishandlingormechanicalfailure.
•Improperinstallation,connectionnot
tight,failureof rubberseal.
• Firein burnertube sectionof burnerdue
to blockage.
•Toomuchgreasebuildupin burnerarea.
•Turnoffgas at LP cylinderor at sourceon naturalgassystems.If
anythingis burned,replacevalve/hose/regulator.If burned,
discontinueuseof productuntila plumberhas investigatedcause
andcorrectionsare made.
•ReplaceLP cylinder.
•Turnoff LPcylindervalve.ReturnLP cylinderto gassupplier.
•Turnoff LPcylindervalve.Removeregulatorfrom cylinderand
visuallyinspectrubbersealfor damage.SeeLPCylinderLeakTest
andConnectingRegulatorto the LP Cylinder.
•TurnoffcontrolknobsandLPcylindervalve.Leavelid opento
allowflamesto diedown.Afterfire is outandgrill is cold,remove
burnerandinspectfor spidernestsor rust.SeeCleaningthe
BurnerAssemblypages.
•TurnoffcontrolknobsandLPcylindervalve.Leavelidopento
allowflamesto diedown.Aftercooling,cleanfood particlesand
excessgreasefrom insidefireboxarea,greasetray,andother
surfaces.
Troubleshooting
Burner(s)will not light
usingignitor.
(SeeElectronicIgnition
Troubleshootingalso)
Continuedonnext
page.
GASISSUES:
•Tryingto lightwrongburner.
• Burnernot engagedwith controlvalve.
• Obstructionin burner.
• Nogas flow.
•Vaporlock at couplingnutto LP cylinder.
• Couplingnut and LP cylindervalve not
fullyconnected.
ELECTRICALISSUES:
• Electrodecrackedor broken;sparksat
• Seeinstructionsoncontrolpanelandin UseandCaresection.
• Makesurevalvesare positionedinsideof burnertubes.
• Ensureburnertubesarenot obstructedwithspiderwebsor other
matter.Seecleaningsectionof UseandCare.
• MakesureLPcylinderis not empty.If LPcylinderis notempty,
referto "Suddendropin gasflow."
•Turnoff knobsanddisconnectcouplingnut fromLPcylinder.
Reconnectandretry.
•Turnthe couplingnutapproximatelyone-halfto three-quarters
additionalturn untilsolidstop.Tightenby handonly- do not use
tools.
• Replaceelectrode(s).
crack.
•Electrodetip not in properposition.
•Wireand/orelectrodecoveredwith
cookingresidue.
•Wiresare looseor disconnected.
•Wiresare shorting(sparking)between
ignitorand electrode.
•Deadbattery.
MainBurners:
•Tip of electrodeshouldbepointingtowardgasport openingon
burner.The distanceshouldbe 1t8"to 1t4".Adjustif necessary.
Sideburner:
•Tip of electrodeshouldbepointingtowardgasport openingon
burner.The distanceshouldbe 1/8"to 3/16".Adjustif necessary.
•Cleanwireand/orelectrodewithrubbingalcoholandcleanswab.
•Reconnectwires or replaceelectrode/wireassembly.
•Replaceignitorwire/electrodeassembly.
•Replacewith a newAA-sizealkalinebattery.
REVO0
24 • 464261709
Troubleshooting (continued)
ELECTRONICIGNITION:
•No spark,noignitionnoise.
•No spark,someignitionnoise.
•Sparks,but not at electrodeor at full
strength.
Burner(s)will not light
usingignitor.
(SeeElectronicIgnition
Troubleshootingalso)
Burner(s)will not
matchlight.
Suddendropin gas
floworlow flame.
Flamesblowout,
Flare-up.
Persistentgreasefire.
Flashback...
(firein burnertube(s)),
Unableto fill LP
cylinder.
•See "GAS ISSUES:"on previouspage.
• SeeSectionI of ElectronicIgnitionSystemon the nextpage.
• SeeSectionII of ElectronicIgnitionSystemonthe next page.
• SeeSectionIII of ElectronicIgnitionSystemon the next page.
•Matchwill notreach.
•Impropermethodof match-lighting,
•Out of gas,
•Excessflow valvetripped.
•Vaporlock at couplingnut/LPcylinder
connection.
•Highor gustingwinds.
•Lowon LPgas,
•Excessflow valvetripped.
,Greasebuildup.
•Excessivefat in meat.
•Excessivecookingtemperature.
•Greasetrappedbyfood builduparound
burnersystem.
•Burnerand/orburnertubesareblocked.
•Somedealershaveolderfill nozzles
withworn threads.
•Uselong-stemmatch(fireplacematch).
•See"Match-Lighting"sectionof Use andCare.
•Checkforgas in LP cylinder.
•Turnoff knobs,wait 30 secondsfor excessflow valve to reset,and
thenlightgrill. Ifflamesare still low, turnoff knobsandLPcylinder
valve.Disconnectregulator.Reconnectregulatorandleak-test,Turn
onLPcylindervalve,wait 30 secondsfor excessflow valve to reset,
andthenlightgrill.
•Turnoff knobsandLPcylindervalve.Disconnectcouplingnutfrom
cylinder.Reconnectand retry.
•Turnfrontof grill to face windor increaseflameheight.
•RefillLPcylinder.
•Referto "Suddendrop in gas flow"above.
•Cleanburnersandinsideof grill/firebox.
,Trimfat from meatbeforegrilling.
•Adjust(lower)temperatureaccordingly.
•Turnknobsto OFF,Turngas off at LPcylinder.Leavelid in position
andlet fire burnout,After grill cools,removeandcleanall parts.
•Turnknobsto OFF,Cleanburnerand/orburnertubes.Seeburner
cleaningsectionof Use and Care.
•Theworn nozzlesdon'thaveenough"bite"to engagethe valve.Try
a secondLPdealer.
464261709 • 25
Troubleshooting - Electronic Ignition
,Battery not installed
properly.
SECTIONI
Nosparksappearat
anyelectrodeswhen
controlknobturnedto
_" ; no noisecan be
heardfromspark
module.
SECTIONII
Nosparksappearat
anyelectrodeswhen
controlknobturnedto
; noisecan be
heardfromspark
•Deadbattery.
•Checkbatteryorientation. •Installbattery(makesurethat"+" and"-"
connectorsareorientedcorrectly,with "+"end up
•Hasbatterybeenused
previously?
and"-" enddown.)
•Replacebatterywith newAA-sizealkalinebattery.
•Ignitionbuttoncap
assemblynot installed
properly.
•Faultysparkmodule.
•Outputlead
connectionsnot
connected.
•Checkto insurethreadsare
properlyengaged.Button
shouldtravelup and down
withoutbinding.
•If nosparksaregenerated
withnew batteryandgood
wire connections,moduleis
faulty.
•Are outputconnectionson
andtight?
•Unscrewbuttoncapassemblyand reinstall,making
sure threadsare alignedand engagedfully.
•Replacespark moduleassembly.
•Removeandreconnectall outputconnectionsat
moduleandelectrodes.
module. L _
SECTIONill
Sparksare present
butnot at all
electrodesand/ornot
at fullstrength
,Outputlead
connectionsnot
connected.
,Electricalarc between
outputwiresandgrill
frame.
•Weakbattery.
,Electrodesarewet.
• Electrodescrackedor
broken;sparksat
electrodecrack.
•Are outputconnectionson
andtight?
•If possible,observegrill in
dark location.Operate
ignitionsystemandlookfor
arcingbetweenoutputwires
andgrillframe.
•All sparkspresentbutweak
or at slowrate.
•Hasmoistureaccumulated
on electrodeand/orin burner
ports?
•Inspectelectrodesfor
cracks.
•Removeandreconnectall outputconnectionsat
moduleandelectrodes.
•Ifsparksareobservedanywhereelsethanon the
burners,wireinsulationmay be damaged.Havethe
wiresreplacedby Searsoranotherqualifiedservice
dealer.
,Replacebatterywitha newAA-sizealkalinebattery.
•Usepapertowelto removemoisture.
,Havethe crackedor brokenelectrodesreplacedby
Searsor anotherqualifiedservicedealer.
26.464261709
464261709•27
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