Assembly Instructions/Useand CareManual
LiquidPropaneGasGrill
Model No. 415.16115 and 640-122390-115
ThisGrillis 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
• EspaSol
Assembly Questions?
Call 1-800-241-7548
Parts Ordering:
Call 1-800-4-MY-HOME ®
To InstallerlAssembler: Leave
these instructions with
consumer,
To Consumer: Keep this
manual for future reference.
Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A.
@2006Sears,Roebuckand Co.,All RightsReserved Printedin China 464321607and464321407°80009281,11-01-06
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,
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 cylinder 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
Ifyou have questions or needassistance during assembly,
please call 1-800-241-7548.Youwill be speakingto a
representativeof the grill manufacturerand not a Sears
employee. Toorder new parts call Sears at 1-800-4-MY-HOME®.
Product Record
iMPORTANT:Filloutthe productrecord informationbelow.
Model Number
Serial Number
See rating label on grill for serial number.
Date Purchased
Safety Symbols
The symbolsand boxesshown below explain what each heading
means. Read and follow all of the messagesfound throughout
the manual.
DANGER: Indicatesan 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.
CAUTION
CAUTION: Indicatesa potentiallyhazardous 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/valveassembly supplied.
• Grill installationmust conform with local codes, or in their
absence of local codes, with either the NationalFuel 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,ANSl A 119.2/NFPA1192,and CSA Z240 RV Series,
Recreational VehicleCode, as applicable.
, All electrical accessories (such as rotisserie) must be
electrically groundedin accordance with local codes, or
National Electrical Code, ANSl / NFPA70. Keepany electrical
cords and/or fuel supply hoses awayfrom any hot surfaces.
, Grill is not for use in or on recreationalvehicles and/or boats.
, This grill is safety certified for use in the UnitedStates only. Do
not modify for use in any other location. Modification will result
in a safety hazard.
CAUTION
For residential use only. Do not use for commercial
cooking.
2 • 464321607and 464321407
ForYour Safety...................................... 2
Grill Service Center................................... 2
Product Record Information ............................ 2
Safety Symbols...................................... 2
InstallationSafety Precautions .......................... 2
Kenmore Grill Warranty ............................... 3
Use and Care..................................... 4-11
Parts List.......................................... 12
Parts Diagram...................................... 13
Assembly ....................................... 14-23
Troubleshooting.................................. 24-26
Repair Protection Agreements
Congratulationson makinga smart pumhase. Your new
Kenmore®product is designed and manufacturedfor years of
dependableoperation. But like all products, it may requirerepair
from time to time. That's when having a Repair Protection
Agreementcan save you moneyand aggravation.
Purchasea Repair ProtectionAgreementnow and protect
yourself from unexpected hassleand expense.
Here's what's included in the Agreement:
[] Expert service by our 12,000 professional repairspecialists
Unlimited service and no charge for parts and labor on all
coveredrepairs
[] Product replacement if your covered product can't befixed
[] Discount of 10% from regular price of service and service-
related parts not covered by the agreement; also, 10%off
regularprice of preventivemaintenance check
[] Fast help by phone - phone supportfrom a Sears
technicianon products requiring in-homerepair, plus
convenientrepair scheduling
Once you purchasethe Agreement, a simple phone call is all that
it takes for you to scheduleservice. Youcan call anytime day or
night, or schedulea service appointment online.
Sears has over 12,000 professionalrepair specialists, who have
access to over 4.5 million quality parts and accessories.That's
the kind of professionalismyou can count on to help prolong the
life of your new purchasefor years to come. Purchase your
Repair ProtectionAgreement today!
Some limitationsand exclusions apply.
For prices and additional informationcall 1-800-827-6655.
Sears Installation Service
For Sears professionalinstallation of homeappliances, garage
door openers,water heaters,and other major home items, in the
U.S.A. call 1-800-4-MY-HOME®
One-YearFull Warrantyon KenmoreGrill
Ifthisgrillfails dueto adefectin materialorworkmanshipwithin
oneyearfromthe dateof purchase,call 1-800-4-MY-HOME®to
arrangeforfree repair(or replacementif repairprovesimpossible).
Five-Year Limited Warranty on Stainless Steel Burners
For five 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.
Allwarrantycoverageis voidif this grill iseverusedfor commercial
or rentalpurposes.
Allwarrantycoverageappliesonly ifthisgrill is usedin theUnited
States.
Thiswarrantygivesyouspecificlegalrights,andyoumayhave
otherrightswhichvaryfromstateto state.
Sears, Roebuck and Co., Hoffman Estates, IL 60179
464321607and464321407• 3
LP Tank
• NEVERstore a spare LP tank under or near grill or in
enclosed areas
hi, _ _Siii_ i _
• Never fill the cylinder beyond 80% full,
• An overfilled or improperly stored tank is a hazard due
to possiblegas release from the safety relief valve.
• If you see, smell or hear escaping gas, immediatelyget
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 Ib. (9 kg.)
capacity maximum.
, LP tanks must be constructed and marked in accordancewith
specificationsfor LP tank of the U.S. Departmentof
Transportation(DOT). See LP tank collar for marking.
• LP tank valve must have:
, Type 1 outlet compatiblewith
regulator or grill.
, Safety relief valve.
, UL listed OverfillProtection
OPDHandWheel
Device (OPD).This OPD safety
feature is identifiedby a unique triangular hand wheel. Use
only LP tanks equipped with this type of valve.
, LP tank must be arrangedfor vapor withdrawal and include
collar to protect LP tank valve.
LP (Liquefied Petroleum Gas)
• LP gas is nontoxic,odorless and colorlesswhen produced. For
Your Safety, LP gas has been given an odor (similarto rotten
cabbage) so that it can be smelled.
• LP gas is highlyflammable and may ignite unexpectedlywhen
mixedwith air.
LP Tank Removal, Transport And Storage
, Turn OFF all control knobs and LP tank valve. Turn coupling
nut counterclockwiseby hand only - do not use tools to
disconnect. Lift LP tank wire upwardoff 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 andlor propertydamage.
LPTankValve
Salty Cap
Retainer Strap
, A disconnectedLP tank in storage or being transported must
have a safety cap installed (as shown). Do not storean LP tank
in enclosedspaces such as a carport, garage, porch,covered
patio or other building. Never leave an LPtank inside a vehicle
which may becomeoverheated by the sun.
, Do not store an LP tank in an areawhere children play.
4 • 464321607and 464321407
LP Tank Filling
• Use only licensedand experienced dealers.
• LP dealer must purge tank before filling.
• Dealer should NEVERfill LP tank more than 80% of LP tank
volume. Volume of propane intank will vary by temperature.
• A frosty regulator indicates gas overfill. Immediatelyclose LP
tank valve and call local LP gas dealerfor assistance.
, Do not release liquid propane(LP) gas into the atmosphere.
This is a hazardouspractice.
, To removegas 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 retailersthat sell grills offer you the option of replacing
your empty LP tank through an exchange service. Use only
those reputable exchange companies that inspect, precisionfill,
test and certifytheir 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 properlysecured onto grill. (Refer to
assemblysection.)
2. Turn all control knobsto the OFF position.
3. Turn LP tank OFF by turning OPD hand wheel clockwise to a
ful! stop.
4. Remove the protectivecap from LP tank valve. Always use
cap and strap supplied with valve.
LP Tank Leak Test
For your safety
• Leak test must be repeatedeach 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,
awayfrom ignition sources such as gas fired or electrical
appliances. During leak test, keep grill away from openflames
or sparks.
, Use a clean paintbrushand a 50/50 mild soap andwater
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!
,L Do not use householdcleaning agents. Damage to gas
train componentscan result.
Type 1 outlet 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 valveso as not to cross-
thread the connection.
Nipplehasto be centered
intothe LPtank valve.
464321607and 464321407• 5
Hold coupling nut and regulator
as shown for 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,Ifyou hear a rushing sound,turn gas off
immediately,There is a major leak at the connection, Correct
before proceeding by calling Searsfor replacement partsat
1-800-4-MY-HOME®.
4. Brush soapy solutiononto areas where bubbles are shown in
picture below:
6. Turn the coupling nut clockwise and tighten to a full stop. The
regulatorwill seal on the back-checkfeature in the LP tank
valve, resulting in some resistance.An additional one-half to
three-quarters turn is requiredto complete the
connection, Tighten by hand only - do not use tools,
NOTE:
Ifyou cannotcomplete 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 reliefvalve. You may damage the valve and cause
a leak. Leaking propanemay 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, immediatelyclose LPtank
valve and call LPgas supplier or your fire department!
,ANeverremovethreaded
orificeat end of valve.
\
5. if "growing" bubbles appear, there is a leak. Close LP tank
valve immediatelyand retightenconnections. If leaks cannot
be stopped do not try to repair, Call Sears for replacement
partsat 1-SO0-4-iVIY-HOME®.
6. Always close LP tank valve after performingleak test by
turning hand wheel clockwise.
, Never attemptto attach this grill to the self-containedLP gas
system of a camper trailer or motor home.
, Do not use grill until leak-tested.
6 • 464321607and 464321407
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
enclosedspace such as carport, garage, porch, covered
patio, or under an overhead structure d any kind.
• Do not use charcoalor 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. clearanceto 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 groundfloor with a three (3)foot
clearancefrom walls or rails. Do not use on or under
balconies.
• NEVERattempt 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
Before opening LP tank valve, check the coupling nut for
tightness.
A When grill is not in use, turn offall control knobs and LP tank
valve.
A Never move grill while in operation or still hot.
,_ Use long-handled barbecue utensilsand oven mitts to avoid
burns and splatters.
,_ Maximum load for shelves is 10 Ibs.
A Do not use a cooking pot largerthan 9" on grid.
A The grease cup must be attached to grease cup clip and
emptied after each use. Do not removegrease cup until grill
has completelycooled.
,= 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. Performa leak test.
,_ The regulator may make a hummingor whistling noise during
operation.This will not affectsafety or use of grill.
A If you have a grill problem see the "TroubleshootingSection".
if the regulatorfrosts, turn off grill and LP tank valve
immediately.This indicatesa problem with the tank and it
should not be used on any product. Return to supplier!
464321607and 464321407• 7
Ignitor Lighting
A Do not lean over grill while lighting.
1. Open lid during lighting,
2. To ignite, turn IGNITION BURNER knob to_ _.
3. Push and hold ELECTRONICIGNITION button.
4. If ignition does NOToccur in 5 seconds, turn the burner
control off, wait 5 minutes, and repeat the lighting procedure.
5. Ignite other burners by turning 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 (hangingfrom side of cart).
Light match, place into lighting hole on right side of firebox.
3. Push in and turn left knob to HIGH position. Be sure burner
lightsand stays lit.
4. Light other burners by pushing knob in and turning to _ HIGH
position.
m
c.uTio.
• 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 gril! 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 d paint and
parts will produce an odor only on first lighting.
Burner Flame Check
, Light burner, rotateknobs from HIGH to LOW. Youshould see
a smaller flame in LOW positionthan 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 TroubleshootingSection.
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/regulatorspecified in the PartsList.
Normal
Hose
Kinked
Hose
8 • 464321607and 464321407
Turning GrillOff
, 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. Tocheck valves,first
push in knobsand release,knobs should spring back. If knobs
do not spring back, replace valve assemblybefore using grill.
Turn knobs to LO position then turn back to OFF position.
Valvesshould turn smoothly.
General Grill Cleaning
, Keep the outside of your grill looking new by cleaning it once a
monthwith warm soap and water or a non-abrasivecleaner. If
you don't have a grill cover, wipe offdust and grime before
starting your grill.
, Coating the cooking grids with spray-oncooking oil will keep the
food from sticking and make clean up easier.After cooking,
scrape the grates with a long handled, brasswire bristle brush.
, Check inside the grill bottom for grease build up and clean
often, especially after cooking fatty meat.
, Do not mistake brown or blackaccumulationof grease and
smoke for paint. Apply a strong solution d detergentand water
or use a grill cleaner with scrub brush on insidesof grill lid and
bottom. Rinseand allow to completelyair dry. Do not apply a
caustic gril!/oven cleaner to painted surfaces.
• Plated wire grates: Wash grates with concentratedgrill
cleaner or use soap and water solution. Dry thoroughlyand
store indoors betweencookouts.
, Plastic parts: Washwith warm soapywater and wipe dry.
A Do not use citrisol, abrasive cleaners, degreasersor a
concentratedgrill cleaner on plastic parts. Damage to and
failure of parts can result.
• Porcelain grates: Becauseof glass-like composition, most
residue can be wiped away with baking soda/watersolution or
specially formulated cleaner. Use non-abrasivescouring
powder for stubbornstains.
m m
cAuT,o.
/ SPIDER ALERT! -"
SPIDERANDWEBS,=o_ J,
INSIDEBURNER 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's,
I,
...............................t
CONTROLPANEL.
SPIDERWEBS
INSIDETUBE
Insomeareasof thecountry,spidersor smallinsectshavebeen
knownto create"flashback"problems.Thespidersspinwebs,build
nestsandlay eggsin the grill'sburnertube(s)obstructingtheflowof
gastothe burner.The backed-upgascanigniteinthetubebehind
thecontrolpanel.Thisis knownas aflashbackandit candamage
yourgrillandevencauseinjury.
Topreventflashbacksandensuregoodperformancetheburner
assemblyshouldberemovedfromthe grillandcleanedbeforeuse
wheneverthe grillhasbeenidleforanextendedperiod.
\ 1'
464321607and 464321407• 9
Cleaning the Burner Assembly
Followthese instructionsto clean and/or replace parts of burner
assemblyor if you have trouble igniting grill
1 Turn gas off at control knobs and LP cylinder.
2. Remove cookinggrates and heat tents.
3. Remove screwsand flame carryover tubes from rear of
burners.
4. Remove screw and washers to disengage burner from
bracket onfirebox.
5. Remove screwsto detach electrode from burner. 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 hangerworks 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 burnertube 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 blockedports with a stiff wire such as an open
paperclip.
9. Check burnerfor 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 re-engage valve
openings. See illustrationsat right, Correct
10. Attach electrode to burner, burner-to-valve
11. Carefully replace burners, engagement ,
12. Attach burners to bracketson firebox.
13. Repositionflame carryover tubes and attach _
to burners. Replace heat tents and __
cooking grates. ,,_
Storing Your Grill
, Clean cooking grates.
, Store in dry location.
, When LP tank is connected to grill, storeoutdoors 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, removedfrom grill and stored outdoors.
, When removing grill from storage follow "Cleaning Burner
Assembly" instructions before starting grill.
Food Safety
Foodsafety is a very important part of enjoying the outdoor
cooking experience.To keep food safe from harmful bacteria,
follow these four basicsteps:
Clean: Wash hands, utensils, and surfaces with hot soapy water
before and after handling raw meat and poultry.
Separate: Separate raw meats and poultryfrom ready-to-eat
foods to avoid cross contamination. Use a clean platter and
utensils when removingcooked foods.
Cook: Cook meat and poultry thoroughlyto kill bacteria. Use a
thermometerto ensure proper internal food temperatures.
Chill: Refrigerateprepared foods and leftovers promptly.
For more information call: USDA Meat and Poultry Hotline 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 veryfast on the
outside. Usea meatthermometer to besure food has reached
a safe internal temperature, and cut into food to check for
visual signs of doneness.
• Whole poultryshould reach 180° F; breasts, 170° F.Juices
should runclear and flesh should not be pink.
• Hamburgers made of any groundmeat or poultryshould reach
160° F,and be brown inthe middle with no pinkjuices. Beef,
veal and lamb steaks, roasts and chops can becooked 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 reheatingtakeout foods orfully cooked meats like hot
dogs, grill to 165° F,or until steaming hot.
10 •464321607and 464321407
indirect Cooking
Poultry and large cuts of meat cook slowly to perfection on
the grill by indirect heat. The heat from selected burners
circulatesgently throughoutthe grill, cookingmeat or poultry
without the touch of a directflame. This methodgreatly reduces
flare-upswhen cookingextra fatty cuts because there is no direct
flame to ignite the fats and juices that dripduring cooking.
indirect Cooking instructions
, Always cookwith the lid closed.
o Due to weatherconditions, cooking times may vary. During
cold and windy conditions the temperature setting may need
to be increasedto insure sufficient cooking temperatures
1 Burner Cooking
Cook with direct or indirect heat,
Best for smaller meals or foods.
Consumes less fuel.
2 Burner Cooking
Greatindirectcooking on low.
Produces slow, even heating.
Ideal for slow roasting and baking.
464321607and 464321407• 11
@y_ _ ................ Part #
1 1 Right Leg Assembly .......... 80009068
2 1 Match Lighter w/Chain ........ 80000274
3 1 Left Leg Assembly ........... 80009069
4 1 Tank Exclusion Wire .......... 80008616
5 1 Bottom Shelf ................ 80009035
6 1 Tank Thumbscrew ............ 80006484
7 4 1/4-20x1-1/2" Screw ........... HMS02520150CPNSTSS
8 12 1/4-20 Flange Nuts ........... HFN02520MNSS
9 1 Upper Front Panels .......... 80009038
10 1 Lower Front Panels .......... 80011105
11 2 Wheels .................... 80009727
12 1 Axle Rod ................... 80009036
13 1 Hitch Pin ................... 80003610
14 1 8ram Fiat Washer .......... 80008091
15 2 Leg Extenders ............... 80008596
16 1 Firebox .................... 80009059
17 1 Control Panel ............... 80009060
18 1 Valve/Hose/Regulator ......... 80009067
19 1 Ignitor Module ............... 80009062
20 3 Bezels ..................... 80009030
21 3 Control Knobs ............... 80009030
22 3 Main Burners ............... 80009027
23 1 Main Burners Electrode ...... 80009029
24 2 Flame Carry-Over Tubes ...... 80009028
K_y _y Description ................ Part #
25 1 Top Lid ................... 80009061
26 1 Temperature Gauge .......... 80009025
27 1 Logo Plate ................. 80009024
28 12 1/4-20x1/2" Screw ........... HMS02520050CPNSTSS
29 8 7 mm Fiber Washers ......... HFWM7PRSTSS
30 4 7ram Lock Washers .......... HSWM7RHSPSS
31 1 Right Side Shelf ............. 80009063
32 1 Right Fascia ................ 80009064
33 1 Left Side Shelf .............. 80009065
34 1 Left Fascia ................ 80009066
35 12 #8x3/8" Self-Tap Screw ....... HMS01632038PPNBD
36 3 Heat Tents.................. 80008530
37 3 Cooking Grates .............. 80008531
38 1 Grill@NightTMLight Handle Assy. 70001074
39 2 #10-24x3/4" Thumbscrew ...... 4080132
40 1 Swing Away ................ 80008532
41 1 Grease Cup Clip ............. 80000271
42 1 Grease Cup ................ 80000270
43 2 Spacer ................... 80009743
44 4 7ram Fiat Washer .......... HFWM7RHSPSS
12 •464321607and 464321407
®
464321607and 464321407 • 13
D Tank Exclusion Wire
Place legs as shown (A). Left leg assembly has large holes on ends of legs. Hook tank exclusion
wire into right and left leg assemblies (B).
A
TankExclusionWire
LeftLegAssembly
haslargeholeson endsof
RightLegno holes
onendsof leg
14 •464321607and 464321407
Bottom Shelf to Legs
" Attach bottom shelf to right and left leg assemblies with (4) 1/4.20x1.1/2" screws and 1/4.20 flange nuts
@
1/4-20FlangeNuts
Qty:4
©
1/4-20X1-1/2"Screw
Qty:4
464321607and 464321407• 15
Front Panels
• Attach lower front panel to lower half of cart with (4) #8x3/8" self=tapscrews.
• Slide slot in upper front panel onto tank exclusion wire and attach to upper half of cart
with (4) #8×3/8" self-tap screws,
#8x3/8" Self-Tap Screw
Qty: 8
Lower Front Panel
Back of cart
\
Upper Front Pane
16 • 464321607and 464321407
D Wheelsand Leg Extenders to Cart
" Turn assembly upside down,
* insert axle rod into wheel, legs, spacersand otherwheel. Attach with (1) _8 flat washerand hitch pin.
* Push leg extenders into right legs.
@ ©
Spacer Hitch Pin
Qty:2 Qty: 1 (_
8ramFiatWasher
Qty: 1
Leg Extenders
Axle R,ed /Wheat
"Cone" side of wheelagainst leg
464321607and464321407°17
Grill Headto Cart
• Stand cartupright.
" Thissteprequirestwo peopleto lift andposition grill headontocart.
" Carefully lowerthe grillheadontothe cart. Makesure the regulatorhose is hangingoutsidethe cart. Attach with (4)
1/4-20x1/2"screws, 7ramfiat washers,7ramlockwashers.
®
GrillHead 1/4-20xl/2"Screw
Qty:4
©
@ ®
7mmFlatWasher 7mmLockWasher
Qty:4 Qty:4
18• 464321607and 464321407
Rightand LeftSide Shelves
" Hook sidewall of shelf over support brackets onside offirebox (A).
• insidefirebox insert(4)fiber washersand (4)1/4-20x1/2"screws as shown(B).
• Attach shelf using(2)flange nutsoneach side. (C). (_)
• Repeatthe samesteps for left shelf. 1/4-20FlangeNuts
Qty: 8
®
7ram Fiber Washers
Qty: 8
®
1/4-20xl/2" Screw
Qty:8
RightSideShelf
B
29
28
Back of Cart
D RightFascia
" Attachfasciatofireboxwith(2)#8x3/8"self-tapscrew
" Repeatthesamestepto attachleft fascia.
®
#8x3/8"Self-TapScrew
Qty:4
RightFascia
35
464321607and 464321407• 19
Heat Tents
• Place heattents over burners by inserting tabs into slots in front of firebox.
Opposite ends of heattents rest on pins in back of firebox.
Pin
Cooking Grate
" Place cooking grates onto grate rests.
Cooking Grate
20. 464321607 and464321407
Grill@NightTM Night Light Handle Assembly
Note: On the underside of the lamp assembliesare "L" for left side and "R" for right side.
Match to letter on the handle.
• Remove Grill@Night label if presentfrom front of grill lid.
" Install lamp assemblies inside grill lid. Position lamp assembly so that terminal passes through larger hole in
grill lid. See CORRECTASSEMBLY BELOW.Insert thumbscrews (provided with handle)through lamp
assemblies and grill lid, then into handle.
" Remove the two battery door screws and install the six C-size batteries as indicated inside battery compartment.
• Replace battery door and screws.
Note: Two extra 6V 3W bulbs are contained inside the bulb holders attached to the bottom ofthe handle.
®
#10-24x314"Thumbscrew
Qty: 2
CAUTION." To prevent a shorting
condition, make sure the lampassemblies
are fully inserted into grill lid. The |ight
wii| not work correctly until
fully assemb|ed to the gril| |id.
Screw Grill lid
/
assembly
Screw Grill lid
assembly
Bulb
/
4-- Battery Door Screws
Grill@NightTM
,if_ LightHandleAssembly
Holder
46432t607 and 464321407 • 2t
Swing Away
" 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.
o Unscrew ignitor cap and place AA battery into ignitor slot with positive end (+} facing outward. Screw ignitor cap onto
ignitor.
SwingAway
Pivot Wire
Wire
Grease Cup Clip and Grease Cup
Hang grease cup clip from bottom of firebox and place grease cup into grease clip.
Grease Cup Clip --
Grease Cup
22 •464321607and 464321407
CAUTION
in nd
I will cause hot grease to drip from bottom
I of grill with risk of fire or property damage.
LPTank
• LPtank is sold separately.UseonlywithanOPD(over-fillprotectiondevice)equippedLPtank. Fill and leakcheck before
attachingto grillandregulator.
" PlaceLPtank intohole in bottom shelf withtank collar openingfacing to sideas shown. Fingertighten tank thumbscrew
to hold LP tank securelyin place.
See Use and Care section to correctly Leak Test and
perform the Burner Flame Check.
m m
cA io.
• Tank collar opening must face to side once tank is
attached.
• Failure to install tank correctly may allow gas hose t_
be damaged in operation, resulting in the risk of fire.
LPTank
TankThumbscrew
464321607and 464321407• 23
Troubleshooting
EMERGENCIES: If a gas leak cannot be stopped, or a fire occurs due to gas leakage, call the fire department.
, Damagedhose. , Turnoffgasat LP tank.If hoseis cutor cracked,replaceGasleakingfrom
cracked/cut/burned valve/hose/regulator.SeeLPTankLeakTestandConnecting
hose. RegulatorToTheLPTank.
GasleakingfromLP , Mechanicalfailuredueto rustingor , Turnoff LPtankvalve.
tank. mishandling.
GasleakingfromLP , Failureof tankvalvefrom mishandlingor , TurnoffLPtank valve.ReturnLPtankto gassupplier.
tankvalve, mechanicalfailure.
Gasleakingbetween , Improperinstallation,connectionnot , TurnoffLPtankvalve.Removeregulatorfromcylinderand visually
LPtankandregulator tight,failureof rubberseal. inspectrubbersealfor damage.SeeLPTankLeakTestand
connection. ConnectingRegulatorToThe LPTank.
Firecomingthrough , Fireinburnertubesectionof burnerdue , Turnoffcontrolknobsand LP tankvalve.Leavelidopento allow
controlpanel, to partialblockage, flamesto diedown.Afterfire isout andgrillis cold.removeburner
andinspectfor spidernestsor rust.SeeNaturalHazardandCleaning
TheBurnerAssemblypages.
DO e : , •
, Toomuchgreasebuildupin burnerarea.
Greasefire or
continuousexcessive
flamesabovecooking
surface.
Burner(s)will not light
usingignitor.
GASISSUES:
, Tryingto lightwrongburner.
, Burnernotengagedwithcontrolvalve.
, Obstructionin burner.
Continuedonnext
page.
, Nogasflow.
, Vapor lock at coupling nut to LP tank.
, CouplingnutandLPtankvalvenotfully
connected.
ELECTRICALISSUES:
, Electrodecrackedor broken;"sparksat
crack."
, Electrodetip notin properposition.
, Wireand/orelectrodecoveredwith
cookingresidue.
, Wiresare looseordisconnected.
, Wiresare shorting(sparking)between
ignitorand electrode.
, Turnoff LPtankvalve.Leavelid opentoallowflamesto die down.
Aftercooling,cleanfoodparticlesandexcessgreasefrom inside
fireboxarea.greasecup/pan/tray,and othersurfaces.
, See instructions on control panel and section in the Use and Care.
, Make sure valves are positioned inside of burner tubes.
, Ensure burner tubes are not obstructed with spider webs or other
matter. See cleaning section of Use and Care.
, Make sure LP tank is not empty. If LP tank is not empty, refer to
"Sudden drop in gas flow."
, Turn off knobs and disconnect coupling nut from LP tank. Reconnect
and retry.
, Turn the coupling nut approximately one-half to three-quarters
additional turn until solid stop. Tighten by hand only - do not use tools.
, Replaceelectrode.
, Tipofelectrodeshouldbe pointingtowardportholein burner.The
distanceshouldbe 1/8"to 3/16".Adjustif necessary.
, Cleanwire and/orelectrodewith rubbingalcoholand cleanswab.
, Reconnectwiresorreplaceelectrode/wireassembly.
, Replaceignitorwire.
24 •464321607and 464321407
Burner(s)will not light
usingignitor.
Troubleshooting (continued)
, Push-buttonsticksat bottom..
Burner(s)will not
match light.
Suddendropin gas
flowor lowflame.
Flamesblowout.
Flare-up.
Persistent grease fire.
Flashback...
(firein burnertube(s)).
Unable to fill LP tank.
Oneburnerdoesnot
lightfromother
burner(s).
, Sparkingbetweenignitorandelectrode.
, See "GAS ISSUES:" on previous page.
, Improper method of match-lighting.
, Outof gas.
, Excessflowvalvetripped.
, Vaporlockatcouplingnut/LPtank
connection.
, High or gusting winds.
, Low on LP gas.
, Excess flow valve tripped.
, Greasebuildup.
, Excessivefat inmeat.
, Excessivecookingtemperature.
, Greasetrappedbyfoodbuilduparound
burnersystem.
, Burnerand/orburnertubesare blocked.
, Somedealershaveolderfill nozzles
withwornthreads.
, Greasebuilduporfoodparticlesin
end(s)of carryovertube(s).
, Replace ignitor.
, Inspect wire insulation and proper connection. Replace wires if
insulation is broken.
, See"Match-Lighting"sectionof UseandCare.
, Check for gas in LP tank.
, Turn off knobs, wait 30 seconds and light grill. If flames are still low,
turn off knobs and LP tank valve. Disconnect regulator. Reconnect
regulator and leak-test. Turn on LP tank valve, wait 30 seconds and
then light grill.
, Turnoff knobsand LPtankvalve.Disconnectcouplingnutfrom
tank.Reconnectandretry.
, Turnfrontof grilltofacewindor increaseflameheight.
, RefillLPtank.
, Referto "Suddendropingasflow"above.
, Cleanburnersandinsideof grill/firebox.
, Trimfatfrom meatbeforegrilling.
, Adjust(lower)temperatureaccordingly.
, Turn knobs to OFR Turn gas off at LP tank. Leave lid in position and
let fire burn out.After grill cools, remove and clean all parts.
, Turnknobsto OFRCleanburnerand/orburnertubes.See burner
cleaningsectionof UseandCaremanual.
oThewornnozzlesdon'thaveenough"bite"toengagethe valve.Try
asecondLPdealer.
, Clean carry-over tube(s) with wire brush.
464321607and 464321407• 25
Troubleshooting - Electronic Ignition
SECTIONI
Nosparksappearat o Batterynotinstalled
anyelectrodeswhen properly.
ignitionbuttonis
pushed;nonoisecan
beheardfrom spark oDeadbattery.
module.
SECTIONII
Nosparksappearat
anyelectrodeswhen
ignitionswitchis
pushed;noisecanbe
heardfromspark
module.
SECTION ill
Sparks are present
but not at all
electrodes and/or not
at full strength
oButtonassemblynot
installedproperly.
oFaultysparkmodule.
, Outputlead
connectionsnot
connected.
oElectrodetip notin
properposition.
, Outputlead
connectionsnot
connected.
, Arcing to grill away
from burner(s).
oWeakbattery.
, Electrodesarewet.
, Electrodescrackedor
broken"sparksat
crack".
, Checkbatteryorientation.
oHasbatterybeenused
previously?
, Check to ensure button
assembly is fully engaged.
Button should travel up and
down without binding.
o Ifnosparksaregenerated
withnewbatteryandgood
wireconnections,moduleis
faulty.
, Are outputconnectionson
andtight?
, Are theelectrodetips
pointingin the right
direction?Isthe gaptoo big?
oAreoutputconnectionson
andtight?
o Ifpossible,observegrillin
darklocation.Operate
ignitionsystemandlookfor
arcingbetweenoutputwires
andgrillframe.
, All sparkspresentbutweak
orat slowrate.
, Has moistureaccumulated
onelectrodeand/orin burner
ports?
, Inspectelectrodesfor
cracks.
oInstallbattery(makesurethat"+"and"-"
connectorsareorientedcorrectly,with"+"end up
and"-" end down.)
, ReplacebatterywithnewAA-sizealkalinebattery.
oRemovebuttoncapassemblyand reinstall,making
sureit canbefullyengaged.
oReplacesparkmoduleassembly.
, Remove and reconnect all output connections at
module and electrodes.
MainBurners:
oTipof electrodeshouldbe pointingtowardporthole
inburner,Thedistanceshouldbe1/8"to 3/16".
Adjustif necessary.
Sideburner:
oTipof electrodeshouldbe pointingtowardgasport
openingonburner.Thedistanceshouldbe 1/8"to
3/16".Adjustif necessary.
, Remove and reconnect all output connections at
module and electrodes.
oIfsparksare observedotherthanfromburner(s),
wire insulationmaybe damaged.Replacewires.
, Replace battery with a new AA-size alkaline battery.
, Use paper towel to remove moisture.
oReplacecrackedor brokenelectrodes.
26 •464321607and 464321407
Page
lank
Intentionally
464321607and 464321407• 27
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