Use & Care Guide
Model: 415.16139110
Kenmore Elite
®
Liquid Propane Gas Grill
P/N G523-001-010801
Sears Brands Management Corporation
Hoffman Estates, IL 60179 U.S.A.
Model 464224211 • Nov-03-10
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Table of Contents
WARRANTY
For Your Safety..............................................................2
Grill Information Center .............................................2
Product Record Information........................................2
Safety Symbols.............................................................2
Installation Safety Precautions...................................2
Kenmore Grill Warranty.............................................3
Use and Care...........................................................4-12
Parts List........................................................................13
Parts Diagram.............................................................14
Assembly................................................................15-20
Troubleshooting.....................................................21-23
KENMORE ELITE FULL WARRANTY
If this grill fails due to a defect in material or workmanship
within two years from the date of purchase, call 1-800-4-MY-
HOME®to arrange for free repair (or replacement if repair
proves impossible).
Limited Warranty on Stainless Steel Burners
Any stainless steel burner that ever rusts through will be
replaced free of charge. After the second year from the date
of purchase you must pay to have it installed.
Limited Warranty on Selected Grill Parts
For two years from the date of purchase, any stainless or
painted steel part will be replaced free of charge if it rusts
through. After the second year from the date of purchase you
must pay to have it installed.
All warranty coverage excludes ignitor batteries and grill
part paint loss or rusting (except for rust-through as specified
above), which are either expendable parts that can wear out
from normal use in less than a year, or are conditions that
can be the result of normal use, accident or improper
maintenance.
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.
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
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
have other rights which vary from state to state.
Sears Brands Management Corporation
Hoffman Estates, IL 60179
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.”
WARNING
• Read and follow all Safety, Assembly, and
Use and Care Instructions in this Guide
before assembling and cooking with this
grill.
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 will 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.
• 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.
This Grill is for Outdoor Use Only
Tools needed for assembly:
Adjustable wrench (not provided)
Screwdriver (not provided)
7/16"Combination wrench n(ot provided)
CONVERSION READY
This grill easily converts from LP liquid
propane to NG natural gas.
Contact 1-800-4-MY-HOME®or
conversion kit, part number 415.7116572.
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®.
Dual Fuel™ is a registered trademarks of
the W. C. Bradley Company and used,
with permission, by Sears Holdings
Corporation. All rights reserved.
464224211 • 3
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LP Tank
USE AND CARE
• 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.
DANGER
• NEVER store a spare LP cylinder under or near the
• LP Tanks 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.
appliance or in an enclosed area.
• LP Tank valve must have:
• Type 1 outlet compatible with
regulator or grill.
• Safety relief valve.
• UL listed Overfill Protection
OPD Hand Wheel
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. Always keep LP Tanks in
upright position during use, transit or storage.
• Never fill a cylinder beyond 80% full.
• If the information in the two points above is not
followed exactly, a fire causing death or serious
injury may occur.
• An overfilled or improperly stored cylinder is a
hazard due to possible gas release from the safety
relief valve. This could cause an intense fire with
risk of property damage, serious injury or death.
• If you see, smell or hear gas escaping, immediately
get away from the LP cylinder and appliance and
call your fire department.
LP Tank in upright position for vapor withdrawal
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.
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.
Failure to use safety cap as directed may result in serious
personal injury and/or property damage.
LP Tank Filling
• Use only licensed and experienced dealers.
• LP dealer must purge new tank before filling.
LP Tank Valve
• 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 Tank valve and call local LP gas dealer for assistance.
Safety Cap
• Do not release liquid propane (LP) gas into the atmosphere.
This is a hazardous practice.
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.
• 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.
• Do not store an LP tank in an area where children play.
4 • 464224211
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LP Tank Exchange
Connecting Regulator To The LP Tank
• 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 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.
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.
• Leak test new and exchanged LP tanks BEFORE
connecting to grill.
• Place dust cap on cylinder valve outlet whenever the
cylinder is not in use. Only install the type of dust cap on
the cylinder valve outlet that is provided with the cylinder
valve. Other types of caps or plugs may result in leakage
of propane.
OPD Hand Wheel
LP Tank Leak Test
Type 1 outlet with
thread on outside
For your safety
• Leak test must be repeated each time LP tank is exchanged
or refilled.
• Do not smoke during leak test.
Safety Relief Valve
• 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.
Strap and Cap
Do not insert a POL transport plug
(plastic part with external threads)
into the Type 1 tank valve outlet.
It will defeat the Safety Relief
Valve feature.
WARNING
If “growing” bubbles appear do not use or move the LP tank.
Contact an LP gas supplier or your fire department!
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.
Do not use household cleaning agents. Damage to gas
valve/hose/regulator components can result.
Nipple has to be centered
into the LP tank valve.
464224211 • 5
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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®.
Hold coupling nut and regulator
as shown for proper connection
to LP tank valve.
4. Brush soapy solution onto areas where bubbles are shown in
picture below:
Never remove threaded
orifice at end of valve.
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!
Call 1-800-4-MY-HOME® for identical replacement parts.
DANGER
• 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.
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®.
• If a leak is detected at any time, STOP and call the fire
department.
6. Always close LP tank valve after performing leak test by
turning hand wheel clockwise.
• If you cannot stop a gas leak, immediately close LP tank
valve and call LP gas supplier or your fire department!
WARNING
• 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 • 464224211
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Safety Tips
Before opening LP cylinder valve, check the coupling nut for
•
WARNING
For Safe Use of Your Grill and to Avoid Serious
tightness.
When grill is not in use, turn off all control knobs and LP
•
cylinder valve.
Injury:
• Never move grill while in operation or still hot.
•
Use long-handled barbecue utensils and oven mitts to avoid
burns and splatters.
• Do not let children operate or play near grill.
• Keep grill area clear and free from materials that burn.
• Do not block holes in sides or back of grill.
• Check burner flames regularly.
Maximum load for sideburner and side shelf is 10 lbs.
The grease tray must be inserted into grill and emptied after
each use. Do not remove grease tray until grill has
completely cooled.
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.
•
•
•
• 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.
• 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.
• 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.
•
Keep ventilation openings in cylinder enclosure (grill cart) free
and clear of debris.
•
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.
The regulator may make a humming or whistling noise during
operation. This will not affect safety or use of grill.
If you have a grill problem see the "Troubleshooting Section".
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!
•
•
•
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 off and
disconnected, removed from grill and stored outdoors.
• When removing grill from storage follow "Cleaning Burner
Assembly" instructions before starting grill.
• 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.
CAUTION
• Do not preheat the grill on HIGH with the lid closed
for longer than 15 minutes. Preheating the grill
with the lid closed beyond this point can result in
excessive cooking temperatures, risk of injury.
• Putting out grease fires by closing the lid is not
possible. Grills are well ventilated for safety
reasons.
• 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.
• 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 HIGH. If grill has not
been regularly cleaned, a grease fire can occur
that may damage the product.
464224211 • 7
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Match-Lighting
Main Burner Ignitor Lighting
• Do not lean over grill while lighting.
• Open lid. Turn on gas at LP cylinder.
• Light Burners one at time.
Match Lighting the Main Burners
1. Place match into match holder (hanging from RH side or
LH side of the cart).
2. Strike the match and position lit match through cooking
grates as shown in Figure A.
3. Position lit match next to far left main burner.
4. Push in and turn far left control knob to
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 lighting procedure.
• Open grill lid during Lighting.
• Do not lean over grill while lighting.
1. Turn OFF all Gas Burner Control Valves.
2. Turn ON gas at LP cylinder.
3. To ignite any main burner, push in and turn the burner
control knob to the
position.
4. Press and hold the ELECTRONIC IGNITOR button until
the burner ignites.
5. Once burner has ignited, turn knob to desired setting.
6. If Ignition does not occur in 5 seconds, turn the burner
control to OFF, wait 5 minutes for gas to clear away, and
repeat the lighting procedure.
position. Be
7. Repeat steps 4 through 6 for the remaining main burners.
Sear Burner Ignitor Lighting
• Do not lean over grill while lighting.
• Open lid during lighting.
1. Turn on gas at LP cylinder.
6. Light other burners in sequence from left to right by
pushing main burner control knob in and turning to
position.
Figure A
2. To ignite the sear burner, push in and turn the sear burner
control knob to the
position.
3. Press and hold the ELECTRONIC IGNITOR button until the
sear burner ignites.
4. Once sear burner has ignited, turn knob to desired
setting.
5. If Ignition does not occur in 5 seconds, turn the burner
control to OFF, wait 5 minutes for gas to clear away, and
repeat the lighting procedure.
er
Sear Burner
Main Burners
Figure B
Figure A
Main Burners
Match-Lighting the Sear Burner
Rotisserie Burner Ignitor Lighting
• Do not lean over grill while lighting.
1. Open grill lid during lighting. Turn on gas at LP cylinder.
2. To ignite the rotisserie burner, push in and turn the
• Do not lean over grill while lighting.
• Open lid. Turn on gas at LP cylinder.
1. Place match into match holder (hanging from RH side of
the cart).
2. Strike the match and position lit match through cooking
grates as shown in Figure B.
3. Position lit match above the burner.
4. Push in and turn sear burner control knob to
Be sure burner lights and stays lit.
rotisserie burner control knob to the
position.
3. Press and hold the ELECTRONIC IGNITOR button until the
rotisserie burner ignites.
4. Once burner has ignited, turn knob to desired setting.
5. If ignition does NOT occur in 5 seconds, turn the burner
control OFF. Wait 5 minutes for gas to clear away, and
repeat the lighting procedure.
position.
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 lighting procedure.
WARNING
Match lighting the Rotisserie Burner - Figure C
1. Place match in match holder. Strike the Match. Position lit
match close to the front center of the rotisserie burner.
2. Push in and turn rotisserie burner control knob to
.
3. 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 lighting procedure.
CAUTION
If ignition does NOT occur in 5 seconds, turn the
burner controls OFF, wait 5 minutes and repeat the
lighting procedure. If the burner does not ignite with
the valve open, gas will continue to flow out of the
burner and could accidently ignite with risk of injury.
Match holder
Rotisserie Burner
Figure C
Match Lighting Instructions continued on next page.
8 • 464224211
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Sideburner Ignitor Lighting
Do not lean over grill while lighting.
CAUTION
1. Open sideburner lid. Turn ON gas at LP cylinder.
2. Turn sideburner knob to the HI position, push and hold
ELECTRONIC IGNITOR button.
3. If sideburner does NOT light within 5 seconds, turn knob
SPIDER ALERT!
to OFF, wait 5 minutes, then repeat lighting procedure.
Match lighting the Side Burner - Figure D
1. Open the sideburner lid during lighting.
2. Place match in match holder. Strike the Match. Position
lit match close to the side burner.
SPIDER AND WEBS
INSIDE BURNER TUBE
3. Push in and turn side burner knob to
burner lights and stays lit.
position. Be sure
4. 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 lighting procedure.
If you notice that your grill is getting hard to light or that the
flame isn’t as strong as it should be, take the time to check and
clean the burner tubes. See section “Cleaning Burner
Assemblies” next page.
Figure D
Burner Flame Check
• Remove cooking grates and flame tamers. Light burners, rotate
VALVE
SPIDER WEBS
INSIDE BURNER TUBE
CONTROL PANEL
knobs from HIGH
to low. You should see a smaller flame in
BURNER
low position than seen on HIGH Perform burner flame check on
sideburner, sear burner and rotisserie also. Always check flame
prior to each use. If only low flame is seen refer to "Sudden drop
or low flame" in the Troubleshooting Section.
HIGH
Spiders or small insects have been known to create “flashback”
problems. The spiders spin webs, build nests and lay eggs in the
grill’s venturi tube(s) obstructing the flow of gas to the burner.
The backed-up gas can ignite in the burner tube behind the
control panel. This is known as a flashback and it can damage
your grill and even cause injury.
LOW
Turning Grill Off
• Turn all knobs to OFF position. Turn LP cylinder off by turning
hand-wheel clockwise to a full stop.
To prevent flashbacks and ensure good performance the burner and
burner tube assembly should be removed from the grill and cleaned
before use whenever the grill has been idle for an extended period.
Ignitor Check
• Turn gas off at LP cylinder. Push and turn control knob to
and hold in. You will hear a clicking sound as the burner is being
ignited. Ignition should occur within 5 seconds, but continue to
hold the knob in for a full 10 seconds to maintain ignition.
Valve Check
CAUTION
Do not remove glass for cleaning.
• Important: Make sure gas is off at LP cylinder before
checking valves. Knobs lock in OFF position. To check
valves, first push in knobs and release, knobs should spring
back. If knobs do not spring back, replace valve assembly
before using grill. Turn knobs to LOW position then turn
back to OFF position. Valves should turn smoothly.
Hose Check
Glass is not dishwasher safe.
• Before each use, check to see if hoses are cut or worn.
Replace damaged hoses before using grill. Use only
valve/hose/regulator specified by manufacturer.
464224211 • 9
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Cleaning the Main 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 Tank.
2. Remove cooking grates and heat diffusers.
3. Remove electrode from burner by prying the clip away as
shown in Figure A. Electrode should remain in firebox.
4. Remove hitch pins and flame carryover tubes from front of
burners as shown in Figure B.
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 or glass
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.
5. Remove remaining hitch pins from rear of burner
to disengage burner from bracket on 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.
• 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.
(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.
Food Safety
9. Check burner for damage, due to normal wear and corrosion
some holes may become enlarged. If any large cracks or
holes are found replace burner.
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 food thermometer to ensure proper internal food
temperatures. Chill: Refrigerate prepared 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).
VERY IMPORTANT: Burner tubes must re-engage valve
openings. See illustrations at right.
Correct
10.
11.
Carefully replace burners.
Attach electrode to burner.
burner-to-valve
engagement
12. Attach burners to brackets on firebox.
13. Reposition flame carryover tubes and
attach to burners. Replace heat tents
Figure A
Electrode
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.
Figure B
Pry off electrode
with a flat blade
screwdriver
• 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.
Firebox burner
bracket
10 • 464224211
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Grill Halogen Light
2.
1.
3.
LIGHT OPERATION INSTRUCTIONS
ON
ON
1. Make sure light switch on the control panel is in the “OFF” position.
OFF
2. Connect light plug to an extension cord, then plug the extension
cord into the outlet on the wall.
OFF
3. Turn the light switch to “ON”.
Light plug
WARNING
Extension cord,
for outdoor use
˙
˙
Keep any electrical supply cord away from any
heated surface.
Use the shortest length extension cord required.
Do not connect 2 or more extension cords together.
Bulb Replacement
▲
Make sure light switch on the control panel is in the “OFF” position and adapter plug is disconnected from outlet.
Step 2
Step 1
Step 3
Remove the screw securing the light
socket.
Loosen the two screws which lock
the bulb in place.
Take out the socket and remove the lens.
Step 4
Step 5
Reverse instructions from step 3
through step 1 to re-install socket.
Bulb Specification
Bulb Type: Halogen
Wattage: 10 W per bulb
Voltage: 12 V
CAUTION
Pull out the bulb and replace
Take care not to touch the bulb with your bare fingers.
Touching bulb with your skin can leave a film on the
bulb that causes it to burn out quickly.
with a new bulb.
Continued on next page
464224211 • 11
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Cleaning the Lens
1. Prior to cleaning, make sure the light switch is in the “OFF” position and the light plug is
disconnected from the power supply.
2. Do not clean the glass lens when warm. Allow to cool before cleaning. Sudden change in
temperature may cause cracking of the glass lens.
3. Use a damp towel to clean the surface of the glass lens.
4. Allow the lens to dry before reconnecting the light plug to the power supply and turning the
light switch to the “ON” position.
IMPORTANT
• Since 1971 the National Electric Code (NEC) has required Ground Fault Interrupter devices on all outdoor
circuits.
• If your residence was built before 1971, check with a qualified electrician to determine if a Ground Fault
Interrupter protector exists.
• Do not use this appliance if the circuit does not have GFI protection.
• Do not plug this appliance into an indoor circuit.
WARNING
1. To protect against electric shock, do not immerse cord or plugs in water or other liquid.
2. Unplug from the outlet when not in use and before cleaning. Allow to cool before putting on or taking off parts.
3. Do not operate grill with a damaged cord, plug, or after the appliance malfunctions or has been damaged in any
manner.
4. Do not let the cord hang over the edge of a table or touch hot surfaces.
5. Do not use an outdoor cooking gas appliance for purposes other than intended.
6. When connecting, first connect plug to the outdoor cooking gas appliance then plug appliance into the outlet.
7. Use only a Ground Fault Interrupter(GFI) protected circuit with this outdoor cooking gas appliance.
8. Never remove the grounding plug or use with an adapter of 2 prongs.
9. Use only extension cords with a 3 prong grounding plug, rated for the power of the equipment, and approved for
outdoor use with a W-A marking.
12 • 464224211
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PARTS LIST
Key Qty Description
Key Qty Description
Part #
Part #
1
2
1
1
1
1
1
1
1
1
1
1
2
LEFT SIDE SHELF
G523-1100-W1
G523-0051-W1
G523-1200-W1
G523-0052-W1
G523-0100-W1
G523-0001-W1
G518-0075-W1
G503-0002-W1
G523-0002-W1
G523-0003-W1
G509-0003-W1
48
49
50
51
1
BOTTOM SHELF
G523-0025-W1
G501-0016-W2
G523-4100-W1
G523-0800-W1
G523-0900-W1
G523-0028-W1
G523-0029-W1
G513-0021-W1
G606-0068-W1
G523-0030-W1
G501-0039-W1
G518-0076-W1
G523-0031-W1
G523-1000-W1
G523-5000-W1
G523-0034-W1
G523-0035-W1
G523-0036-W1
G509-0011-W1
G523-0037-W1
G523-0039-W1
G523-0040-W1
G523-0038-W1
G523-0041-W1
FASCIA, LEFT SHELF
RIGHT SIDE SHELF
2
1
DOOR MAGNET ASSEMBLY
TANK SHELF ASSY
3
4
5
FASCIA, RIGHT SHELF
TOP LID
1
LEFT SIDE PANEL
52
53
54
55
56
57
58
59
60
61
1
RIGHT SIDE PANEL
6
INNER INSERT, F/ TOP LID
TEMPERATURE GAUGE
BEZEL, F/ TEMPERATURE GAUGE
LOGO PLATE
2
2
1
LOCKING CASTER
7
8
FIXED CASTER
ELECTRONIC IGNITION MODULE
ELECTRODE WIRE, F/ SIDEBURNER
LOWER BACK PANEL
GROMMET
9
1
10
11
HANDLE, F/ TOP LID
BEZEL, F/ LID HANDLE
1
1
RUBBER BUMPER, RECTANGLE, F/
TOP LID
1
12 VOLT ADAPTER
12
2
G413-0025-W1
1
RIGHT PANEL F/ DRAWER
HEAT SHIELD, F/ TANK
FRONT BRACE
13
14
15
16
2
1
LID BUMPER, ROUND
HARDWARE F/ TOP LID ASSEMBLY
FIREBOX
G501-0066-W1
G515-0035-W1
G523-3100-W1
G517-7300-W1
1
62
63
64
65
66
67
68
69
70
71
1
1
2
2
4
8
1
DRAWER FRONT
3
MAIN BURNER
DRAWER FRAME
ELECTRODE, F/MAIN BURNER,
900MM WIRE
17
2
G515-0014-W1
HANDLE, F/ DOOR & DRAWER
HANDLE END, F/ DOOR & DRAWER
18
19
20
2
1
FLAME CARRYOVER TUBE
SEAR BURNER
G524-0036-W1
G523-3200-W1
G614-1900-W1
DOOR, LEFT, NO HANDLE
BAG HOOK, F/ DOOR
CONDIMENT TRAY, LEFT DOOR
DOOR LINER, LEFT
1
ROTISSERIE BURNER
1
RIGHT WIND SHIELD, ROTISSERIE
BURNER
1
21
1
1
1
G614-0052-W1A
G614-0053-W1
G515-0067-W1
1
LEFT WIND SHIELD, ROTISSERIE
BURNER
22
23
1
DOOR, RIGHT, NO HANDLE
CONDIMENT TRAY, RIGHT DOOR,
UPPER
ELECTRODE, F/MAIN BURNER,
600MM WIRE
72
73
1
1
G523-0043-W1
G523-0044-W1
CONDIMENT TRAY, RIGHT DOOR,
LOWER
24
25
26
27
28
29
30
31
1
ELECTRODE, F/ ROTISSERIE
ELECTRODE WIRE, F/ ROTISSERIE
GROUND WIRE, F/ EI MODULE
BACK COVER, ROTISSERIE BURNER
LIGHT SWITCH
G614-0094-W1
G614-0059-W1A
G614-0098-W1
G523-0011-W1
G520-0013-W1
G614-8200-W1
G608-0041-W1
G523-3400-W1
G523-0012-W1
G430-2604-W1
G507-0011-W2
G508-0033-W1
G523-0058-W1
G501-0077-W1
G523-0014-W1
G523-3700-W1
G523-0020-W1
G614-0064-W1
G614-0065-W1
G518-0026-W1A
G523-0013-W1
G523-3800-W1
G523-3900-W1
G508-0039-W1
1
74
75
76
77
78
79
80
1
PAPER TOWEL HOLDER, DOOR
DOOR LINER, RIGHT
G523-6300-W1
G523-0042-W1
G523-0048-W1
G523-0053-W1
G523-0049-W1
G523-0050-W1
G516-4600-W1A
1
1
1
2
1
HEAT DIFFUSER, LONG
HEAT DIFFUSER, SHORT
COOKING GRATE, MAIN
WARMING RACK
1
1
HALOGEN LIGHT ASSEMBLY
HOSE CLIP
4
1
7
1
SB EXTEND SHELF
1
GREASE TRAY
32
33
34
35
36
37
38
39
40
41
1
SIDEBURNER PAN
CAP, F/ ELECTRONIC IGNITION
MODULE
1
ELECTRODE, F/ SIDEBURNER
LID, F/ SIDEBURNER
81
1
G513-0021-W2
1
2
1
BUMPER, F/ SIDEBURNER LID
SIDEBURNER
Not Pictured
Key Qty Description
1
SIDEBURNER GRATE
Part #
1
INNER PANEL, F/ CONTROL PANEL
HOSE VALVE REGULATOR
CONTROL PANEL
…
…
…
1
1
1
HARDWARE PACK
G523-B001-W1
G523-010801-W1
G523-010802-W1
1
ASSEMBLY MANUAL, ENGLISH
ASSEMBLY MANUAL, SPANISH
1
5
1
BEZEL, F/ CONTROL KNOB
BEZEL, F/ ROTISSERIE KNOB
IGNITER SWITCH MODULE
REAR UPPER PANEL, FIREBOX
CONTROL KNOB
42
43
44
45
46
47
If you are missing hardware or have damaged parts after
unpacking grill, call 1-800-241-7548 for replacement.
1
1
5
1
To order replacement parts after using grill, call
®
CONTROL KNOB, F/ ROTISSERIE
MATCH HOLDER AND CHAIN
1-800-4-MY-HOME
2
NOTE: Some grill parts shown in the assembly steps may differ slightly in appearance from
those on your particular grill model. However, the method of assembly remains the same.
464224211 • 13
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PARTS DIAGRAM
6
5
14
10
79
27
11
12
8
77
76
13
15
9
7
19
47
47
78
38
34
21
44
39
37
32
16
22
40
23
17
20
29
18
33
36
31
3
25
41
42
43
41
56
58
45
35
46
1
45
28
45
30
80
4
57
2
55
59
52
48
51
26
81
50
49
60
54
53
61
63
49
62
64
65
65
64
63
66
66
66
66
66
66
72
65
68
65
74
66
69
66
67
70
73
71
75
14 • 464224211
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Insert flange on left side shelf into side shelf brackets, shown A.
1
Attach left side shelf rear using two 1/4-20x1/2” screws, 7mm lock washers and 7mm flat washers,
shown B.
Attach left side shelf front using three 1/4-20x1/2” screws, 7mm lock washers and 7mm flat washers,
shown C.
7mm flat washer
Qty.5
7mm lock washer
Qty.5
1/4-20x1/2” screw
Qty.5
A
Bracket
Flange into bracket
B
C
7mm lock
washer
7mm lock
washer
1/4-20x1/2”
7mm flat
washer
screw
1/4-20x1/2”
screw
7mm flat
washer
464224211 • 15
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Insert flange on right side shelf into side shelf brackets, shown A.
Attach right side shelf top using two 1/4-20x3/4” screws, 7mm flat washers, 7mm lock washers and
1/4” nuts, shown B.
2
Attach right side shelf rear using one 1/4-20x3/4” screw, 7mm lock washer and 7mm flat washer,
shown C.
Attach right side shelf front using two 1/4-20x1/2” screws, 7mm lock washers and 7mm flat washers,
shown D.
A
1/4-20x3/4” screw
Qty.3
Bracket
Flange into bracket
1/4-20x1/2” screw
Qty.2
7mm flat washer
B
Qty.5
7mm lock
washer
1/4-20x3/4”
screw
7mm lock washer
Qty.5
7mm flat
washer
1/4” nut
1/4” nut
Qty.2
D
C
7mm lock
washer
1/4-20x1/2”
screw
7mm flat
washer
7mm lock
washer
7mm flat
washer
1/4-20x3/4”
screw
16 • 464224211
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Install heat diffusers by sliding one end of each heat diffuser into slots at front of firebox and resting
opposite end on pins at back of firebox. Make sure to install the shorter heat diffuser in A position,
and install the two longer heat diffusers in B and C position.
3
Heat diffuser
Front of firebox
A
Rear of firebox
B
Pin
C
Place cooking grates onto the firebox as shown. Insert the three wire ends at rear of warming rack into
holes in back of firebox. Front wires of warming rack rest on sides of firebox.
4
Warming rack
Cooking grate
464224211 • 17
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Place sideburner grate into sideburner shelf, aligning grate legs with holes in shelf.
5
On back of grill, slide grease tray into opening in lower back panel.
6
CAUTION
Failure to install grease tray will
cause hot grease to drip from
bottom of grill with risk of fire or
property damage.
Grease tray
18 • 464224211
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Unscrew electronic ignition cap on cart right side panel. Insert AA battery into ignitor, negative(-) end
first. Replace the cap.
7
AA Battery
-
+
Electronic Ignition Cap
LP TANK IS SOLD SEPARATELY. Fill and leak check the tank before attaching to grill and regulator (see
Use & Care section).
Once tank has been filled and checked for leaks, slide tank tray in bottom shelf forward. Fully loosen tank
screw at bottom of tank tray. Insert tank into tray with tank valve facing to right side of cart. Secure tank
by tightening tank tray screw. Connect regulator to tank as described in Use and Care section. Slide tank
shelf back into place.
8
See Use & Care section of this manual to perform the "Burner Flame Check" and for important safety
instructions before using.
Always keep LP tank in upright position during use,
transport, and storage.
Tank Screw at bottom of tank tray
Tank
CAUTION
(not included)
LP Tank valve must face to right side of
cart once tank is attached. Failure to
install cylinder correctly may cause gas
hose to be damaged in operation,
resulting in the risk of fire.
Regulator
464224211 • 19
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Install door organizers
9
Back of left door:
Attach bag hook by inserting wire ends in the holes on the door, shown A.
Attach condiment tray by sliding it onto tabs on lower door back panel, shown A.
Back of right door:
Attach condiment trays by sliding them onto tabs on upper and lower door back panel, shown B.
Attach paper towel holder between condiment trays, shown B.
B
A
Condiment tray
Bag hook
Paper towel
holder
Condiment tray
Condiment tray
Tabs
20 • 464224211
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EMERGENCIES: If a gas leak cannot be stopped, or a fire occurs due to gas leakage, call the fire department.
Emergencies
Possible Cause
Prevention/Solution
Gas leaking from
cracked/cut/burned
hose.
• Damaged hose.
• Turn off gas at LP cylinder or at source on natural gas systems.
If the hose is cracked or cut but not burned, simply replace
valve/hose/ regulator. If the hose is burned, the cause could be
other than a faulty valve/hose/regulator. Discontinue use of
grill until a plumber or gas technician has investigated and
corrected the problem.
• Mechanical failure due to rusting or
mishandling.
Gas leaking from LP
cylinder.
• Replace LP cylinder.
• Failure of cylinder valve from
mishandling or mechanical failure.
Gas leaking from LP
cylinder valve.
• Turn off LP cylinder valve. Return LP cylinder to gas supplier.
• Improper installation, connection not
tight, failure of rubber seal.
Gas leaking between
LP cylinder and
regulator connection.
• Turn off LP cylinder valve. Remove regulator from cylinder and
visually inspect rubber seal for damage. See LP Cylinder Leak
Test and Connecting Regulator to the LP Cylinder.
• Fire in burner tube section of burner
due to blockage.
Fire coming through
control panel.
• Turn off control knobs and LP cylinder valve. Leave lid open to
allow flames to die down. After fire is out and grill is cold,
remove burner and inspect for spider nests or rust. See Spider
Alert and Cleaning the Burner Assembly sections of this Use &
Care Guide.
• Turn off control knobs and LP cylinder valve. Leave lid open to
allow flames to die down. After cooling, clean food particles
and excess grease from inside firebox area, grease tray, and
other surfaces.
• Too much grease buildup in burner
area.
Grease fire or
continuous excessive
flames above cooking
surface.
Troubleshooting
Problem
Possible Cause
Prevention/Solution
GAS ISSUES:
• Trying to light wrong burner.
• See instructions on control panel and in Use and Care section.
Burner(s) will not light
using ignitor.
(See Electronic Ignition
Troubleshooting also)
• Burner not engaged with control valve. • Make sure valves are positioned inside of burner tubes.
• Obstruction in burner.
• Ensure burner tubes are not obstructed with spider webs or other
matter. See cleaning section of Use and Care.
Continued on next
page.
• No gas flow.
• Make sure LP cylinder is not empty. If LP cylinder is not empty,
refer to “Sudden drop in gas flow.”
• Vapor lock at coupling nut to LP
cylinder.
• Turn off knobs and disconnect coupling nut from LP cylinder.
Reconnect and retry.
• Coupling nut and LP cylinder valve not
fully connected.
• Turn the coupling nut approximately one-half to three-quarters
additional turn until solid stop. Tighten by hand only - do not
use tools.
ELECTRICAL ISSUES:
• Electrode cracked or broken; “sparks at
crack.”
• Replace electrode(s).
Main Burners:
• Electrode tip not in proper position.
• Tip of electrode should be pointing toward gas port opening on
burner. The distance should be 1/8” to 1/4”. Adjust if necessary.
Sideburner:
• Tip of electrode should be pointing toward gas port opening on
burner. the distance should be 1/8” to 3/16”. Adjust if necessary.
• Wire and/or electrode covered with
cooking residue.
• Clean wire and/or electrode with rubbing alcohol and clean
swab.
• Wires are loose or disconnected.
• Reconnect wires or replace electrode/wire assembly.
• Replace ignitor wire/electrode assembly.
• Wires are shorting (sparking) between
ignitor and electrode.
• Dead battery.
• Replace with a new AA-size alkaline battery.
464224211 • 21
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Troubleshooting (continued)
Problem
Possible Cause
Prevention/Solution
Burner(s) will not light ELECTRONIC IGNITION:
using ignitor.
• No spark, no ignition noise.
• See Section I of Electronic Ignition System.
• See Section II of Electronic Ignition System.
• See Section III of Electronic Ignition System.
(See Electronic Ignition
Troubleshooting also)
• No spark, some ignition noise.
• Sparks, but not at electrode or at full
strength.
Burner(s) will not
match light.
• See “GAS ISSUES:” on previous page.
• Match will not reach.
• Use long-stem match (fireplace match).
• Improper method of match-lighting.
• Out of gas.
• See “Match-Lighting” section of Use and Care.
• Check for gas in LP cylinder.
Sudden drop in gas
flow or low flame.
• Excess flow valve tripped.
• Turn off knobs, wait 30 seconds and light grill. If flames are still
low, turn off knobs and LP cylinder valve. Disconnect regulator.
Reconnect regulator and leak-test. Turn on LP cylinder valve,
wait 30 seconds and then light grill.
• Vapor lock at coupling nut/LP cylinder
connection.
• Turn off knobs and LP cylinder valve. Disconnect coupling nut
from cylinder. Reconnect and retry.
Flames blow out.
Flare-up.
• High or gusting winds.
• Low on LP gas.
• Turn front of grill to face wind or increase flame height.
• Refill LP cylinder.
• Excess flow valve tripped.
• Grease buildup.
• Refer to “Sudden drop in gas flow” above.
• Clean burners and inside of grill/firebox.
• Excessive fat in meat.
• Trim fat from meat before grilling.
• Excessive cooking temperature.
• Adjust (lower) temperature accordingly.
Persistent grease fire.
• Grease trapped by food buildup
around burner system.
• Turn knobs to OFF. Turn gas off at LP cylinder. Leave lid in
position and let fire burn out. After grill cools, remove and clean
all parts.
Flashback...
(fire in burner tube(s)).
• Burner and/or burner tubes are
blocked.
• Turn knobs to OFF. Clean burner and/or burner tubes. See
burner cleaning section of Use and Care.
Unable to fill LP
cylinder.
• Some dealers have older fill nozzles
with worn threads.
• The worn nozzles don’t have enough “bite” to engage the valve.
Try a second LP dealer.
One burner does not
light from other
burner(s).
• Grease buildup or food particles in
end(s) of carryover tube(s).
• Clean carry-over tube(s) with wire brush.
22 • 464224211
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Troubleshooting - Electronic Ignition
Problem (Ignition)
Possible Cause
Check Procedure
Prevention/Solution
SECTION I
• Battery not installed
properly.
• Check battery orientation.
• Install battery (make sure that “+” and “–”
connectors are oriented correctly, with “+” end up
and “–” end down.)
No sparks appear at
any electrodes when
Electronic Ignition
Button is pressed; no
noise can be heard
from spark module.
• Dead battery.
• Has battery been used
previously?
• Replace battery with new AA-size alkaline battery.
• Button assembly not
installed properly.
• Check to insure threads are • Unscrew button cap assembly and reinstall,
properly engaged. Button
should travel up and down
without binding.
making sure threads are aligned and engaged
fully.
• Faulty spark module.
• If no sparks are generated
with new battery and good
wire connections, module is
faulty.
• Replace spark module assembly.
SECTION II
• Output lead
connections not
connected.
• Are output connections on
and tight?
• Remove and reconnect all output connections at
module and electrodes.
No sparks appear at
any electrodes when
Electronic Ignition
Button is pressed; noise
can be heard from
spark module.
• Output lead
connections not
connected.
• Are output connections on
and tight?
• Remove and reconnect all output connections at
module and electrodes.
SECTION III
Sparks are present
but not at all
electrodes and/or not
at full strength
• Arcing to grill away
from burner(s).
• If possible, observe grill in
dark location. Operate
ignition system and look for
arcing between output wires
and grill frame.
• If sparks are observed other than from burner(s),
wire insulation may be damaged. Replace wires.
• Weak battery.
• All sparks present but weak • Replace battery with a new AA-size alkaline
battery.
or at slow rate.
• Electrodes are wet.
• Has moisture accumulated
on electrode and/or in
burner ports?
• Use paper towel to remove moisture.
• Electrodes cracked or • Inspect electrodes for
• Replace cracked or broken electrodes.
broken “sparks at
crack”.
cracks.
464224211 • 23
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