Use & Care Guide
®
Liquid Propane Gas Grill
Sears Model No. 415.16128010
• Safety
• Parts
• Use and Care
• Assembly
This Grill is for Outdoor Use Only
Grill Information Center
Missing Parts? Assembly Questions?
Operation Problems? Before returning
grill to store, call 1-800-241-7548
WARNING
•
•
Read and follow all Safety, Assembly,
and Use & Care Instructions in this
Guide before assembling and cooking
with this grill.
Tools needed for assembly:
Adjustable wrench (not provided)
Screwdriver (not provided)
Failure to follow all instructions in this
Use & Care Guide may lead to fire or
explosion, which could result in property
damage, personal injury or death.
7/16" Combination wrench (not provided)
SAVE THESE INSTRUCTIONS!
See our extensive assortment of outdoor living products on-line at
Sears Brands Management Corporation, Hoffman Estates, IL 60179 U.S.A.
G550-001-010801 • Nov-26-09
©2010 Sears Brands, LLC
Printed in China
Model 464220110
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Parts Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-22
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-25
KENMORE GRILL WARRANTY
One Year Full Warranty on Kenmore Grill
If this grill fails due to a defect in material or workmanship
within one year from the date of purchase, call 1-800-4-MY-
HOME® to arrange for free repair (or replacement if repair
proves impossible).
Five-Year Limited Warranty on Burners
For five years from the date of purchase, any 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 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.
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
also have other rights which vary from state to state.
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.”
Sears, Roebuck and Co., Hoffman Estates, IL 60179
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.
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®.
464220110 • 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.
• 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.
DANGER
• NEVER store a spare LP cylinder under or near the
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
Device (OPD). This OPD safety
OPD Hand Wheel
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 (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 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 gas is highly flammable and may ignite unexpectedly when
mixed with air.
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
Safety Cap
Tank valve and call local LP gas dealer for assistance.
Retainer Strap
• Do not release liquid propane (LP) gas into the atmosphere.
This is a hazardous practice.
• 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 • 464220110
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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.
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.
• Always keep new and exchanged LP tanks in upright position
4. Remove the protective cap from LP tank valve. Always use
during use, transit or storage.
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
For your safety
Type 1 outlet with
thread on outside
• Leak test must be repeated each time LP tank is exchanged or
refilled.
Safety Relief Valve
• 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.
Strap and Cap
• 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.
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.
s
Do not use household cleaning agents. Damage to gas
train components (valve/hose/regulator) can result.
Nipple has to be centered
into the LP tank valve.
464220110 • 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 part.
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
• If you cannot stop a gas leak, immediately close LP tank
turning hand wheel clockwise.
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 • 464220110
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Safety Tips
s
Before opening LP cylinder valve, check the coupling nut for
WARNING
tightness.
s
When grill is not in use, turn off all control knobs and LP
cylinder valve.
Never move grill while in operation or still hot.
Use long-handled barbecue utensils and oven mitts to avoid
burns and splatters.
Maximum load for sideburner and side shelf is 10 lbs.
For Safe Use of Your Grill and to Avoid Serious
s
Injury:
s
• Do not let children operate or play near grill.
• Keep grill area clear and free from materials that burn.
• Do not block holes in sides or back of grill.
• Check burner flames regularly.
• Use grill only in well-ventilated space. NEVER use in
enclosed space such as carport, garage, porch,
covered patio, or under an overhead structure of any
kind.
s
s
The grease tray must be inserted into grill and emptied after
each use. Do not remove grease tray until grill has
completely cooled.
s
Clean grill often, preferably after each cookout. If a bristle
brush is used to clean any of the grill cooking surfaces,
ensure no loose bristles remain on cooking surfaces prior to
grilling. It is not recommended to clean cooking surfaces
while grill is hot.
s
If you notice grease or other hot material dripping from grill
• Do not use charcoal or ceramic briquets in a gas 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.
(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.
s
Keep ventilation openings in cylinder enclosure (grill cart) free
and clear of debris.
s
Do not store objects or materials inside the grill cart
enclosure that would block the flow of combustion air to the
underside of either the control panel or the firebox bowl.
s
The regulator may make a humming or whistling noise during
operation. This will not affect safety or use of grill.
s
If you have a grill problem see the "Troubleshooting Section".
s
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!
CAUTION
• 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.
• Apartment Dwellers:
Ignitor Lighting the Grill
s
Do not lean over grill while lighting.
Check with management to learn the requirements
and fire codes for using an LP gas grill in your
apartment complex. If allowed, use outside on the
ground floor with a three (3) foot clearance from walls
or rails. Do not use on or under balconies.
• NEVER attempt to light burner with lid closed. A
buildup of non-ignited gas inside a closed grill is
hazardous.
1. Turn OFF gas burner control valves.
2. Turn ON gas at LP cylinder.
3. Open lid during lighting.
4. To ignite, push and turn the IGNITION BURNER knob to HI.
5. P. ush and hold ELECTRONIC IGNITION button until the IGNITION
BURNER lights.
6. 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.
• Never operate grill with LP cylinder out of correct
7. To ignite remaining burners, turn each burner knob in sequence
to the HI position, starting with the burner closest to the
IGNITION BURNER.
position specified in assembly instructions.
• Always close LP cylinder valve and remove
coupling nut before moving LP cylinder from
specified operation position.
8. Once each burner has ignited, turn knobs to desired setting.
If ignitor does not work, follow match lighting instructions.
Lighting instructions are continued on the next page
464220110 • 7
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Burner Flame Check
• Remove cooking grates and flame tamers. Light burners, rotate
knobs from HI to LOW. You should see a smaller flame in
LOW position than seen on HI. Perform burner flame check
on sideburner, also. Always check flame prior to each use. If
only low flame is seen refer to "Sudden drop or low flame" in
the Troubleshooting Section.
WARNING
Turn controls and gas source or tank OFF when not
in use.
HI
CAUTION
LOW
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.
Turning Grill Off
• Turn all knobs to the OFF position. Turn LP cylinder OFF by
turning hand-wheel clockwise to a full stop.
Ignitor Check
Match-Lighting
• Turn gas off at LP cylinder. Press and hold electronic ignitor
button. "Click" should be heard and spark seen each time
between each collector box or burner and electrode. See
"Troubleshooting" if no click or spark.
s
Do not lean over grill while lighting.
1. Open lid. Turn ON gas at LP cylinder.
2. Place match into match holder (hanging from side panel of
grill). Light match; then light burner by placing match through
the match light hole on right or left side of grill.
3. Push in and turn far right or far left burner knob to the HI
position, depending on match light hole selected. Be sure
burner lights and stays lit.
4. Light adjacent burners in sequence by pushing knobs in and
turning to the HI position.
Valve Check
• 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
• Before each use, check to see if hoses are cut or worn.
Replace damaged hoses before using grill. Use only
identical replacement part valve/hose/regulator as
specified in the Parts List of this Use and Care Guide.
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.
Sideburner Ignitor Lighting
sDo not lean over grill while lighting.
• Plastic parts: Wash with warm soapy water and wipe dry.
s
Do not use citrisol, abrasive cleaners, degreasers or a
1. Open sideburner lid. Turn ON gas at LP cylinder.
concentrated grill cleaner on plastic parts. Damage to and
2. Turn sideburner knob to the HI position, push and hold
failure of parts can result.
ELECTRONIC IGNITION button.
• 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.
3. If sideburner does NOT light within 5 seconds, turn knob to OFF,
wait 5 minutes, then
repeat lighting procedure.
• Painted surfaces: Wash with mild detergent or nonabrasive
cleaner and warm soapy water. Wipe dry with a soft
nonabrasive cloth.
Sideburner Match Lighting
1. Open sideburner lid. Turn ON
• 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.
gas at LP cylinder.
2. Place lit match near burner.
3. Turn sideburner knob to the
HI position.
Be sure burner lights and
stays lit.
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3. Remove carryover tubes and burners.
4.
Detach electrode from burner.
CAUTION
NOTE: Removal/Detachment method will depend on the
burner configuration. See different configurations in
illustrations below.
SPIDER ALERT!
5. Carefully lift each burner up and away from valve openings.
We suggest three ways to clean the burner tubes. Use the one
SPIDER AND WEBS
easiest for you.
INSIDE BURNER TUBE
(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.
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.
(C) Wear eye protection: Use an air hose to force air into
the burner tube and out the burner ports. Check each
port to make sure air comes out each hole.
6. Wire brush entire outer surface of burner to remove food
residue and dirt.
7. Clean any blocked ports with a stiff wire such as an open
paper clip.
VALVE
SPIDER WEBS
CONTROL PANEL
INSIDE BURNER TUBE
8. Check burner for damage, due to normal wear and corrosion
some holes may become enlarged. If any large cracks or
holes are found replace burner.
BURNER
VERY IMPORTANT: Burner tubes must reengage valve
openings. See illustration at right.
9. Attach electrode to burner.
10. Carefully replace burners.
Correct
burner-to-valve
engagement
In some areas of the country, spiders or small insects have been
known to create “flashback” problems. The spiders spin webs, build
nests and lay eggs in the grill’s burner 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.
11. Attach burners to brackets on firebox.
12. Reposition carryover tubes and attach
to burners. Replace flame tamers and
cooking grates.
Remove screws
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.
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 manufacturers.
Firebox
Electrode
burner
bracket
• 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.
Cleaning the Burner Assembly
Electrode
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.
Pry off
electrode with
a flat blade
screwdriver
Firebox burner
bracket
464220110 • 9
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Indirect Cooking
Food Safety
Poultry and large cuts of meat cook slowly to perfection on the
grill by indirect heat. Place food over unlit burner(s); the heat
from lit burners circulates gently throughout the grill, cooking
meat or poultry without the touch of a direct flame. This method
greatly reduces flare-ups when cooking extra fatty cuts because
there is no direct flame to ignite the fats and juices that drip
during cooking.
Food safety is a very important part of enjoying the outdoor
cooking experience. To keep food safe from harmful bacteria,
follow these four basic steps:
Clean: Wash hands, utensils, and surfaces with hot soapy water
before and after handling raw meat and poultry.
Separate: Separate raw meats and poultry from ready-to-eat
foods to avoid cross contamination. Use a clean platter and
utensils when removing cooked foods.
Cook: Cook meat and poultry thoroughly to kill bacteria. Use a
thermometer to ensure proper internal food temperatures.
Chill: Refrigerate prepared foods and leftovers promptly.
For more information call: USDA Meat and Poultry Hotline at
1-800-535-4555 (In Washington, DC (202) 720-3333, 10:00 am-
4:00 pm EST).
1 Burner Cooking
Cook with direct or indirect heat.
Best for smaller meals or foods.
Consumes less fuel.
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.
Indirect Cooking Instructions
• Always cook with the lid closed.
• Due to weather conditions, cooking times may vary. During
cold and windy conditions the temperature setting may need
to be increased to insure sufficient cooking temperatures.
• Place food over the unlit burner(s).
• 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.
2 Burner Cooking
Great indirect cooking on low.
Produces slow, even heating.
Ideal for slow roasting and baking.
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
Pork
Egg Dishes
145°F
160°F
160°F
Steaks and Roasts of Beef,
Veal or Lamb
145°F
160°F
Ground Beef, Veal or Lamb
Whole Poultry (Turkey,
Chicken, Duck, etc.)
165°F
165°F
Ground or Pieces Poultry
(Chicken Breast, etc.)
*United States Department of Agriculture
10 • 464220110
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PARTS LIST
Key Qty Description
Part#
Key Qty Description
Part#
1
1
1
1
1
1
2
1
2
2
1
1
1
1
1
2
LEFT LEG ASSEMBLY
MATCH HOLDER
RIGHT LEG ASSEMBLY
BOTTOM SHELF
FRONT PANEL
G550-0700-W1
G401-0079-W1
G550-1000-W1
G550-0800-W1
G550-0900-W1
G550-0004-W1
G550-0009-W1
G401-0058-W1
G430-0023-W1
G550-0100-W1
G528-0002-W2
G430-0022-W1
G404-0034-W1
G550-0001-W1
G430-00B8-W1
40
41
42
43
44
45
46
2
1
1
1
1
1
1
COOKING GRATE
SWING AWAY GRATE
BUTTON, F/ EI MODULE
CLIP, F/ GREASE CUP
GREASE CUP
G550-0200-W1
G550-0002-W1
G409-0030-W1
G305-0043-W1
G430-0033-W1
G550-1100-W1
G430-C001-W2
2
3
4
5
6
7
TANK EXCLUSION WIRE
AXLE ROD
GREASE TRAY
TANK THUMBSCREW
8
WHEEL
9
LEG EXTENDER
Not Pictured
1
1
1
10
11
12
13
14
15
TOP LID
LOGO PLATE
…
…
…
PRODUCT MANUAL, ENGLISH
PRODUCT MANUAL, SPANISH
HARDWARE PACK
G550-010801-W1
G550-010802-W1
G55001-B001-W1
TEMPERATURE GAUGE
BEZEL, F/ TEMPERATURE GAUGE
HANDLE F/ TOP LID
SILICONE RUBBER BUMPER,
F/ MAIN LID
16
2
SILICONE REAR RUBBER BUMPER, G303-0038-W1
F/ MAIN LID
17
18
19
1
1
4
TOP LID HARDWARE
FIREBOX
MAIN BURNER TUBE,
G430-0024-W1
G550-0300-W1
G430-3800-W2
NO ELECTRODE
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
1
3
1
1
1
5
5
1
1
1
1
1
1
1
1
1
1
1
1
4
ELECTRODE, MAIN BURNER
FLAME CARRY OVER TUBE
MAIN CONTROL PANEL
ELECTRONIC IGNITION MODULE
HOSE VALVE REGULATOR
BEZEL, F/ CONTROL KNOB
CONTROL KNOB
RIGHT SIDE SHELF
FASCIA, F/ RIGHT SHELF
SIDEBURNER SHELF
DRIP PAN, F/ SIDEBURNER
SIDEBURNER LID
FASCIA, F/ SIDEBURNER SHELF
SIDEBURNER
ELECTRODE, F/ SIDEBURNER
IGNITOR WIRE, F/ SIDEBURNER
CLIP F/ SIDEBURNER
SIDEBURNER GRID
SHIELD, HEAT, FIREBOX
HEAT DIFFUSER
G501-0010-W2
G413-0004-W2
G550-0003-W1
G409-0021-W1
G550-5200-W1
G430-0027-W1
G432-0010-W1
G550-0400-W1
G550-5301-W1
G550-0500-W1
G430-0034-W2
G430-0018-W1
G550-5401-W1
G550-5600-W1
G430-0042-W1
G430-5303-W1
G405-0019-W1
G430-0053-W1
G550-5104-W1
G550-0006-W1
If you are missing hardware or have damaged parts
after unpacking grill, call 1-800-241-7548 for
replacement.
To order replacement parts after using grill, call
1-800-4-MY-HOME®.
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.
464220110 • 11
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PARTS DIAGRAM
16
39
20
17
40
40
41
12
39
10
39
13
11
39
15
21
21
21
19
33
19
31
37
19
19
14
34
18
27
35
30
29
38
36
42
22
28
23
32
26
24
26
25
25
45
3
46
1
4
2
43
6
44
6
8
7
5
9
8
12 • 464220110
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CAUTION: When unpacking grill components, two people should raise grill head from the shipping box.
Bottom Shelf to Legs
Place bottom shelf end with cut out hole for LP cylinder between leg assembly with axle holes. Attach to right and left leg
1
assemblies with (4) 1/4-20x1-1/2" screws and (4) 1/4-20 flange nuts.
Tighten securely.
1/4-20 Flange nuts
Qty. 4
Match Holder
Left Leg Assembly
1/4-20x1-1/2" Screws
Qty. 4
Right Leg Assembly
Bottom Shelf
Axle hole
464220110 • 13
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Front Panel
Attach front panel to grill cart with (6) #8-32x3/8” sheet metal screws. Make sure metal tabs are toward bottom.
2
#8-32x3/8"
sheet metal screws
Qty. 6
Tank Exclusion Wire
Hang tank exclusion wire onto front panel brackets; attach other ends to bottom shelf with (2) #8-32x3/8” sheet metal screws.
3
#8-32x3/8"
sheet metal screws
Qty. 2
14 • 464220110
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Wheels and Leg Extenders to Cart
Turn cart assembly upside down.
4
Insert axle rod through wheel, wheel spacer, legs and other wheel. Be sure to face “cone” side of wheel against leg. Attach with (1)
axle washer and hitch pin.
Hammer leg extenders into right legs.
Wheel Spacer
Hitch Pin
Qty. 1
Leg Extenders
Qty.1
Axle Washer
Qty. 1
Wheel
Axle Rod
Axle Washer
Wheel Spacer
Hitch Pin
"Cone" side of wheel against leg
464220110 • 15
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Grill Head to Cart
Stand cart upright.
5
This step requires two people to lift and position grill head onto cart.
Carefully lower the grill head onto the cart. Make sure the regulator hose is hanging outside the cart. Attach head to cart with (4)
1/4-20x1/2" screws.
1/4-20x1/2" screws
Qty. 4
Grill Head
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Right Side Shelf
Hook side wall of shelf over support brackets on side of firebox (A).
Insert (4) 7mm fiber washers and (4) 1/4-20x1/2" screws through inside front of firebox
and through outside back of firebox as shown (B).
6
Attach shelf with (4) 1/4-20 flange nuts (C).
B
A
Support Bracket
Right Side Shelf
7mm
Fiber Washer
Qty: 4
1/4-20
Flange Nut
Qty: 4
1/4-20x1/2"
screws
Qty: 4
Fascia, Right Side Shelf
Attach fascia and side shelf to firebox with (3) #8-32x3/8" sheet metal screws.
7
CAUTION: Fascia must be securely tightened to firebox to safely move grill.
Fascia, Right Side Shelf
#8-32x3/8"
sheet metal screws
Qty. 3
464220110 • 17
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Side Burner Shelf
Hook side wall of side burner shelf over support brackets on side of firebox (A).
Inside firebox insert (4) fiber washers and (4) 1/4-20x1/2" screws as shown (B).
Attach shelf using (4) 1/4-20 flange nuts (C).
8
1/4-20x1/2" screws
Qty. 4
Lid removed for clarity
B
Side Burner Shelf
7mm Fiber Washers
Qty. 4
A
1/4-20
Flange Nuts
Qty. 4
C
Left Fascia
Attach fascia to firebox with (3) #8-32x3/8" sheet metal screws.
9
CAUTION: Fascia must be securely tightened to firebox to safely move grill.
#8-32x3/8"
sheet metal screws
Qty. 3
Left Fascia
18 • 464220110
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Sideburner Valve, Sideburner, Sideburner Bezel, Ignitor Wire, Control Knob
Position valve behind fascia and line up holes (A).
10
Insert (1) of the #8-32x3/8” stainless steel screws, but do not fully tighten.
Slip bezel under inserted screw and position as shown (A).
Line up other hole and insert (1) #8-32x3/8” stainless steel screw through bezel and into valve.
Tighten both securely.
Place sideburner into shelf (B). Make sure to insert valve into sideburner tube. Attach sideburner with (1) wing nut ( C). Under
sideburner shelf, install sideburner clip to sideburner tube and valve. Attach sideburner ignitor wire to electrode as shown (D).
Place grate onto sideburner shelf (E).
Press control knob onto sideburner valve stem (F).
Sideburner
Bezel
B
A
C
Wing Nut
Sideburner Valve
Sideburner Valve
E
D
Sideburner
Grid
Burner Clip
Correctly assembled burner-to-valve engagement
F
Control Knob
Insert this tip into
hole in bottom of
#8-32X3/8”
sideburner tube
Stainless Steel Screw
Clip around
Qty. 2
sideburner
valve
Wing Nut
Qty. 1
464220110 • 19
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Heat Shield
Attach heat shield over burners inside front of grill with (2) #8-32x3/8’’ sheet metal screws.
11
Heat Shield
#8-32x3/8"
sheet metal screws
Qty. 2
Lid removed for clarity
Grill Front
Grill Back
20 • 464220110
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Heat Diffusers
Place heat diffusers over burners by inserting tabs into slots in front of firebox.
12
Opposite ends of heat diffusers rest on pins in back of firebox.
Pin
Cooking Grate and Swing Away
Place cooking grates onto grate rests.
13
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.
Unscrew ignitor cap and place AA battery into ignitor slot with positive end (+) facing outward. Screw ignitor cap onto ignitor.
Swing Away
Pivot Wire
Leg Wire
Cooking Grate
+
–
AA Battery
464220110 • 21
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Grease Cup Clip, Grease Cup, Grease Tray
Hang grease cup clip from bottom of grease tray and place grease cup into grease cup clip. Place the tray into the cart.
14
CAUTION
Failure to install grease cup clip and cup
will cause hot grease to drip from bottom
of grill with risk of fire or property damage.
Grease Tray
Grease Cup Clip
Grease Cup
LP Tank
LP tank is sold separately. Use only with an OPD (over-fill protection device) equipped LP tank. Fill and leak check before attaching
15
to grill and regulator.
Place LP tank into hole in bottom shelf with tank collar opening facing to side as shown. Finger tighten tank thumbscrew to hold LP
tank securely in place.
See Use and Care section to correctly Leak Test and
CAUTION
perform the Burner Flame Check.
Failure to install tank correctly may allow gas hose to
be damaged in operation, resulting in the risk of fire.
LP Tank
Tank Thumbscrew
22 • 464220110
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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.
Gas leaking from LP
cylinder.
• Mechanical failure due to rusting or
mishandling.
• Replace LP cylinder.
Gas leaking from LP
• Failure of cylinder valve from
• Turn off LP cylinder valve. Return LP cylinder to gas supplier.
cylinder valve.
mishandling or mechanical failure.
Gas leaking between
LP cylinder and
• Improper installation, connection not
tight, failure of rubber seal.
• 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.
regulator connection.
Fire coming through
control panel.
• Fire in burner tube section of burner due
to blockage.
• 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.
Grease fire or
• Too much grease buildup in burner area.
• 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.
continuous excessive
flames above cooking
surface.
Troubleshooting
Problem
Possible Cause
Prevention/Solution
GAS ISSUES:
Burner(s) will not light
using ignitor.
• Trying to light wrong burner.
• See instructions on control panel and in Use and Care section.
• Make sure valves are positioned inside of burner tubes.
(See Electronic Ignition
Troubleshooting also)
• Burner not engaged with control valve.
• 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).
• Electrode tip not in proper position.
Main Burners:
• 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.
464220110 • 23
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Troubleshooting (continued)
Problem
Possible Cause
Prevention/Solution
Burner(s) will not light
using ignitor.
ELECTRONIC IGNITION:
• 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...
• 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.
(fire in burner tube(s)).
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.
24 • 464220110
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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
properly engaged. Button
should travel up and down
without binding.
• Unscrew button cap assembly and reinstall, 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
or at slow rate.
• Replace battery with a new AA-size alkaline battery.
• Use paper towel to remove moisture.
• Electrodes are wet.
• Has moisture accumulated
on electrode and/or in burner
ports?
• Electrodes cracked or
broken “sparks at
crack”.
• Inspect electrodes for
cracks.
• Replace cracked or broken electrodes.
464220110 • 25
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NOTES
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NOTES
464220110 • 27
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Get it fixed, at your home or ours!
Your Home
For expert troubleshooting and home solutions advice:
For repair – in your home – of all major brand appliances,
lawn and garden equipment, or heating and cooling systems,
no matter who made it, no matter who sold it!
For the replacement parts, accessories and
owner’s manuals that you need to do-it-yourself.
For Sears professional installation of home appliances
and items like garage door openers and water heaters.
1-800-4-MY-HOME® (1-800-469-4663)
Call anytime, day or night (U.S.A. and Canada)
Our Home
For repair of carry-in items like vacuums, lawn equipment,
and electronics, call anytime for the location of your nearest
Sears Parts & Repair Service Center
1-800-488-1222 (U.S.A.)
1-800-469-4663 (Canada)
To purchase a protection agreement on a product serviced by Sears:
1-800-827-6655 (U.S.A.)
1-800-361-6665 (Canada)
Para pedir servicio de reparación
a domicilio, y para ordenar piezas:
Au Canada pour service en français:
MC
1-800-LE-FOYER
1-888-SU-HOGAR®
(1-800-533-6937)
(1-888-784-6427)
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