Assembly Instructions/Use and Care Manual
NO TOOLS
ASSEMBLY
Liquid Propane Gas Grill
Model No. 415.162090
This Grill Is For
Outdoor Use Only
WARNING
• Read this manual before cooking on
grill. Failure to follow all
manufacturers’ instructions could
result in fire or explosion which could
cause property damage, personal
injury or death.
• Combustion by-products produced
when using this product contain
chemicals known to the State of
California to cause cancer, birth
defects, or other reproductive harm.
• Parts
• Use and Care
• Assembly
• Troubleshooting
• Safety Rules • Español, p. 33
Assembly Questions?
Call 1-800-241-7548
CAUTION
Parts Ordering:
Call 1-800-4-MY-HOME®
• Read and follow all Safety
Statements, Assembly Instructions
and Use & Care Directions before
attempting to assemble and cook.
To Installer/Assembler: Leave
these instructions with
consumer.
• Some parts may contain sharp edges,
especially as noted in these
instructions. Wear protective gloves
if necessary.
To Consumer: Keep this
manual for future reference.
Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A.
Printed in USA
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TABLE OF CONTENTS
WARRANTY
For Your Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Grill Service Center. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Product Record Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Kenmore Grill Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Parts Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Use and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-25
Cooking Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
KENMORE GRILL WARRANTY
Full 1-Year Warranty on Grill
For one year from the date of purchase Sears will repair or
replace, at our option, any grill part (except for paint finish)
that is defective in material or workmanship.
Limited Warranty on Selected Grill Parts
From one year after the date of purchase for the designated
time periods listed below, Sears will replace the following grill
parts if they are defective in material or workmanship. You
will be charged for labor.
• Lifetime of Grill: Aluminum Top and Bottom Castings
(except for paint finish)
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
• 2 years: Burner Assembly
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.
WARRANTY SERVICE
Warranty service is available by contacting Sears at
1-800-4-MY-HOME®.
Purchase a Repair Protection Agreement now and protect
yourself from unexpected hassle and expense.
WARRANTY RESTRICTIONS
This warranty is void if grill is used for commercial or rental
purposes.
Here’s what’s included in the Agreement:
Expert service by our 12,000 professional repair specialists
Unlimited service and no charge for parts and labor on all
covered repairs
Product replacement if your covered product can’t be fixed
Discount of 10% from regular price of service and service-
related parts not covered by the agreement; also, 10% off
regular price of preventive maintenance check
Fast help by phone – phone support from a Sears
technician on products requiring in-home repair, plus
convenient repair scheduling
This warranty applies only when the grill is used in the United
States.
This warranty gives you specific legal rights, and you may
also have other rights which vary from state to state.
Sears, Roebuck and Co., Dept. 817WA,
Hoffman Estates, IL 60179
Once you purchase the Agreement, a simple phone call is all that
it takes for you to schedule service. You can call anytime day or
night, or schedule a service appointment online.
Sears has over 12,000 professional repair specialists, who have
access to over 4.5 million quality parts and accessories. That’s
the kind of professionalism you can count on to help prolong the
life of your new purchase for years to come. Purchase your
Repair Protection Agreement today!
Some limitations and exclusions apply.
For prices and additional information call 1-800-827-6655.
Sears Installation Service
For Sears professional installation of home appliances, garage
door openers, water heaters, and other major home items, in the
U.S.A. call 1-800-4-MY-HOME®
463350505 • 3
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PARTS LIST – Model No. 415.162090
Key Qty
Description
Part #
Key Qty
Description
Part #
1
1
1
1
23
1
1
2
3
1
1
2
1
2
4
1
4
1
2
2
1
Right Leg Assembly w/ Match Holder. 7000622
Left Leg Assembly. . . . . . . . . . . . . . . . 7000621
Bottom Shelf . . . . . . . . . . . . . . . . . . . . 7000612
#10-16x1/2” Self-Tap Screw . . . . . . . . 7000737 STD611005
Match Holder w/Chain. . . . . . . . . . . . . 7000364
Push Fastener. . . . . . . . . . . . . . . . . . . 4080112
Leg Extender. . . . . . . . . . . . . . . . . . . . 7000320
“U” Nut 1/4-20. . . . . . . . . . . . . . . . . . . 7000185
1/4-20 x 6” Tank Thumbscrew. . . . . . . 7000355
1/4-20 Flanged Hex Nut . . . . . . . . . . . 7000394
#10-24x1/2” Washer Head Screw. . . . 7000829
Axle Rod . . . . . . . . . . . . . . . . . . . . . . . 7000265
Wheel . . . . . . . . . . . . . . . . . . . . . . . . . 7000262
Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . 7000480
Grill Bottom. . . . . . . . . . . . . . . . . . . . . 7000842
#10-1” Self-Tap Screw . . . . . . . . . . . . 4080716
Carry-Over Tube. . . . . . . . . . . . . . . . . 7000277
3/16 Pal Nut . . . . . . . . . . . . . . . . . . . . 7000132
Casting Bumper . . . . . . . . . . . . . . . . . 7000184
Electrode w/Wing Nut . . . . . . . . . . . . . 7000378
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
1
1
2
1
1
2
1
1
1
1
2
1
2
2
2
1
1
1
1
Ignitor . . . . . . . . . . . . . . . . . . . . . . . . . 4153713
Ignitor Wire . . . . . . . . . . . . . . . . . . . . . 4153196
Burners . . . . . . . . . . . . . . . . . . . . . . . . 7000083
Control Panel . . . . . . . . . . . . . . . . . . . 7000619
Valve/Hose/Regulator Assembly. . . . . 7000062
Shelves. . . . . . . . . . . . . . . . . . . . . . . . 7000351
Top Casting. . . . . . . . . . . . . . . . . . . . . 7000615
Logo Plate Assembly . . . . . . . . . . . . . 4157167
Bezel Temperature Gauge . . . . . . . . . 4157169
Temperature Gauge w/Wing Nut. . . . . 4157171
Shoulder Bolt . . . . . . . . . . . . . . . . . . . 7000186
Handle. . . . . . . . . . . . . . . . . . . . . . . . . 7000199
#10-24 Wing Nut. . . . . . . . . . . . . . . . . 4080063 STD541610
Control Knob. . . . . . . . . . . . . . . . . . . . 7000312
Vaporizer Tents . . . . . . . . . . . . . . . . . . 7000044
Cooking Grid. . . . . . . . . . . . . . . . . . . . 7000023
Warming Rack . . . . . . . . . . . . . . . . . . 7000180
Grease Tray . . . . . . . . . . . . . . . . . . . . 7000042
Grease Pan. . . . . . . . . . . . . . . . . . . . . 7000046
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
4 • 463350505
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PARTS DIAGRAM – Model No. 415.162090
35
27
35
37
36
31
18
31
18
17
23
23
32
30
8
19
8
33
16
19
29
28
26
26
15
4
4
4
14
4
14
14
4
14
5
4
2
6
4
38
4
25
20
24
11
39
1
4
4
4
4
4
4
7
21
4
22
4
13
9
7
8
12
34
4
10
4
13
11
3
463350505 • 5
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ASSEMBLY – Model No. 415.162090
Use included Phillips head screwdriver to assemble your grill.
Size and type of hardware used in assembly of your grill may vary, but will not affect grill integrity, performance or assembly.
“NEW”
T. L. M. - Torque Locking Method
2
Thru Part
2
3
1
Screw + Thru Part + Formed Lock = Solid Lock Cart Structure
• The cart assembly utilizes the new T.L.M. fastening method.
• No need for the old style “Bolt & Nut” combination
1
Screw
3
Formed Locking System
Cart Assembly
‘ Place bottom shelf on table or grill container.
1
“ Insert tabs on leg assembly with match lighting chain into right side of bottom shelf.
“ Attach leg assembly with one screw on each side.
“ Insert tabs on leg assembly without match lighting chain into left side of bottom shelf.
“ Attach leg assembly with one screw on each side.
4
Qty:8
Right Leg Assembly w/Match Lighting Chain
Bottom Shelf
Correctly assembled legs
4
6 • 463350505
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Leg Extenders, Axle Rods, Wheels and Tank Thumbscrew
“ Turn cart upside down.
2
‘ Insert leg extenders. Check to make sure leg extender is all the way
into the leg.
9
Qty: 1
Not to scale
“ Attach u-nut to tab. See enlargement of u-nut for correct position.
“ Thread tank thumbscrew into hole and u-nut. Screw flanged hex
nut onto end of tank thumbscrew.
8
Qty: 1
Not to scale
“ Attach washer head screw to axle rod. Slide wheel on axle rod.
Insert axle rod/wheel into large hole in bottom shelf. Attach other
wheel and washer head screw.
10
Qty: 1
11
Qty: 2
8
Leg Extender
Correct position
11
10
Hub on wheel faces
into grill bottom
9
Axle Rod
Wheel
Stand cart upright and remove
cardboard sleeves
463350505 • 7
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Rail Assembly
‘ Overlap rails (all identical) and hook tabs into slots. Pull rails
to latch.
3
“ Attach rail to legs with two screws in each corner.
HINT:
Firmly push rail down into leg notches. Attach lower screw first.
4
Qty:10
“ Attach one screw in center of each rail.
Rail
4
8 • 463350505
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Grill Bottom Assembly
‘ Angle grill bottom assembly around and under the rails.
4
“ Make sure ribs on each side of bottom casting are nestled
into notches on casting seat.
“ Attach four screws inside grill bottom and into casting seat.
16
Qty: 4
16
Grill Bottom
Casting Seat
463350505 • 9
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Electrode with Wing Nut or Nut
‘ Inside bottom casting insert electrode and attach
with wing nut or nut.
5
View of electrode attached and aligned
with a porthole in the burner.
Wing Nut Or Nut
Finger tighten only
Front
Electrode
10 • 463350505
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Console Assembly
‘ Hold control panel close to bottom casting. Attach ignitor wire to
electrode.
6
“ Position valves into burner tubes (see burner-valve view). Rotate
control panel up and rest flange over rail.
“ Attach control panel to legs with four screws.
4
Qty:4
Correctly assembled burner tube and valve.
Ignitor Wire
Burner Tube
Control Panel
4
Valve/Hose
Regulator Assy
Ignitor
463350505 • 11
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Shelves
‘ Snap shelves into small slots on rail.
7
Slots
Tab fully secured
Shelf
12 • 463350505
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Top Casting, Handle and Control Knobs
‘ Attach top casting with shoulder bolts.
“ Attach handle with wing nuts.
8
“ Push control knobs onto valve stems.
33
Qty. 2
31
Qty. 2
Bezel Temperature Gauge
Temperature Gauge
Logo Plate
Top Casting
31
33
Handle
Control Knob
463350505 • 13
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Vaporizer Tents, Cooking Grid and Warming Rack
‘ Note correct position of vaporizer tents directly
over burners.
9
Warming Rack
Cooking Grid
Grid rest
Vaporizer Tents
Warming rack slots
LP Tank
‘ LP tank is sold separately. Use only with an
(over-fill protection device) OPD equipped
LP tank. Fill and leak check before attaching
to grill and regulator.
See Use and Care section to correctly Leak Test and
perform the Burner Flame Check.
10
“ Place LP tank into hole in bottom shelf.
Finger tighten tank thumbscrew to hold
LP tank securely in place.
CAUTION
Back of cart
• Tank collar opening must face to front of cart once
tank is attached.
• Failure to install tank correctly may allow gas hose to
be damaged in operation, resulting in the risk of fire.
14 • 463350505
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Grease Tray and Grease Pan
‘ Slide grease tray onto grill bottom.
“ Slide grease pan onto grease tray.
CAUTION
11
Failure to install the grease tray and grease
pan will cause hot grease to drip from bottom
of grill with risk of fire or property damage.
Grease Tray
Grease Pan
Do not be concerned if you have some
hardware left over. Extra hardware has been
included to make sure you have enough.
463350505 • 15
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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 fill the cylinder beyond 80% full. An overfilled
spare LP tank is hazardous due to possible gas
released from the safety relief valve.
• LP tanks must be constructed and marked in accordance with
specifications for LP tank of the U.S. Department of
Transportation (DOT). See LP tank collar for marking.
• When LP tank is over 80% full, the safety relief valve on
the LP tank could activate, releasing gas and cause an
intense fire with risk of property damage, serious
injury or death.
• LP tank valve must have:
• Type 1 outlet compatible with
regulator or grill.
• Safety relief valve.
• NEVER store a spare LP tank under or near grill or in
enclosed areas.
• 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.
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.
• If you see, smell or hear escaping gas, immediately get
away from the LP tank/grill and call your fire
department.
• LP gas is highly flammable and may ignite unexpectedly when
mixed with air.
• All spare LP tanks must have safety caps installed on
the LP tank outlet.
LP Tank Filling
LP Tank Removal, Transport And Storage
• Use only licensed and experienced dealers.
• LP dealer must purge tank before filling.
• 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.
• 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.
• Do not release liquid propane (LP) gas into the atmosphere.
This is a hazardous practice.
LP Tank Valve
• 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.
Safety Cap
Retainer Strap
• A disconnected LP tank in storage or being transported must
have a safety cap installed (as shown). Do not store an LP tank
in enclosed spaces such as a carport, garage, porch, covered
patio or other building. Never leave an LP tank inside a vehicle
which may become overheated by the sun.
• Do not store an LP tank in an area where children play.
16 • 463350505
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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 cylinders. 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
during use, transit or storage.
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.
ck
LP Tank Leak Test
For your safety
OPD Hand Wheel
• Leak test must be repeated each time LP tank is exchanged or
refilled.
Type 1 outlet with
thread on outside
• 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.
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 use a POL transport plug
(plastic part with external threads)!
It will defeat the safety feature of
the valve.
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 can result.
Nipple has to be centered
into the LP tank valve.
463350505 • 17
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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:
s 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!
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.
18 • 463350505
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Safety Tips
WARNING
s Before opening LP tank valve, check the coupling nut for
tightness.
For Safe Use Of Your Grill And To Avoid Serious
Injury:
s When grill is not in use, turn off all control knobs and LP tank
valve.
• Do not let children operate or play near grill.
• Keep grill area clear and free from materials that burn.
• Do not block holes in bottom or back of grill.
• Check burner flames regularly.
s Never move grill while in operation or still hot.
s Use long-handled barbecue utensils and oven mitts to avoid
burns and splatters.
s Maximum load for shelves is 10 lbs.
• 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 The grease cup must be attached to grease tray and emptied
after each use. Do not remove grease cup until grill has
completely cooled.
• Do not use charcoal or ceramic briquets in a gas grill.
(Unless briquets are supplied with your grill.)
s 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.
• 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 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".
WARNING
If the regulator frosts, turn off grill and LP tank valve
immediately. This indicates a problem with the tank and it
should not be used on any product. Return to supplier!
• Apartment Dwellers:
Check with management to learn the requirements and fire
codes for using an LP gas grill in your apartment complex. If
allowed, use outside on the ground floor with a three (3) foot
clearance from walls or rails. Do not use on or under
balconies.
• NEVER attempt to light burner with lid closed. A buildup
of non-ignited gas inside a closed grill is hazardous.
• Never operate grill with LP tank out of correct position
specified in assembly instructions.
• Always close LP tank valve and remove coupling nut
before moving LP tank from specified operation
position.
463350505 • 19
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Match-Lighting
CAUTION
s Do not lean over grill while lighting.
1. Open lid. Turn on gas at LP tank.
• Putting out grease fires by closing the lid is not
possible. Grills are well ventilated for safety reasons.
2. Match holder is on the right rear leg. Attach match to match
holder, light match. Place match into match lighting hole from
outside of grill bottom (as shown).
• Do not use water on a grease fire. Personal injury may
result. If a grease fire develops, turn knobs and LP tank
off.
3. Push in and turn right knob to preheat position. Be sure
burner lights and stays lit.
• Do not leave grill unattended while preheating or
burning off food residue on high. If grill has not been
regularly cleaned, a grease fire can occur that may
damage the product. Follow instructions on General
Grill Cleaning and Cleaning The Burner Assembly to
prevent grease fires.
4. Light left burner by pushing left knob in and turning to
preheat position.
Ignitor Lighting
s Do not lean over grill while lighting.
1. Open lid. Turn on gas at LP tank.
2. Turn left knob to preheat to light.
Match lighting hole
3. Push ignitor button rapidly (up to 5 times) to light. Be sure
burner lights and stays lit.
Hose Check
4. If burner does not light, turn knobs to OFF, wait 5 minutes, try
again.
• Before each use, check to see if hoses are cut, worn or kinked.
Replace damaged hoses before using grill. Use only
valve/hose/regulator specified in the Parts List.
5. Once left burner is lit, turn right knob to preheat to light.
6. If ignitor does not work, wait 5 minutes, then follow match
lighting instructions.
After Lighting: Turn knobs to HIGH position for warm-up. Do
not warm up grill with knobs in preheat position. Knobs and
handle will become uncomfortably hot if left in preheat
position.
Normal
Hose
Kinked
Hose
CAUTION
Before Your First Cookout
If burner does not light, turn knobs to OFF, wait 5
minutes, and try again. Always close valve during the 5
minute waiting period. If the burner does not ignite with
the valve open, gas will continue to flow out of the burner
and could accidentally ignite with risk of injury.
• Light burners, check to make sure they are lit, close the lid and
warm up grill on HIGH for 15 minutes. This curing of paint and
parts will produce an odor only on first lighting.
Burner Flame Check
• Light burner, rotate knobs from HI to LO. You should see a
smaller flame in LO position than seen on HI. Always check
flame prior to each use. If only low flame is seen refer to
"Sudden drop or low flame" in the Troubleshooting Section.
HI
LO
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Turning Grill Off
Repainting Your Grill
• Turn all knobs to OFF position. Turn LP tank off by turning
OPD hand wheel clockwise to a full stop.
• After extended use and exposure to weather, paint on grill may
deteriorate or become spotted. Although this detracts from
grill's appearance, it will not impair its performance.
Ignitor Check
• To refinish your grill brush outside of grill lid and bottom with
wire brush and lightly sand with fine grit sandpaper. Sanding
allows new paint to adhere more easily. Wash grill lid and
bottom with soap and water to remove dust and grease. Do not
use a grill cleaner on outside of grill. Wipe with vinegar.
Refinish outside with heat-resistant paint. Do not paint inside
of grill.
• Turn gas off at LP tank. Press and hold ignitor button. "Click"
should be heard and spark seen each time between collector
box or burner and electrodes. See "Troubleshooting" if no click
or spark.
Valve Check
• Important: Make sure gas is off at LP tank before checking
valves. Knobs lock in OFF position. To check valves, first
push in knobs and release, knobs should spring back. If knobs
do not spring back, replace valve assembly before using grill.
Turn knobs to LO position then turn back to OFF position.
Valves should turn smoothly.
CAUTION
NATURAL HAZARD • SPIDERS
FACT: Sometimes spiders and other small insects climb into
the burner tubes attached to the burners. The spiders spin
webs, build nests and lay eggs. The webs or nests can be
very small, but they are very strong and can block the flow of
gas. Clean burners prior to use after storing, at the beginning
of grilling season or after a period of one month not being
used.
General Grill Cleaning
• Keep the outside of your grill looking new by cleaning it once a
month with warm soap and water or a non-abrasive cleaner. If
you don’t have a grill cover, wipe off dust and grime before
starting your grill.
• Coating the cooking grids with spray-on cooking oil will keep the
food from sticking and make clean up easier. After cooking,
scrape the grates with a long handled, brass wire bristle brush.
• Check inside the grill bottom for grease build up and clean
often, especially after cooking fatty meat.
• Do not mistake brown or black accumulation of grease and
smoke for paint. 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.
Typical spider webs inside burner.
Spider guards are on the air intakes in an effort to reduce this
problem, but it will not eliminate it! An obstruction can result
in a "flashback" (a fire in the burner tubes). The grill may still
light, but the obstruction does not allow full gas flow to the
burners.
• Plated wire grates: Wash grates and V-bar with concentrated
grill cleaner or use soap and water solution. Dry thoroughly and
store indoors between cookouts.
IF YOU EXPERIENCE THE FOLLOWING:
1. Smell gas.
• Plastic parts: Wash with warm soapy water and wipe dry.
2. Burner(s) will not light.
s Do not use citrisol, abrasive cleaners, degreasers or a
concentrated grill cleaner on plastic parts. Damage to and
failure of parts can result.
3. A small yellow flame from burner (should be blue).
4. Fire coming from around or behind control knob.
STOP!
• Porcelain grates: Because of glass-like composition, most
residue can be wiped away with baking soda/water solution or
specially formulated cleaner. Use non-abrasive scouring
powder for stubborn stains.
Immediately turn off gas at LP tank!
s After a burner tube fire, you must inspect the hose and
do a “Leak Test” to assure no damage has occured to
the parts.
SOLUTION:
Wait for grill to cool.
Follow the “Cleaning The Burner Assembly” instructions.
Clean burners often. Use a 12” pipe cleaner to clean out the
burner tubes. You may also force a stream of water from a
hose nozzle through burner tubes to clean them.
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Cleaning The Burner Assembly
Follow these instructions to clean and/or replace parts of burner
assembly or if you have trouble igniting the grill.
Pal Nuts
1. Turn gas off at control knobs and LP tank.
2. Remove cooking grids and vaporizer tents.
Carry-Over Tube
3. Remove two pal nuts, carry-over tube and burners.
4. Under grill remove grease pan and tray. Clean with soap and water.
5. Under console disengage ignitor wire.
Burner
6. Wipe ceramic electrode with rubbing alcohol and cloth.
7. Clean carry-over tube and burners exterior with soap and water. Lay
burners on flat surface, insert garden hose (preferably with nozzle),
into burner tubes forcing water through tubes. Make sure water
comes out of every porthole. Open clogged portholes with a thin
wire. Shake out excess water and examine porthole. Due to
normal wear and corrosion some portholes may become enlarged,
if so replace burner. If any horizontal cracks appear from porthole to
porthole or large holes (other than portholes) are found replace
burner.
8. If grill is to be stored, coat burners lightly with cooking oil. Wrap in
protective cover to keep insects out. If not storing use following
steps.
VERY IMPORTANT: Burner tubes must engage valve openings as
shown (A).
9. Attach ignitor wire to electrode.
A
10. Reposition cooking grids and vaporizer tents. Place clean grease
tray and pan into grill bottom.
11. Before cooking again on grill, perform a “Leak Test” and “Burner
Flame Check”.
s Do not use ceramic briquets or charcoal in your grill.
Correctly assembled burner tube and valve.
Cleaning the Grease Tray
Your grill is equipped with a removable grease tray. Although grease
will drain from the grease tray to the grease cup provided, food particles
and debris may accumulate in the bottom and should be removed after
cooking 5 to 10 times. This can easily be done by sliding the grease tray
out of the rear of the unit. Make sure in replacing the tray to push it all the
way forward.
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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.
Food Safety
Food safety is a very important part of enjoying the outdoor
cooking experience. To keep food safe from harmful bacteria,
follow these four basic steps:
Clean: Wash hands, utensils, and surfaces with hot soapy water
before and after handling raw meat and poultry.
Separate: Separate raw meats and poultry from ready-to-eat
foods to avoid cross contamination. Use a clean platter and
utensils when removing cooked foods.
Cook: Cook meat and poultry thoroughly to kill bacteria. Use a
thermometer to ensure proper internal food temperatures.
Chill: Refrigerate prepared foods and leftovers promptly.
For more information call: USDA Meat and Poultry Hotline at
1-800-535-4555 In Washington, DC (202) 720-3333, 10:00 am-
4:00 pm EST.
How To Tell If Meat Is Grilled Thoroughly
• Meat and poultry cooked on a grill often browns 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 180° F; breasts, 170° F. Juices
should run clear and flesh should not be pink.
• Hamburgers made of any ground meat or poultry should reach
160° F, and be brown in the middle with no pink juices. Beef,
veal and lamb steaks, roasts and chops can be cooked to 145°
F. All cuts of pork should reach 160° F.
• NEVER partially grill meat or poultry and finish cooking later.
Cook food completely to destroy harmful bacteria.
• When reheating takeout foods or fully cooked meats like hot
dogs, grill to 165° F, or until steaming hot.
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Cooking Table
Cooking times and temperatures may vary according to specific recipes, cooking conditions or barbecue equipment used. Take these
factors into consideration to insure best results. If you use the indirect cooking method (indirect cooking is lighting only one burner and
placing food on opposite side of cooking grate), allow more grilling time.
Temperatures: High = 650°F / Medium = 450°F / Low = 300°F.
Food
Setting
Cooking Time
Beef
Hamburger 1/2” thick
Medium
Medium-Hot
Low
Med: 7-10 min. / Well done: 10-15 min.
Steak 1/2”
Roast
Rare: 3-6 min. / Med: 6-9 min. / Well done: 9-12 min.
Rare: 18-22min. per lb. / Med: 22-28 min. per lb. / Well done: 28-32 min. per lb.
Pork
Chops 1/2”
Medium
Well done: 15-20 min.
Well done: 45-90 min.
Well done: 18-23 min. per lb.
12-15 min.
Ribs 5-6 lbs.
Low-Medium
Low-Medium
Medium-Hot
Low-Medium
Roast 3-5 lbs.
Ham Steak 1/2”
Ham 5 lb. fully cooked
20 min. per lb.
Lamb
Chops 1/2”
Medium
6-12 min.
Poultry
Chicken 2-1/2 to 3-1/2 lbs.
Low
1 hr., 15 min. to 1 hr., 30 min.
40-60 min.
Low
Chicken halved or quartered
Turkey
Low-Medium
18-20 min. per lb.
Seafood
Steaks 1” thick
Medium-Hot
Medium-Hot
Low-Medium
Well done: 10-25 min.
8-12 min.
Fillets 6-8 oz.
8-12 min.
Shrimp large or jumbo
Venison
Steak 1” thick
Medium
Rare: 8-10 min. / Med: 10-12 min.
Medium
Rare: 10-12 min. / Med: 12-15 min.
Burgers 1/2”
Low-Medium
Rare: 20-22 min. per lb. / Med: 22-25 min. per lb.
Roast 3-4 lbs.
Wrap vegetables in foil
55-60 min.
Vegetables
Baking Potato whole
Low
Low
45 min.
Onions whole
Tomatoes half
Corn whole
Medium
Low
30-40 min.
35-45 min.
15-20 min.
Medium
Mushrooms
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Troubleshooting
Emergencies
Possible Cause
Prevention/Solution
Gas leaking from
cracked/cut/burned
hose.
• Old hose, cut in hose.
• Turn off gas at LP tank. If hose is cut or cracked, replace
valve/hose/regulator. If burned, discontinue use of product until a gas
service technician/plumber has investigated cause and correction is
made.
Gas leaking from LP
tank.
• Mechanical failure due to rusting or
mishandling.
• Turn off LP tank valve.
Gas leaking from LP
tank valve.
• Failure of tank valve from mishandling or
mechanical failure.
• Call LP gas dealer 800-number on tank label or call local fire
department.
Gas leaking between
LP tank and regulator
connection.
• Improper installation, connection not
tight, failure of rubber seal.
• Remove regulator from tank and visually inspect rubber seal for
damage. Reinstall and check for leaks. Ensure black knob is on tight.
Fire coming through
control panel.
• Fire in burner tube section of burner due
to partial blockage.
• Turn off LP tank valve (if possible without injury to self). If fire cannot
be controlled with baking soda/extinguisher, call local fire department.
Remove burner and inspect for spider nest or rust. Clean using bottle
brush.
• Misalignment of valve to burner tube.
• Too much grease buildup in burner area.
• Ensure valves and burner tubes are aligned per assembly
instructions.
Grease fire or
• Turn off LP tank valve. Leave lid open to allow flames to die down.
After cooling, clean food particles and excess grease from inside
firebox area, grease cup/pan/tray, and other surfaces.
continuous excessive
flames above cooking
surface.
Problem
Possible Cause
Prevention/Solution
GAS ISSUES:
• Trying to light wrong burner.
Burner(s) will not light
using ignitor.
• See instructions on control panel and section in the Use and Care.
• Make sure valves are positioned inside of burner tubes.
• Burner not engaged with control valve.
• Obstruction in burner.
Continued on next
page.
• Ensure burner tubes are not obstructed with spider webs or other
matter. See cleaning section of Use and Care.
• No gas flow.
• Make sure LP tank is not empty. If LP tank is not empty, refer to
“Sudden drop in gas flow.”
• Vapor lock at coupling nut to LP tank.
• Turn off knobs and disconnect coupling nut from LP tank. Reconnect
and retry.
• Coupling nut and LP tank 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.
• Tip of electrode should be pointing toward port hole in burner. The
distance should be 1/8” to 3/16”. Adjust if necessary.
• Electrode tip not in proper position.
• Clean wire and/or electrode with rubbing alcohol and clean swab.
• Wire and/or electrode covered with
cooking residue.
• Reconnect wires or replace electrode/wire assembly.
• Replace ignitor wire.
• Wires are loose or disconnected.
• Wires are shorting (sparking) between
ignitor and electrode.
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Troubleshooting (continued)
Problem
Possible Cause
Prevention/Solution
Burner(s) will not light
using ignitor.
• Push-button sticks at bottom..
• Sparking between ignitor and electrode.
• Replace ignitor.
• Inspect wire insulation and proper connection. Replace wires if
insulation is broken.
Burner(s) will not
match light.
• See “GAS ISSUES:” on previous page.
• Improper method of match-lighting.
• See “Match-Lighting” section of Use and Care.
• Check for gas in LP tank.
Sudden drop in gas
flow or low flame.
• Out of gas.
• Excess flow valve tripped.
• Turn off knobs, wait 30 seconds and light grill. If flames are still low,
turn off knobs and LP tank valve. Disconnect regulator. Reconnect
regulator and leak-test. Turn on LP tank valve, wait 30 seconds and
then light grill.
• Vapor lock at coupling nut/LP tank
connection.
• Turn off knobs and LP tank valve. Disconnect coupling nut from
tank. Reconnect and retry.
Flames blow out.
• High or gusting winds.
• Low on LP gas.
• Turn front of grill to face wind or increase flame height.
• Refill LP tank.
• Excess flow valve tripped.
• Refer to “Sudden drop in gas flow” above.
Flare-up.
• Grease buildup.
• Clean burners and inside of grill/firebox.
• Trim fat from meat before grilling.
• Excessive fat in meat.
• 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 tank. 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 manual.
Unable to fill LP tank.
• 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.
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Please register your grill online at:
Sirvase registrar su parrilla en línea, en:
WWW.GRILLREGISTRATION.COM
(If you register online, you do not need to send in this registration card./Si la registra en línea, no es necesario que envíe esta tarjeta de registro.)
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