Kenmore 25916238 Owner’s Manual

Assembly and Operation

Liquid Propane Gas Grill

Model No. 16238

THIS GRILL IS FOR OUTDOOR

USE ONLY

CAUTION Read and follow all Safety Statements,

Assembly instructions, and Use

and Care Manual Directions before

attempting to assemble and cook.

I//

Failure to follow all manufacturer's instructions could result

in serious personal injury and/or property damage.

Customer Service

Toll Free 1-800-396-3838

To Installer/Assembler: Leave these

CAUTION

Some parts may contain sharp edges,

wear protective gloves if necessary.

Sears, Roebuck and Co., Hoffman Estates, IL 60179, U.S.A

instructions with consumer. To Consumer: Keep this manual for future

reference.

www.sears.com

SP5327A-37

Warranty ......................................................... 2

Safety. ............................................................. 2

Caring for your equipment .............................. 3

Hardware ........................................................ 6

Assembly. .................................................. 7-24

Operation ................................................. 25-26

Cleaning and Maintenance ...................... 27-28

One Year Full Warranty on Kenmore 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. If this grill is defective in material or workmanship within one year from the date of

purchase, contact Sears at 1-800-4-MY-HOME_.

Additional Warranty on Specific Grill Parts For the time periods listed below, Sears will replace the following

specific grill parts free of charge if they are defective in material of workmanship (Part replacement only, labor not included) :

Parts .............................................................. 29

Exploded view ............................................... 30

Troubleshooting ............................................. 31

Product Record

IMPORTANT: Fill out the product record information below.

Model Number

UPC (on carton) Label Lot # GG Serial Number

Date Purchased

Combustion byproducts produced when using this product contain chemicals

known to the State of California to cause cancer, birth defects, or other reproductive

harm.

Lifetime on Cast Aluminum Lids and Bottoms Five years from purchase date on Stainless Burners

All warranty coverage excludes ignitor batteries and any paint loss or rusting 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 abnormal use, accident or improper mainte-

nance.

All warranty coverage is void if this grill is used for commercial or rental purposes.

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

IF YOU SMELL GAS:

1. Shut off gas supply to the

appliance.

2. Extinguish any open flame.

3. Open lid.

4. If odor continues, immediately call your gas supplier or your fire

department.

• Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

• An LP cylinder not connected

for use shall not be stored in

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the vicinity of this or any other appliance.

For residential use only. Do not use forl commercial cooking,

CARBON MONOXIDE HAZARD

Combustion byproducts include carbon monoxide which has no odor and can

cause serious injury or death. Never use inside homes, vehicles or tents.

Call Grill Service Center For Help And Parts

If you have questions or need assistance during assembly, please call 1-800-396-3838. You will be speaking to a representative of the grill manufacturer and not a Sears employee. To order new parts call

Sears at 1-800-4-MY-HOME ®.

Failure to ensure correct venturi tube assembly may result in a hazardous fire or explosion causing serious bodily injury and/or property damage.

CARING FOR YOUR EQUIPMENT

INSTALLATION

THE INSTALLATION OF THIS APPLIANCE MUST

CONFORM WITH LOCAL CODES OR, IN THE

ABSENCE OF LOCAL CODES:

In Canada: must conform to CAN/CGA - B149.2 Propane Installation Code or CAN/CGA B149.1 Natural Gas

Installation. In the U.S.A.: must conform to National Fuel Gas Code

ANSI Z223.1.

When deciding where to place your appliance,

follow these minimum clearance distances to

adjacent combustible materials:

GETTING FAMILIAR WITH YOUR GRILL

understood all of the information in this manual. It

Oono u e our r,,,un ,, o h w eada d

is extremely important to be sure that:

• Your grill is properly assembled.

• There are no leaks in the gas supply system (see 'Leak Testing' section).

• The burner is properly assembled with the venturi tubes seated over the valve outlets (Figure 1 below) and there are no blockages present in the venturi tubes (see 'Cleaning Venturi Tubes' section).

• Electrical supply cords and/or gas supply hoses are kept away from any heated surfaces.

• Your grill is positioned in a safe location (see 'Installation' section).

Figure 1.

• Ensure valve outlets (orifices) are assembled 3/8" (1 cm) into the venturi tubes.

• Check to see that the valve outlets and venturi tubes are parallel to the bottom of the base casting of your appliance.

• 24 inches (61 cm) from side of unit (See Figure 2) 18 inches (46 cm) from back of unit (See Figure 2)

FOR YOUR OWN SAFETY:

• Only use your grill OUTDOORS in a well ventilated area

-- preferably 10 feet (3m) from your residence or any

outbuildings.

• Always keep the area around your grill clear of any combustible materials, gasoline, or other flammable liquids.

• DO NOT operate this grill under overhead or unprotected construction.

• DO NOT obstruct the flow of combustion and

ventilation air to the grill.

• DO NOT use in garages, sheds, breezeways, or

other enclosed areas.

• DO NOT store a spare L.E (propane) cylinder under or near your grill.

• DO NOT leave your grill unattended while in operation.

• DO NOT allow children to operate or play near your

grill. DO NOT use while under the influence of alcohol or drugs.

DO NOT install/use in or on recreational vehicles and/or boats

24"

I (61cm)

_'/ (46cml

MODEL MAYNOT BE EXACTLYAS SHOWN.

W CASTING

ELECTRICAL CAUTION

• If any accessory installed on this grill requires an external

electrical power source, it must be electrically grounded in accordance with local laws or in the absence of local laws,

with the Canadian Electrical Code CSA C22.1 or in the U.S., with the National Electrical Code ANSI-NFPA 70.

• The three-prong plug provides protection against shock

hazard and should be plugged directly into a properly grounded three-prong receptacle. Do not cut or remove the grounding prong from this plug.

• Ensure all electrical supply cords and fuel supply hoses are

kept well away from any heated surfaces.

L.P. GAS CYLINDER

Gas cylinders manufactured today have

NEW OPD

HANDWHEEL

mechanisms to provide worry free

grilling year round:

Q.C.C.I or Type 1-Quick Connect Coupling Valve, ensure fast tank

hook-ups requiring only hand

tightening. The redundant valve system inhibits the flow of gas to the burner if the

connection is not correct.

O.RD. or Overfill Protection

Device prevents accidental

gas leaks caused by cylinder

'over-pressurization', the leading cause of cylinder gas

leaks. The float in the tank

will automatically stop filling at 80% capacity, leaving a 20% area for the expansion of liquid. Without this safety feature, the relief valve may FILLING STOPS AT 80% open and discharge propane, creating a potential safety hazard. An O.P.D. cylinder is easily distinguished by its triangular hand wheel valve. (Figure 3)

_hreads

1. SPECIFICATIONS

Self-contained propane gas grill systems are designed to be used only with a 20 Ib (9.1 kg) propane cylinder, equipped with a Type 1 cylinder valve and incorporating an overfill protection device (O.P.D).THE CYLINDER SHOULD NOT EXCEED 18

1/2" (472 MM) IN HEIGHT AND 12 1/2" (317 MM) IN DIAMETER.

This grill cannot be connected to a #510 P.O.L type valve (ones with left-hand threads).

The cylinder for your gas grill must be constructed and marked in accordance with the specifications of LP. gas cylinders:

THE CYLINDER MUST ALSO BE EQUIPPED WITH:

a. A shut-off valve terminating in a proper cylinder valve outlet

specified in current standards:

• Canada: CAN/CGA - 1.6a - M98 - Outdoor Gas Grills - Amend. 1.

• U.S.: ANSI Z 21.58a-1998 OUTDOOR COOKING

APPLIANCES.

b. A listed overfilling protection device (O.P.D.). c. A safety relief valve having direct communication with the

vapor space of the cylinder.

d. A collar to protect the tank shut off valve. e. An arrangement for vapor withdrawal.

f. A bottom ring for mounting.

SAFETY:

• Always turn off the cylinder valve tightly when your grill is not in use.

• Handle tank valves with care.

• Never connect an unregulated L.P. gas cylinder to your grill.

• Never store a spare cylinder under or near your grill when in

use.

• Never subject any cylinder to excessive heat or direct

sunlight.

• Always keep your in-use cylinder securely fastened in an upright position.

• Do not insert any foreign objects into the valve outlet. You may damage the back-check. A damaged back-check can be the source of a leak. Leaking propane may result in

explosion, fire, severe personal injury or death.

• DO NOT fill the cylinder beyond 80% full.

If the above instructions are not followed exactly, a fire causing death or serious injury

may occur.

In Canada: The National Standards of Canada CAN/CSA-B339,

Cylinders, Spheres and Tubes for Transportation of Dangerous Goods; and Commission.

In the U.S.: U.S. Department of Transportation (D.O.T.)

DO NOT CONNECT TO A PROPANE GAS CYLINDER EXCEEDING THIS CAPACITY, OR USE A CYLINDER WITH

ANY OTHER TYPE OF VALVE CONNECTION DEVICE.

The Type 1 valve is recognizable by the large external thread on the outlet part of the valve. Non Type 1 valves do not have these exterior threads. Any attempt to connect a regulator, with

other than the:

i) Mating Type 1 connector (recognized by the large black

coupling nut)

ii) Standard #510 P.O.L. fitting, by use of adapters or any other

means.

Could result in damage, fire or injury and may negate the important safety features designed into the Type 1 system. The connection of a #510 P.O.L fitting will not provide the flow control or temperature shut-off features built into the complete

Type 1 System.

2. TRANSPORTATION AND STORAGE:

WARNING: Although it is safe when used properly, careless

handling of the propane gas cylinder could result in fire, explosion, and/or serious injury.

PROPANE GAS IS HEAVIER THAN AIR, AND WILL COLLECT IN LOW AREAS, INCREASING THE ABOVE RISKS THEREFORE:

• ALWAYS use the cylinder cap provided with your cylinder whenever the cylinder is not connected to your grill. (Figure 4)

• DO NOT store in a building, garage or any

other enclosed area. Store in a well-ventilated CYLINDER

area. CAP _ STRAP

• DO NOT store near any gas burning apparatus or

LP TANK VALVE

in any

high-heat areas such as a closed car or trunk.

• Transport and store the cylinder in an upright position -- do not tip on its side.

• Store out of reach of children.

• DO NOT smoke while transporting a cylinder in your vehicle.

FILLING: FOR SAFETY REASONS, IF AN OPTIONAL L.P. GAS

CYLINDER WAS SUPPLIED WITH YOUR GRILL, IT HAS BEEN SHIPPED EMPTY. THE CYLINDER MUST BE PURGED

OF AIR AND FILLED PRIOR TO USING ON YOUR GRILL. WHEN GETTING YOUR CYLINDER FILLED:

• Allow only a qualified UP. gas dealer to fill or repair your cylinder.

• DO NOT allow the cylinder to be filled beyond 80% full.

• Make sure the L.P. gas dealer checks the cylinder for leaks after filling.

If the above instructions are not followed

exactly, a fire causing death or serious injury

may occur.

HOSE & REGULATOR

PROPANE GAS MODELS:

Your grill is designed to operate on L.R (propane) gas at a pressure regulated at 11" water

column(2.74 kPa). A regulator preset to this pressure is supplied with the grill and MUST be used. REGULATOR

This regulator is equipped with Q.C.C.I the Q.C.C. Type 1, quick connect

coupling system, which incorporates the following safety features: (Figure 5)

• It will not allow gas to flow until a positive seal has been made. (Figure 6)

• It has a thermal element that will shut off the flow of gas between 240 and 300°F (115 and150°C).

• It also has a flow-limiting device which,when activated, will restrict the flow of gas to 10 cubic feet per hour (0.28 cubic

meters per hour).

Q.C.C.

REGULATOR

Prior to attaching the propane cylinder to the hose and regulator,

be sure the cylinder valve and the appliance valves are OFF. The cylinder valve is turned off by rotating the handwheel (see Figure 3)

clockwise (left to right) until it stops and all appliance valves should be in the off position. When attaching the regulator to the cylinder, make sure that the small probe in the nipple is centered in the

mating Q.C.C. 1 cylinder valve (see Figure 6). Turn the right hand threaded Q.C.C.1 black nut onto the valve in a clockwise motion

until there is a positive stop. DO NOT USE A WRENCH, HAND TIGHTEN ONLY.

Should the large black thermally sensitive coupling nut be exposed to temperatures above 240 and 300°F, it will soften

and allow the regulator probe to disengage from the cylinder valve -- thereby shutting off the flow of gas. Should this occur, do not attempt to reconnect the nut. Remove the entire regulator assembly, and replace it with a new one. (See 'REPLACEMENT PARTS' section in assembly instructions or

corrected before operating your grill again. The regulator probe also contains a flow-sensing element, which will limit the flow of

gas to the regulator to a manageable amount (10 cubic feet per hour) in the event of a hose or regulator rupture. If it is evident that the flow control device has been activated, the cause of the excessive flow should be determined and corrected before using

your grill again.

Please refer to the troubleshooting guide on page 34 or

CAUSE THE FLOW CONTROL TO ACTIVATE, RESULTING

IN REDUCED HEAT OUTPUT. IF THIS IS SUSPECTED, RESET THE FLOW CONTROL BY SHUTTING OFF ALL

BURNER CONTROLS AND THE CYLINDER VALVE. WAIT

30 SECONDS, THEN TURN THE CYLINDER VALVE ON

EXTREMELY SLOWLY - WAIT 5 SECONDS AND TURN THE BURNER VALVE ON AND LIGHTAS NORMAL.

• Never connect a propane gas grill to an unregulated propane gas supply or any other gas. Do not attempt to

alter the hose or regulator in any way.

• The connection fitting must be protected when disconnected from the propane tank. If the fitting is allowed to drag on

the ground, nicks and scratches could occur resulting in a leak when connected to the propane tank.

PROPANE AND NATURAL GAS MODELS:

• Do not allow any grease (or other hot material) to fall onto

the hose, or allow the hose to come in contact with any hot surfaces of the grill.

• Visually inspect the entire length of the hose assembly

before each use of the grill. If it is evident there is excessive abrasion/wear, or the hose is cut, it must be replaced prior to using your grill. Only the hose assembly as specified in the Parts List should be used.

• Follow the 'LEAK TEST' instructions before lighting your

grill for the first time, every time a propane cylinder is refilled, if any gas component is changed, if the regulator flow-limiting device has been activated, after prolonged periods of storage or non-use or at least once per season.

:r_._illivc#_._ii

Master Bagpack

#8-32 x 3/8 Tapping Screw

(2 pieces)

i i i i i

i i

1/4" - 20 X 2" Carriage Bolt

(8 pieces)

#10x 1F2Phillips Screw

(24 pieces)

1/4" - 20 X 1/2" Carriage Bolt

(2 pieces )(Black)

1/4"-20 Large Body Tapered Wing Nut

(2 pieces)

Shoulder Screw

(2 pieces)

1/4"-20 Wingnut

(10 pieces)

(2 Black)

#2 Phillips Screwdriver

(! piece)

#6-32 Wing Nut

[

Upper Tank Bracket

(Overlay)

(2 pieces)

(Tank)

(! piece)

#10-24 Wing Nut Push Pin Hinge Clip

(Sideburner) (Side Panel) (Lid)

(1 piece)

#10-24 Wing Nut

(Handle)

(2 pieces)

(2 pieces) (1 piece)

Handle

1/4-3/4 Washer

(2 pieces)

Cross Lighter/Burner Bagpack

#10-24 Wing Nut

(Cross Lighter)

(3 pieces)

Tube Spacer

(Cross Lighter)

(3 pieces)

1/4" - 20 X 3/4" Carriage Bolt

(Cross Lighter)

(3 pieces)

1/4"-20 Knurl Nut

(Burners) (3 pieces)

I'l

NoTank Bracket

Left hand leg assembly

1. Turn leg assembly upside down as

shown and insert caster plug.

Make sure caster plug tab is in line with notch in leg. (SEE FIG "A")

2. Turn leg assembly over and tap on a hard surface until the caster plugs are fully seated.

Right hand leg assembly

Tank

Bracket

Notch

Caster Plug

FIG. "A"

Insert caster into holes on outside corner of caster plug as shown.

Leg Assembly (Left Hand shown)

Locking Caster

3. Insert locking casters into the caster plugs on front of leg

assemblies and press in until caster is fully seated as shown.

Non-Locking Caster

tabs are on front side of leg

Console mounting

assemblies.

4. Insert non-locking casters into the caster plugs on rear of leg assembiles.

5. Position left hand leg assembly as shown with console mounting tab facing up.

Place non-tank side of bottom pan over bottom support. Attach bottom pan with

1/4"-20 x 1/2" carriage bolt (Black) and wing nut (Black).

Console mounting tab facing up.

Bottom Su

Bottom Pan

Tank opening on right side.

6. Position right hand leg assembly as shown, with console mounting tab facing up. Place tank side of bottom pan over bottom support. Attach bottom pan with

1/4-20 x 1/2" carriage bolt and wing nut.

1/4"-20 Wingnut

Console mounting tab facing up.

1/4" - 20 X 1/2" Carriage Bolt

7. Position side panels over legs and slide up into position. Bottom flange of side panel hooks over bottom support.

Push against leg assembly

Then slide up into position

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no matter who made it, no matter who sold it!

For the replacement parts, accessories and

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Call anytime, day or night (U.S.A. and Canada)

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Our Home

For repair of carry-in items like vacuums, lawn equipment,

and electronics, call or go on-line for the location of your nearest

Sears Parts & Repair Center.

1-800-488-1 222

Call anytime, day or night (U.S.A. only)

www.sears.com

To purchase a protection agreement (U.S.A.)

or maintenance agreement (Canada) on a product serviced by Sears:

1-800-827-6655 (U.S.A.) 1-800-361-6665 (Canada)

Para pedir servicio de reparaci6n

a domicilio, y para ordenar piezas:

1-888-SU-HOGAR sM

(1-888-784-6427)

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MC MD

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Au Canada pour service en fran_ais:

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(1-800-533-6937)

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