Kenmore 259162504 Owner’s Manual

Assembly and Operation

Liquid Propane Gas Grill

®

NOTOOL

ASSEMBLY

THIS GRILL IS FOR OUTDOOR

instructions could result

USE ONLY

CAUTION Read and follow all Safety Statements

,, IAssembly instructions, and Use

A I and Care Manual Directions before

,_ attempting to assemble and cook.

CAUTION Some parts may contain sharp edges, 1

I ,_ wear protective gloves if necessary. I

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

W_G Failure to follow all manufacturer's

Customer Service
Toll Free 1-800-396-3838

To Installer/Assembler: Leave these

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

reference.

in serious personal injury andlor
property damage.

SP5319-37

Warranty.........................................................1

Safety..............................................................1

Caringforyourequipment...........................2-4

Hardware........................................................5

Assembly...................................................6-17

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. Ifthis grill is defective in
material or workmanship within one year from the date of

purchase, contact Sears at 1-SO0-4-MY-HOME®.

Operation.................................................18-20

CleaningandMaintenance......................21-22

Parts..............................................................23

Explodedview...............................................24

Troubleshooting.............................................25

Notes.............................................................26

Product Record

IMPORTANT: Fill out the product record

information below.

Model Number

UPC (on carton) Label Lot # GG

Serial Number

Date Purchased

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

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

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

All warranty coverage excludes ignitor batteries and any grill part
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 normal use, accident or improper

maintenance.

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.

Seam, Roebuck and Co., Dept. 817WA, Hofi'man Estates, IL 60179

Combustion byproducts produced when
using this product contain chemicals
known to the State of California to cause

cancer, birth defects, or other reproductive

harm.

lWARNINGIF YOU SMELL GAS:

1. appliance.Shut offgas supply tothe

2. Extinguish any open flame.

3. Open lid.

4. Ifodor continues, immediately

call your gas supplier or your

fire department.

© Sears, Roebuck and Co. 1

• 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

the vicinity of this or any other
appliance.

:iicommercia,F°rresidentiaicooki, o.useon,y.Donotuse

N

"_"'"_Ni:G,i _N CARBON MONOXIDE HAZARD

I_ _,_:::,_',;_Combustion byproducts include carbon

monox de wh ch has no odor and can

[_ J_{ • 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 ®.

:WARN NG Failure to ensure correct venturi tube

Iassembly may result in a hazardous fire I

1, ii: _, I°r explosion causing serious bodily injury
Iii_;l 1 and/°r 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

combustivle materials:

GETTING FAMILIAR WITH YOUR GRILL

Do not use your grill until you

have read and understood all the

information in this manual. It 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 propedy assembled with the ventud tubes
seated over the valve outlets (Figure 1 below) and there

are no blockages present in the venturi tubes
(see 'Cleaning Ventud 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 ventud tubes are
parallel to the bottom of the base casting of your appliance.

CASTING

3/8_ VENTURI

'

'VALVE OUTLETS

• 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

venfilation 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 al!ow 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 end/or

boats

24"

(6 crn)l_ I

18"

,

MODEL MAYNOT BE EXACTLYAS SHOWN.

ELECTRICAL CAUTION

• If any accessory installed on this grill requires an external
electrical power source, it must be electrically grounded in

accordance with local taws or in the absence of iocal laws,
with the Canadian Electdca_ 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 propedy
grounded three-prong receptacle, Do not cut or remova 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
mechanisms to provide worry free
grilling year round:

Q.C.C.1 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.P.D. 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

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)

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 L.P. gas cylinders:
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.)

FILLING STOPS AT 80%

NEW OPD

HANDWHEEL

--xternalthreads

on Coupling Valve.

q

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 I
exactly, a fire causing death or serious injury

may occur.

I

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 _arge 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)

or

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.

3

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 LPTANKVALVE

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 _ETAINER
area. CAP -- STRAP

• DO NOT store near any
gas burning apparatus or

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 L.P. 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.

WAR_N:!N If the above instructions are not followed

!exact,yafirecausingdeathorsedousin)ury

may occur.

HOSE & REGULATOR

PROPANE GAS MODELS:

Your grill is designed to operate

on L.P. (propane) gas at a
pressure regulated at 11" water
column(2.74 kPa). A regulator Q.C.C
preset to this pressure is supplied

with the grill and MUST be used. REGULATOR

This regulator is equipped with
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).

_EGULATOR

STRAIGHT

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

be sure the cylinder valve and the appliance valves are OFR The
cylinder valve is turned off by rotating the handwheet (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

contact us at 1-800-396-3838)

The cause of the excessive heat should be determined and

corrected before operating your grill again, The regulator probe

also contains a flow-sensing element, which will limitthe 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 29 or

contact us 1-800-396-3838.

NOTE: IMPROPER LIGHTING PROCEDURES CAN
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.

Master Bagpack

1/4" - 20 X 2" Carriage Bolt

(2 pieces)

1/4" - 20 X 2" Phillips

(4 pieces)

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

(16 pieces)

Hinge Clip

(Lid)

(1 piece)

Upper Tank Bracket

(Tank)

(1 piece)

1/4"-20 Large Body Wing Nut

(2 pieces)

©

3/8"-t6 Knurl Nut

(logo, Heat Indicator)

(2 pieces)

#10-24 Wing Nut

1/4"-20 Tapered Wingnut

(22 pieces)

#10-24 Knurl Screw

(Console)

(2 pieces)

Handle

(Handle)

(2 pieces)

5

o

No lank

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.

2. Turn leg assembly over and tap on a hard su,'face
until the caster plugs are fully seated.

Right hand leg assembly

-4!

Tank

Bracket

Caster Plug

Leg Assembly
(Left Hand shown)

%. ),v"

"q._/•

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

J

Console mounting
tabs are on front

side of leg

assemblies.

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

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 3/4" carriage bolt and tapered wing nut.

Console mounting tab facing up.

Bottom SL

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 3/4" carriage bolt and tapered wing nut.

1/4"-20 Tapered Wingnut

Console mounting tab facing up.

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

7. Attach console/valve assembly by positioning console over tabs and inserting two #10 knurl screws.
Locate Console on tabs as shown.

(Right side shown)

Mounting Hole

@

Locate battery in the electronic
ignitor bag pack,

¸

i

Install Battery and Ignitor
Button as shown.

#10-24 Knurl Screw