Kenmore D02 M90221 Use And Care Manual

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Page 1

Use & Care Guide

Model: D02 M90221

Kenmore

®/MD

Natural Gas Grill

P/N G651-001-160801 Sears Canada Inc. Toronto, ON., M5B 2C3 www.sears.ca

/MC

™

Model 466225712 • Dec-21-11

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DANGER

WARNING

If you smell gas:

1. Shut off gas to the appliance.

2. Extinguish any open flame.

3. Open lid.

4. If odor continues, keep away from the appliance and immediately call your gas supplier or your fire department.

WARNING

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

2. An LP Tank not connected for use shall not be stored in the vicinity of this or any other appliance.

Call the Grill Information Center for Help and Parts

Missing Parts? Assembly Questions? Before returning grill to store, call 1-800-241-7548

Product Record

IMPORTANT: Fill out the product record information below.

Model Number

Serial Number

See rating label on grill for serial number.

Operation Problems?

CALIFORNIA PROPOSITION 65

1. Combustion by-products produced when using this product contain chemicals known to the State of California to cause cancer, birth defects, and other reproductive harm.

2. This product contains chemicals, including lead and lead compounds, known to the State of California to cause cancer, birth defects or other reproductive harm.

Wash your hands after handling this product.

Installation Safety Precautions

• Use grill, as purchased, only with LP (propane) gas and the regulator/valve assembly supplied.

• Grill installation must conform with local codes, or in the absence of local codes, with either the National Fuel Gas Code, ANSI Z223.1/ NFPA 54, Natural Gas and Propane Installation Code, CSA B149.1, or Propane Storage and Handling Code, B149.2, or the Standard for Recreational Vehicles, ANSI A 119.2/NFPA 1192, and CSA Z240 RV Series, Recreational Vehicle Code, as applicable.

• All electrical accessories (such as a rotisserie) must be electrically grounded in accordance with local codes, or National Electrical Code, ANSI / NFPA 70 or Canadian Electrical Code, CSA C22.1. Keep any electrical cords and/or fuel supply hoses away from any hot surfaces.

• Grill is not for use in or on recreational vehicles and/or boats.

• This grill is safety certified for use in the United States and/or Canada only. Do not modify for use in any other location. Modification will result in a safety hazard.

Safety Symbols

The symbols and boxes shown below explain what each heading means. Read and follow all of the messages found throughout the manual.

Date Purchased

To Installer/Assembler: Leave these instructions with consumer.

To Consumer: Keep this manual for future reference.

CAUTION

Some parts may contain sharp edges, especially as noted in these instructions. Wear protective gloves if necessary.

CAUTION

For residential use only. Do not use for commercial cooking.

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DANGER

DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

WARNING: Be alert to the possibility of serious bodily injury if the instructions are not followed. Be sure to read and carefully follow all of the messages.

CAUTION

CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

Printed in China

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Table of Contents

For Your Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Grill Information Center

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

WARRANTY

KENMORE GRILL WARRANTY

Product Record Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Safety Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Installation Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . 2-4

Kenmore Grill Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Grilling Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Use and Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Parts Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-26

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27-29

WARNING

• Read and follow all Safety, Assembly, and Use and Care Instructions in this Guide before assembling and cooking with this grill.

• Failure to follow all instructions in this Use and Care Guide may lead to fire or explosion, which could result in property damage, personal injury or death.

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 1-800-241-

7548 to arrange for free repair parts (or replacement if repair

proves impossible).

One-Year Limited Warranty on Burners

For one year from the date of purchase, any burner that rusts through will be replaced free of charge.

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.

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 Canada.

Sears Canada Inc.

Toronto, ON., M5B 2C3

This Grill is for Outdoor Use Only

Tools needed for assembly:

Adjustable wrench (not provided) Screwdriver (not provided)

7/16" Combination wrench (not provided)

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WARNING

CAUTION

Do not attempt to repair or alter the hose/qucik disconnect for any “assumed” defect. Any modification to this assembly will void your warranty and create the risk of a gas leak and fire. Use only authorized replacement parts supplied by manufacturer.

NOTE: DO NOT over tighten screws and washers that

come into contact with porcelain coated surfaces. Over tightening may cause the porcelain coating to crack and break, resulting in exposed metal that will be prone to rust.

Natural Gas Connections and Service Regulators Above 1/2 psi.

Prior to 1998, all residual gas service regulators were set with an outlet pressure of 7 inches water column.

In the 1998 edition of NFPA 54, the National Fuel Gas Code, a change was made allowing service regulators of 2 and 5 psi.

With this change it was also required that an in line regulator be connected between the service regulator and the appliance regulator if the 2 or 5 psi system is used. This additional regulator is not supplied with the product.

It is possible for a consumer, making the connection themselves, or a plumber, not checking, to tap into a 2 or 5 psi line. If a pressure of 2 psi or greater is supplied to the appliance regulator on certain grills it will shut down and not deliver any gas to the grill. Other concerns are the quick disconnect socket and hose which are only rated to 1/2 psi.

If the quick disconnect socket, hose, and grill are properly connected and still not getting gas, delivery pressure needs to be verified. If pressure is greater than 1/2 psi, make sure that an in line regulator is present.

Once the grill has been over-pressured, the regulator may or may not have been damaged. The best practice is to replace the regulator.

Using pots larger than 6 quarts in capacity could exceed weight limit of the side burner shelf or side shelf, resulting in failure of grill cart components.

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GRILLING GUIDE – Getting Started

First Time Use

Read your Assembly Manual and ensure the grill is put together properly. Remove all Point-of-Purchase advertising material from all grill surfaces before first use. We recommend operating your grill on its highest setting for 1520 minutes prior to your first use. This aids in removing the oils used during manufacturing.

Lava Rock / Briquettes

This gas grill has been designed, engineered, and tested to be used with flame tamers or heat distribution plates to provide more even heating, improve the cleaning process, and reduce flare-ups. The addition of after market lava rocks, charcoal, or briquettes of any type will cause poor combustion and increase the likelihood of a grease fire, and is not recommended. Using briquettes, lava rock, or charcoal in this grill will void your warranty. For extra smoke flavor, we recommend using a smoker box with wood chips.

Temperature - Convective Grills ONLY.

The temperature gauge in the hood of your new grill measures air temperature. The air temperature inside your grill will never be as hot as the temperature at the cooking surface.

Pre-Heating Your Grill

Just like your home oven, your grill should be pre-heated to provide optimum performance. Pre-heat the grill on high for 10-15 minutes – longer if weather conditions require. Please refer to the lighting instructions inside the Product Guide if you have questions about how to light your grill. A matchlight chain and hole is provided for your convenience.

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GRILLING GUIDE – Grilling 101

Outdoor grilling is really quite simple. You'll succeed with burgers, dogs, or steaks usually on your very first try. With experience, you will learn how to work with your grill, creating more imaginative meals all the time. This knowledge makes up the art of grilling. Before you start grilling, organize your food according to cooking technique and required cooking time, and optimize the use of your grilling area.

Direct Cooking

Direct cooking involves grilling your meat directly over high heat. It is perfect for searing steaks, chops, and other smaller pieces of meat and vegetables that quickly make their way to the table.

Rotisserie Cooking

Rotisserie cooking is best for 'round' meat, such as large roasts, whole poultry, and pork. It generally requires an accessory motor and spit rod that allows the meat to be turned at a constant speed. Rotisserie cooking is best done in front of a special rotisserie burner, or utilizing an indirect cooking burner arrangement. A pan can be placed underneath the meat to catch grease and food drippings, and helps minimize clean-up.

Indirect Cooking

Indirect cooking utilizes select burners to circulate heat throughout the grill, without direct contact between the meat and the flame. The meat is placed over the burner that is 'off'. This method is generally used to slow cook large cuts of meat and poultry. A pan can be placed underneath the meat to catch grease and food drippings, and helps minimize clean-up.

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. Separate: Separate raw meats 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.

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GRILLING GUIDE – Tips & Tricks

Food Temperature

Beef, veal an d l amb (pieces and whole cuts) -

medium-rare 63°C (145°F) Beef, veal an d l amb (pieces and whole cuts) medium 71°C (160°F) Beef, veal an d l amb (pieces and whole cuts) well done 77°C (170°F

Po rk (pieces and whole cuts) 71°C (160°F) Po ultry (e.g. chicken, turkey, duck) - pieces 74°C (165°F) Po ultry - whole 85°C (185°F)

Ground meat and meat mixture s (e.g.

burgers, sausages, meatballs, meatloaf, casseroles)- beef, veal, lamb and pork 71°C (160°F)

Ground meat and meat mixture s - poultry 74°C (165°F) Egg dishe s 74°C (165°F) Othe rs (hot dogs, stuffing and leftovers) 74°C (165°F)

Cooking on your new grill is a hands-on experience, and it is recommended to remain outside with your grill while cooking. Grilling can be affected by many external conditions. In cold weather, you will need more heat to reach an ideal cooking temperature, and grilling may take longer. The meat's internal temperature and thickness can also affect cooking times. Cold and thicker meats will take longer to cook.

Internal Meat Temperatures

Meat cooked on a grill often browns very fast on the outside. Therefore, use a meat thermometer to ensure it has reached safe internal temperatures.

Canadian Food Inspection Agency

Recommended Internal cooking tempeaures

Wood Chips

For extra smoke flavor when grilling, try adding wood chips. Soak the chips in water for approximately 30 minutes before adding to a smoke box or pan. Place smoke box or pan on top of the cooking grate above the flame. Turn grill on high until the wood starts to smoke. Reduce heat to desired temperature for cooking, and place food on cooking grate as desired. Close lid to retain more smoke. Hardwood varieties that work particularly well with grilled foods include Alder, Apple, Cherry, Grapevines, Hickory, Mesquite, Oak, Rosemary and Sassafras.

Skewers

Metal skewers should be flat, with long handles. Round skewers allow food to roll when turned, so it may not cook as evenly. Use metal skewers when cooking meat kabobs. Wooden skewers should be soaked in water for an hour before use, and are best used for quick cooking foods such as vegetables and fruits.

Sauces

Sauces containing sugars and fats can cause flare-ups, and your food may burn. In general, apply these sauces during the final 10 minutes of cooking. Keep in mind, use of excessive sauces or glazes will also require extra cleaning afterwards.

Marinades and Rubs

To enhance the flavor of grilled foods, a liquid marinade or dry rub can be used prior to cooking. Meat can be either soaked or injected with liquid marinade up to 24 hours prior to grilling. Dry rubs can be applied directly to the meat immediately before grilling.

Utensils

Use tongs or a spatula to handle the food instead of a fork, and don't turn the food too often. Piercing the food with a fork will release juices that you want in the meat, and may cause flare-ups.

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GRILLING GUIDE – Cleaning Your Grill

Why Clean?

We've all heard the saying, “an ounce of prevention is worth a pound of cure.” This is great advice when it comes to keeping your grill clean.

Routine Care

Periodic cleaning of this grill is necessary, as grill fires can occur when grease and food debris collect in the bottom of the grill. After each use, remove any remaining food particles from the cooking grate and inside of the grill using a grill brush. Do this after the grill has cooled down, yet is still warm. It is much easier to clean food particles while warmth is still present, than after the food particles have completely cooled and hardened. This grill is not designed to be 'burned off' by closing the lid and turning the burners on High for an extended time. The excessive heat generated can cause leftover grease to catch fire, and can cause permanent damage to your grill.

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.

Storing Your Grill

• Clean cooking grates.

• Store grill 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 manufacturer.

• Store grill indoors ONLY if LP cylinder is turned off, disconnected, and removed from grill. Never store LP cylinder indoors.

• When removing grill from storage, follow the 'Cleaning the Burner Assembly' instructions in the Use and Care section of the Product Guide.

General Cleaning

Plastic parts: Wash with warm soapy water and wipe dry. Do not use abrasive cleaners, degreasers or a concentrated grill cleaner on plastic parts. Damage to and failure of parts can result.

Porcelain surfaces: Because of glass-like composition, most residue can be wiped away with baking soda/water solution or glass cleaner. Use non-abrasive scouring powder for stubborn stains.

Painted surfaces: Wash with mild detergent or non-abrasive cleaner and warm water. Wipe dry with a soft nonabrasive cloth.

Stainless steel surfaces: Stainless steel can rust under certain conditions. This can be caused by environmental conditions such as chlorine or salt water, or improper cleaning tools such as wire or steel wool. It can also discolor due to heat, chemicals, or grease build-up. To maintain your grill's high quality appearance, wash with mild detergent and warm water, or use a stainless steel grill cleaner. 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.

Critters

Spiders like to make their homes in the venturi tubes of grills. These must be inspected and cleaned regularly to ensure there are no blockages. Refer to the Use and Care portion of this Product Guide for complete information.

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This unit should be hard plumbed using components that meet National Fuel Gas Code.

WARNING

Do not use flexible gas hose supplied for Drop-in Models.

Connecting Your Grill to the Natural Gas Source.

1. A professionally-installed shut-off valve between the

supply piping and the socket is recommended, but not required, by the National Fuel Gas Code. Socket connection must be made outdoors.

2. Coat the gas supply pipe nipple with gas resistant pipe dope or approved teflon tape. Screw socket onto gas supply pipe (house gas source) as shown in

Figure A below, and wrench-tighten.

CAUTION

4.When the quick disconnect socket and the gas hose

are connected, a valve in the socket opens automatically to permit full gas flow. When the gas hose is disconnected, the valve in the socket instantly and positively shuts off the flow of gas. Because the valve in the socket positively shuts off the flow of gas, the grill can be disconnected from the gas source by disconnecting the gas hose from the quick disconnect socket. The socket should be left attached to the gas source (house piping). Figure C, below, shows properly connected hose and socket.

The quick disconnect socket should never be connected to the grill. Direction of gas flow is indicated on the socket.

Quick disconnect socket House piping

Figure A

3. Pull back the sleeve on the quick disconnect socket

and insert the unattached end of the gas hose into the socket. Release the sleeve and continue pushing the hose into the socket until the sleeve snaps into the locked position. See Figure B.

Figure C

With proper assembly, the gas hose cannot be removed without pushing the quick disconnect sleeve back. To disconnect, push sleeve back and pull plug

out of sleeve (this automatically shuts off gas).

Please Note: Hose and assembly are C.S.A. listed for natural gas, manufactured gas, mixed gas and for liquefied petroleum and for LP Gas-Air mixtures on basis of 0.64 specific gravity for 1000 BTU’s per cubic foot of gas at 0.3 in. water column pressure drop. Only ANSI Z21.54 approved hoses should be used with this grill.

The appliance and its individual shut off valve must be disconnected from the gas supply piping system during any pressure testing on that system at test pressures in excess of 1/2 psig (3.5kPa).

The appliance must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psi (3.5kPa).

Gas hose

Sleeve

Figure B

WARNING

Do not use hard metal piping of any kind to connect this type of grill to natural gas source. Use only hose specified by manufacturer. Using hard metal piping or convoluted metal tubing is an unsafe practice. Movement of the grill can cause breakage of metal pipe.

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USE AND CARE

Leak Testing

1. Turn all grill control knobs to OFF.

DANGER

• NEVER store a spare LP cylinder under or near the appliance or in an enclosed area.

• Never fill a cylinder beyond 80% full.

• An over filled 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/appliance and call your fire department.

2. Be sure gas hose is tightly connected to gas

source.

3. Completely open gas source. If you hear a rushing sound, turn gas off immediately. There is a major leak at the connection. Correct before proceeding.

4.Brush soapy solution onto area circled below.

NOTE: Sideburner shelf fascia not shown for clarity.

NOTE: Your grill may NOT be equipped with a sideburner.

WARNING

• Outdoor gas appliance is not intended to be installed in or on a boat.

• Outdoor gas appliance is not intended to be installed in or on an RV.

• 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.

• If a leak is detected at any time, STOP and call the fire department.

• If you cannot stop a gas leak, immediately close gas valve and call your fire department!

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5. If “growing” bubbles appear, there is a leak. Close gas source immediately and tighten connection. If leaks cannot be stopped do not

try to repair.

6.Always close gas source after performing leak

test.

Safety Tips

When grill is not in use, turn off all control

•

knobs and gas source.

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WARNING

For Safe Use of Your Grill and to Avoid Serious Injury:

• 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.

• Do not use charcoal or ceramic briquets in a gas grill.

• Do not cover grates with aluminum foil or any other material. This will block burner ventilation and create a potentially dangerous condition resulting in property damage and/or personal injury.

• 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.

Safety Tips

s When grill is not in use, turn off all control knobs

and LP cylinder valve.

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 sideburner and side shelf is 10

lbs.

s The grease tray or cup must be installed during

use and emptied after each use. Do not remove grease tray or cup 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 onto valve or gas hose, 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.

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 If you have a grill problem see the "Troubleshooting

Section".

• 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 cylinder out of correct position specified in assembly instructions.

• Always close LP cylinder valve and remove coupling nut before moving LP cylinder from specified operation position.

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. Follow instructions on General Grill Cleaning and Cleaning The Burner Assembly to prevent grease fires.

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Ignitor Lighting s Do not lean over grill while lighting.

1. Turn OFF gas burner control valves.

2. Turn ON gas at tank or source.

3. Open lid during lighting.

4. To ignite, push and turn IGNITION BURNER knob to HIGH.

5. Push and hold ELECTRONIC IGNITION button until

the burner lights.

6. If ignition does NOT occur in 5 seconds, turn the burner controls OFF, wait 5 minutes and repeat the lighting procedure.

7. To ignite remaining burners, turn knob to the HI position starting with the burners closest to IGNITION BURNER first. If ignitor does not work, follow match lighting instructions.

8. For grills equipped with ELECTRONIC IGNITION at each burner:

Repeat steps 4 through 6 to light each burner.

9. Once each burner has ignited, turn knobs to desired setting.

SEAR Burner Ignitor Lighting s Do not lean over grill while lighting.

1. Turn OFF gas burner control valves.

2. Turn ON gas at tank or source.

3. Open lid during lighting.

4. To ignite, push and turn SEAR burner knob to HGHI.

5. Push and hold ELECTRONIC IGNITION button until

the burner lights.

6. If ignition does NOT occur in 5 seconds, turn the burner controls OFF, wait 5 minutes and repeat the lighting procedure.

SEAR Burner Match-Lighting s Do not lean over grill while lighting.

1. Open lid. Turn ON gas at tank or source.

2. Place match into match holder (hanging from right

side panel of grill). Light match; then light burner by placing match through the match light hole on right side of grill.

3. Push in and turn SEAR burner knob to the HIGH position. Be sure burner lights and stays lit.

WARNING

Turn controls and gas source when not

in use.

CAUTION

If ignition does NOT occur in 5 seconds, turn the burner controls OFF, wait 5 minutes and repeat the lighting procedure. If the burner does not ignite with the valve open, gas will continue to flow out of the burner and could accidently ignite with risk of injury.

Match-Lighting s Do not lean over grill while lighting.

1. Open lid. Turn ON gas at tank or source.

2. Place match into match holder (hanging from left

side panel of grill). Light match; then light burner by placing match through the match light hole on left side of grill.

3. Push in and turn far left burner knob to the HIGH position. Be sure burner lights and stays lit.

4. Light adjacent burners in sequence by pushing knobs in and turning to the HIGH position.

NOTE: Your grill may NOT be equipped with a Sideburner! Sideburner Ignitor Lighting s Do not lean over grill while lighting.

1. Open sideburner lid. Turn ON gas at tank or source.

2. Turn sideburner knob to the HGHI position, push and hold ELECTRONIC IGNITOR button.

3. If sideburner does NOT light within 5 seconds, turn

knob to OFF, wait 5 minutes, then repeat lighting procedure.

Sideburner Match Lighting

1. Open sideburner lid. Turn ON gas at source.

2. Place lit match near burner.

3. Turn sideburner knob to the HIGH position. Be sure

burner lights and stays lit.

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Burner Flame Check

General Grill Cleaning

• Remove cooking grates and heat diffusers. Light burners, rotate knobs from HIGH to LOW. You should see a smaller flame in LOW position than seen on HIGH. 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.

LOW

Turning Grill Off

• Turn all knobs to the OFF position. Turn LP cylinder OFF by turning hand-wheel clockwise to a full stop

or turn of NG source.

Ignitor Check

• Turn gas off at LP cylinder or source. 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.

Valve Check

• Important: Make sure gas is off at LP cylinder or source 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 or kinked. Replace damaged hoses before using grill. Use only valve/hose/regulator specified by manufacturer.

• 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.

• Plastic parts: Wash with warm soapy water and wipe dry. Do not use citrisol, abrasive cleaners, degreasers or a concentrated grill cleaner on plastic parts. Damage to and failure of parts can result.

• Porcelain surfaces: Because of glass-like composition, most residue can be wiped away with baking soda/water solution or specially formulated cleaner. Use nonabrasive scouring powder for stubborn stains.

• Painted surfaces: Wash with mild detergent or nonabrasive cleaner and warm soapy water. Wipe dry with a soft nonabrasive cloth.

• 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.

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CAUTION

SPIDER ALERT!

Important: Always ensure that the venturi burner tubes are clean. A

venturi burner tube has a narrow area in which spiders tend to build nests.

4. Detach electrode from burner.

NOTE: Removal/Detachment method will depend on the burner configuration. See different configurations in illustrations below.

5. Carefully lift each burner up and away from valve

openings. We suggest three ways to clean the burner tubes. Use the one easiest for you.

(A) Bend a stiff wire (a light weight coat hanger

works well) into a small hook. Run the hook through each burner tube several times.

SPIDER AND WEBS

INSIDE BURNER TUBE

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.

CONTROL PANEL

VALVE

Spiders or small insects have been known to create “flashback” problems. The spiders spin webs, build nests and lay eggs in the grill’s venturi tube(s) obstructing the flow of gas to the burner. The backed-up gas can ignite in the burner tube behind the control panel. This is known as a flashback and it can damage your grill and even cause injury.

To prevent flashbacks and ensure good performance the burner and venturi tube assembly should be removed from the grill and cleaned before use whenever the grill has been idle for an extended period.

SPIDER WEBS

INSIDE VENTURI TUBE

BURNER

(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.

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.

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.

VERY IMPORTANT: Burner tubes must reengage

valve openings. See illustrations at right.

9. Attach electrode to burner.

10. Carefully replace burners.

11. Attach burners to brackets on firebox.

12. Reposition carryover

tubes and attach to burners. Replace heat

Correct

burner-to-valve

engagement

diffusers and cooking grates.

Remove screws

Firebox

Storing Your Grill

• Clean cooking grates.

• Store in dry location.

• Cover grill if stored outdoors. Choose from a variety of grill covers offered by manufacturers.

• When removing grill from storage, follow “Cleaning the Burner Assembly” instructions before starting grill.

Cleaning the Burner Assembly

Follow these instructions to clean and/or replace parts

of burner assembly or if you have trouble igniting grill.

1. Turn gas OFF at control knobs and LP cylinder.

2. Remove cooking grates and heat diffusers.

3. Remove carryover tubes and burners.

14 • 466225712

Firebox

Carryover tube

Firebox burner bracket

Carryover tube

Firebox burner bracket

Electrode

Pry off electrode with a flat blade screwdriver

Page 15

PARTS LIST

Key Qty Descr ipt ion Part #

1 1

BOTTOM SHELF G651-0036-W1

2 1 LEFT SIDE CART PANEL G651-2200-W1

3 1 RIGHT SIDE CART PANEL G651-2300-W1

4 2 MATCH HOLDER G401-0079-W1

5 1 LOWER BACK PANEL G651-7701-W1

6 2 MAGNET ASSEMBLY G439-0035-W1

7 1 FRONT DOOR BRACE G651-0600-W1

8 2 CASTER, LOCKING G350-0023-W1

9 2 CASTER, FIXED G350-0024-W1

10 4 CASTER SOCKET G408-0036-W1

11 1 WEIGHT BLOCK G651-0012-W1

12 1 TOP LID G651-4200-W1

13 1 LOGO PLATE F/ LID G528-0002-W2

14 1 TEMPERATURE GAUGE G430-0022-W1 15 1 BEZEL, F/ TEMPERATURE

GAUGE

G404-0034-W1

16 2 LID BUMPER, RECTANGLE G430-00B8-W1

17 2 LID BUMPER, ROUND G303-0038-W1

18 1 TOP LID HARDWARE G430-0024-W2

19 1 HANDLE, F/ LID G651-0008-W1

20 1 FIREBOX G651-0200-W2

21 5 MAIN BURNER-TUBE BURNER G651-4000-W1

22 1 MAIN BURNER-BAR BURNER G651-4100-W1

23 1 ELECTRODE, F/ TUBE BURNER G501-0010-W2

24 1 ELECTRODE, F/ BAR BURNER G651-5103-W1

25 4 CARRY OVER TUBE G501-0015-W1

26 1 CONTROL PANEL, MAIN G651-0035-W1

27 1 ELECTRONIC IGNITION

MODULE

G651-1300-W1

28 1 SHIELD, F/ ELECTRONIC

IGNITION MODULE

G308-0025-W1

29 1

HOSE VALVE REGULATOR ASSEMBLY

G651-A700-W1

30 7 BEZEL F/ CONTROL KNOB G430-0027-W2

31 7 CONTROL KNOB G432-0010-W1

32 1 RIGHT SIDE SHELF G432-3600-W1

33 1 FASCIA, F/ RIGHT SHELF G651-7501-W1

34 1 LEFT SIDE SHELF F/ SB G432-3900-W1

35 1 DRIP PAN, F/ SB G651-0038-W1

Key Qty Descr ipt ion Part #

36 1

SIDEBURNER LID G651-0037-W1

37 1 CONTROL PANEL, F/ SB

G651-A501-W1

38 1 SIDEBURNER G550-6300-W1

39 1 ELECTRODE, F/ SB G431-0034-W1 40 1 ELECTRODE WIRE, F/

SIDEBURNER

G602-0007-W1

41 1 SIDEBURNER VALVE CLIP G405-0019-W1

42 1 SIDEBURNER GRATE G430-0053-W1

43 1 LEFT DOOR G651-7801-W1

44 2 HANDLE, F/ DOOR G651-0006-W2

45 1 RIGHT DOOR G651-7901-W1

46 2 DOOR PIN, FIXED G401-0053-W1

47 2 DOOR PIN, SPRING G439-0036-W2

48 5 HEAT DIFFUSER G430-0005-W1

49 1 HEAT DIFFUSER, F/ BAR BURNER G651-0011-W1

50 4 COOKING GRATE G432-0002-W1

51 1 WARMING RACK G651-0017-W1

52 1 BUTTON, F/ IGNITION MODULE G409-0030-W1

53 1 GREASE TRAY G651-3900-W1

54 1 GREASE PAN G416-0015-W1

55 1 NATURAL GAS HOSE G501-0099-W1

NOT Pictured

… 1 CASTER PIN

G350-0026-W1

… 1 PRODUCT MANUAL, ENGLISH

G651-160801-W1

… 1 PRODUCT MANUAL, SPANISH

G651-160802-W1

… 1 HARDWARE PACK

G65116-B001-W1

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.

To order replacement par ts after using grill, call 1-800-241-7548.

466225712 • 15

Page 16

PARTS DIAGRAM

16 • 466225712

Page 17

ASSEMBLY

• Attach bottom shelf to left and right leg assemblies with 1/4-20x2-3/8” machine screws and 1/4-20 flange nuts. The

cut out hole for the LP cylinder should be on the left side.

For Front Door

Brace Assembly

Left Side Panel

Front

Rear

Bottom Shelf

Right Side Panel

1/4-20x2-3/8" Machine Screw

Qty: 6

1/4-20

Flange Nut

Qty: 6

• Place lower back panel between side panels as shown. Attach to left and right side panels with (4) #8x3/8” sheet metal

screws. Then attach to bottom shelf with (2) #8x3/8” sheet metal screws.

#8x3/8"

Sheet Metal Screws

Qty. 6

Left Side Panel

Right Side Panel

Lower Back Panel

Bottom Shelf

Magnet Assembly

466225712 • 17

Page 18

• Attach to left and right leg assemblies with

Place front door brace as shown. 1/4-20x2-3/8" machine screws and 1/4-20 flange nuts.

1/4-20

Flange Nut

Qty: 4

1/4-20x2-3/8" Machine Screw

Qty: 4

18 • 466225712

Front Door Brace

Page 19

•

Turn assembly upside down.

• Insert Caster Pin into the caster mounting plate to lock it in place, shown A. Spin the caster clockwise into the threads on

the bottom shelf until secure. Remove the Caster Pin and repeat for remaining casters. Make sure the two locking casters are secured at the rear and the non-locking casters are secured at the front (B). After all 4 casters are secure remove the Caster Pin and save for future maintenance.

• Stand cart upright.

• Attach weight block to bottom shelf with (2) 1/4-20x2” machine screws and 1/4-20 flange nuts (C).

Caster Pin

Fixed Caster

Locking Caster

Rear

Locking Caster

1/4-20x2"

Machine Screw

Qty: 2

1/4-20

Flange Nut

Qty: 2

466225712 • 19

Page 20

• T

his 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 with

1/4-20x1/2” screws.

Grill Head

20 • 466225712

1/4-20x1/2" Screw

Qty: 4

Page 21

• H 7mm fiber washer

ook side wall of shelf over support brackets on side of firebox. At back of firebox, insert (1)

and (1) 1/4-20x1/2” screw as shown(A).

• Inside firebox, insert (3) 7mm fiber washers and (3) 1/4-20x1/2” screws as shown (B).

• Attach shelf with (4) 1/4-20 flange nuts on each side (C).

1/4-20x1/2"

Screw

Qty. 4

1/4-20x1/2"

Screw

1/4-20

Flange Nut

Qty: 4

7mm

Fiber Washer

Qty. 4

Fiber Washer

7mm

Right Side Shelf

Support Bracket

7mm

Fiber Washer

1/4-20x1/2"

Screw

Back of Firebox

• Attach fascia to firebox with #8x3/8” sheet metal screws.

#8x3/8"

Sheet Metal Screws

1/4-20

Flange Nut

Fascia,

Right Side Shelf

Qty. 3

466225712 • 21

Page 22

• Hook side wall of side burner shelf over support brackets on side of firebox.

washer and (1) 1/4-20x1/2” screw as shown (A).

At back of firebox, insert (1) 7mm fiber

• Inside firebox, insert (3) 7mm fiber washers and (3) 1/4-20x1/2” screws as shown (B).

• Attach side burner shelf with (4) 1/4-20 flange nuts on each side (C).

1/4-20x1/2"

Screw

7mm Fiber

Washer

Back of Firebox

1/4-20x1/2"

Machine Screw

Qty. 4

Support Bracket

1/4-20

Flange Nut

Qty: 4

Left Side Shelf

7mm

Fiber Washer

1/4-20x1/2"

Screw

7mm

Fiber Washer

Qty. 4

• Attach fascia to firebox with #8x3/8” sheet metal screws.

sheet metal screws

1/4-20

Flange Nut

#8x3/8"

Qty. 3

22 • 466225712

Page 23

• Attach side burner bezel and valve with #8x3/8” SS screws. (A).

• Place side burner into shelf. Make sure valve is inside side burner tube. Attach side burner with #8 wing nut (B). Hook

venturi clip to side burner tube and around manifold. Attach side burner ignitor wire to ignitor as shown (C).

• Press side burner control knob onto valve stem (D).

• Place grate onto side burner shelf (E).

Side Burner

Side Burner Tube

Sideburner Bezel

Sideburner Valve

Sideburner Ignitor Wire

Burner Tube

#8 wing nut

Sideburner Control Knob

Valve

#8X3/8” SS Screw

Qty. 2

#8 Wing Nut

Qty. 1

Venturi Clip

Sideburner Grate

466225712 • 23

Page 24

• Attach handle to door with #10-24x1/2” machine screws, 5mm flat washers and 5mm lock washers (A).

• Insert hinge pin on bottom shelf into hole in door. Press upper hinge pin in front door brace, align hinge hole on top of

door, and release hinge pin into door.

Left Handle

Left Door

Hinge Pin hole

5mm Lock Washer

5mm Flat Washer

Hinge Pin hole

#10-24x1/2"

Machine Screw

Qty: 4

Right Handle

5mm Flat Washer

Qty: 4

Right Door

5mm Lock Washer

Qty: 4

24 • 466225712

Page 25

• Place heat tents over tube burners and the heat tent for sear burner over sear burner by inserting tabs into slots in front

of firebox. Opposite ends of heat tents rest on pins in back of firebox.

Pivot Wire

(side to side)

Heat Tent, F/Sear Burner (Stainless Steel)

Heat Tent (Black)

Sear Burner

Back of Firebox

Front of Firebo

Heat Tent

• Place cooking grates onto grate rests.

• Insert ends of Warming Rack pivot wire into holes in sides of gril lid. Insert ends of Warming Rack 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, Warming Rack is installed upside-down.

• Unscrew ignitor cap and place AA battery into ignitor slot with positive end (+) facing outward. Screw ignitor cap onto

ignitor.

Warming Rack Wires

(front-to-back)

Leg Wire

(side to side)

Pivot Wire

–

AA Battery

Warming Rack

Leg Wire

Cooking Grate

466225712 • 25

Page 26

Grease Tray

• Place grease pan into grease tray, then place the tray into the cart .

CAUTION

Grease Pan

Failure to install grease tray and grease pan will cause hot grease to drip from bottom of grill with risk of fire or property damage.

• Attach natural gas hose as shown.

26 • 466225712

Natural Gas Hose

Page 27

EMERGENCIES: If a gas leak cannot be stopped, or a fire occurs due to gas leakage, call the fire department.

Emergencies

Gas leaking from cracked/cut/burned hose.

Gas leaking from LP cylinder.

Gas leaking from LP cylinder valve.

Gas leaking between LP cylinder and regulator connection.

Fire coming through control panel.

Grease fire or continuous excessive flames above cooking surface.

Troubleshooting

Problem

Burner(s) will not light using ignitor. (See Electronic Ignition Troubleshooting also)

Continued on next page.

Possible Cause

• Damaged hose.

• Mechanical failure due to rusting or mishandling.

• Failure of cylinder valve from mishandling or mechanical failure.

• Improper installation, connection not tight, failure of rubber seal.

• Fire in burner tube section of burner due to blockage.

• Too much grease buildup in burner area.

Possible Cause

GAS ISSUES:

• Trying to light wrong burner.

• Burner not engaged with control valve.

• Obstruction in burner.

• No gas flow.

Prevention/Solution

• 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.

• Replace LP cylinder.

• Turn off LP cylinder valve. Return LP cylinder to gas supplier.

• 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.

• 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. Alert and Cleaning the Burner Assembly sections of this Use & Care Guide.

• Turn off control knobs and LP cylinder valve. Leave lid open to allow flames to die down. After cooling, clean food particles and excess grease from inside firebox area, grease tray, and other surfaces.

Prevention/Solution

• See instructions on control panel and in Use and Care section.

• Make sure valves are positioned inside of burner tubes.

• Ensure burner tubes are not obstructed with spider webs or other matter. See cleaning section of Use and Care.

• Make sure LP cylinder is not empty. If LP cylinder is not empty, refer to “Sudden drop in gas flow.”

See Spider

• Vapor lock at coupling nut to LP cylinder.

• Coupling nut and LP cylinder valve not fully connected.

ELECTRICAL ISSUES:

• Electrode cracked or broken; “sparks at crack.”

• Electrode tip not in proper position.

• Wire and/or electrode covered with cooking residue.

• Wires are loose or disconnected.

• Wires are shorting (sparking) between ignitor and electrode.

• Dead battery.

• Turn off knobs and disconnect coupling nut from LP cylinder. Reconnect and retry.

• Turn the coupling nut approximately one-half to three-quarters additional turn until solid stop. Tighten by hand only - do not use tools.

• Replace electrode(s).

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.

Side burner:

• Tip of electrode should be pointing toward gas port opening on burner. the distance should be 1/8” to 3/16”. Adjust if necessary.

• Clean wire and/or electrode with rubbing alcohol and clean swab.

• Reconnect wires or replace electrode/wire assembly.

• Replace ignitor wire/electrode assembly.

• Replace with a new AA-size alkaline battery.

466225712 • 27

Page 28

Troubleshooting (continued)

Problem

Burner(s) will not light using ignitor. (See Electronic Ignition Troubleshooting also)

Burner(s) will not match light.

Sudden drop in gas flow or low flame.

Flames blow out.

Possible Cause

ELECTRONIC IGNITION:

• No spark, no ignition noise.

• No spark, some ignition noise.

• Sparks, but not at electrode or at full strength.

• See “GAS ISSUES:” on previous page.

• Match will not reach.

• Improper method of match-lighting.

• Out of gas.

• Excess flow valve tripped.

• Vapor lock at coupling nut/LP cylinder connection.

• High or gusting winds.

• Low on LP gas.

Prevention/Solution

• See Section I of Electronic Ignition System.

• See Section II of Electronic Ignition System.

• See Section III of Electronic Ignition System.

• Use long-stem match (fireplace match).

• See “Match-Lighting” section of Use and Care.

• Check for gas in LP cylinder.

• 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.

• Turn off knobs and LP cylinder valve. Disconnect coupling nut from cylinder. Reconnect and retry.

• Turn front of grill to face wind or increase flame height.

• Refill LP cylinder.

Flare-up.

Persistent grease fire.

Flashback... (fire in burner tube(s)).

Unable to fill LP cylinder.

One burner does not light from other burner(s).

• Excess flow valve tripped.

• Grease buildup.

• Excessive fat in meat.

• Excessive cooking temperature.

• Grease trapped by food buildup around burner system.

• Burner and/or burner tubes are

blocked.

• Some dealers have older fill nozzles with worn threads.

• Grease buildup or food particles in end(s) of carryover tube(s).

• Refer to “Sudden drop in gas flow” above.

• Clean burners and inside of grill/firebox.

• Trim fat from meat before grilling.

• Adjust (lower) temperature accordingly.

• 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.

• Turn knobs to OFF. Clean burner and/or burner tubes. See burner cleaning section of Use and Care.

• The worn nozzles don’t have enough “bite” to engage the valve. Try a second LP dealer.

• Clean carry-over tube(s) with wire brush.

28 • 466225712

Page 29

Troubleshooting - Electronic Ignition

Problem (Ignition)

SECTION I

No sparks appear at any electrodes when Electronic Ignition

Button is pressed; no

be heard noise can

from spark module.

SECTION II

No sparks appear at any electrodes when Electronic Ignition

Button is pressed; noise

be heard from can

spark module.

Possible Cause

• Battery not installed properly.

• Dead battery.

• Button assembly not installed properly.

• Faulty spark module.

• Output lead connections not connected.

Check Procedure

• Check battery orientation.

• Has battery been used previously?

• Check to insure threads are properly engaged. Button should travel up and down without binding.

• If no sparks are generated with new battery and good wire connections, module is faulty.

• Are output connections on and tight?

Prevention/Solution

• Install battery (make sure that “+” and “–” connectors are oriented correctly, with “+” end up and “–” end down.)

• Replace battery with new AA-size alkaline battery.

• Unscrew button cap assembly and reinstall, making

sure threads are aligned and engaged

fully.

• Replace spark module assembly.

• 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

• Output lead connections not connected.

• Arcing to grill away from burner(s).

• Weak battery.

• Electrodes are wet.

• Electrodes cracked or broken “sparks at crack”.

• Are output connections on and tight?

• If possible, observe grill in dark location. Operate ignition system and look for arcing between output wires and grill frame.

• All sparks present but weak or at slow rate.

• Has moisture accumulated on electrode and/or in burner ports?

• Inspect electrodes for cracks.

• Remove and reconnect all output connections at module and electrodes.

• If sparks are observed other than from burner(s), wire insulation may be damaged. Replace wires.

• Replace battery with a new AA-size alkaline

battery.

• Use paper towel to remove moisture.

• Replace cracked or broken electrodes.

466225712 • 29

Page 30

NOTES

30 • 466225712

Page 31

NOTES

466225712 • 31

Page 32