Permasteel PG-40407SOLF, 14646372610 Owner’s Manual

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Use & Care Guide

Manual de Uso y Cuidado

English / Español

Kenmore®

Liquid Propane Gas Grill

Parrilla a gas de propane liquido

Model/Modelo: 146.46372610

Item / Artículo: 640-08432439-1

P/N 407F0063A

Sears Brands Management Corporation

Hoffman Estates, IL 60179 U.S.A.

www.kenmore.com

www.sears.com

www.kmart.com

DANGER

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 cylinder not connected for use shall not be stored in the vicinity of this or any other appliance.

Call Grill Service Center For Help And Parts

If you have questions or need assistance during assembly, please call 1-888-287-0735. You will be speaking to a

representative of the grill manufacturer and not a Sears employee. To order new parts call Sears at 1-844-553-6667.

Product Record

IMPORTANT: Fill out the product record information below.

Model Number

Serial Number

See rating label on grill for serial number.

Date Purchased

Installation Safety Precautions

•Please read this User’s Manual in its entirety before using the grill.

•Failure to follow the provided instruction can result in seriously bodily injury and/or property damage.

•Some parts of this grill may have sharp edges. Please wear suitable protective gloves.

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

•Grill installation must conform with local codes, or in their 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 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.

•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.

IMPORTANT: This grill is intended for outdoor use only and is not intended to be installed in or on recreational vehicles or boats.

NOTE TO INSTALLER: Leave this User’s Manual with the customer after delivery and/or installation.

NOTE TO CONSUMER: Leave this User’s Manual in a convenient place for future reference.

Safety Symbols

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

DANGER

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

WARNING

WARNING: Indicates an potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

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

2 • 46372-407F0063 © KCDIP, LLC

CAUTION

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

TABLE OF CONTENTS

For Your Safety . . .	. . 2
Grill Service Center. . .	. . 2
Product Record Information . . .	. 2
Installation Safety Precautions . . .	. . 2
Safety Symbols . . .	. . 2
Kenmore Grill Warranty . . .	. . 3-4
Use and Care . . .	. . . 5-11
Parts List . . .	. . . 12
Parts Diagram . . .	. . 13
Before Assembly . . .	. . . 14-16
Assembly . . .	. 17-34
Troubleshooting . . .	. 35-37

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.

Purchase a Repair Protection Agreement now and protect yourself from unexpected hassle and expense.

Here’s what the Repair Protection Agreement* includes:

Expert service by experienced service technicians trusted in millions of homes every year.

Unlimited service and no charge for parts and labor on all covered repairs

Product replacement up to $1500 if your covered product can't be fixed

Discount of 25% from regular price of service and related installed parts not covered by the agreement.

Fast help by phone - phone support from a service agent on all products to help troubleshoot problems. Think of us as a “talking owner’s manual.”

Once you purchase the Repair Protection Agreement, a simple phone call is all that it takes for you to schedule service. You can call anytime day or night.

The Repair Protection Agreement is a risk-free purchase. If you cancel for any reason during the product warranty period, we will provide a full refund. Or, a prorated refund anytime after the product warranty period expires. Purchase your Repair

Protection Agreement today!

Some limitations and exclusions apply. For prices and additional information call 1-800-827-6655.

*Coverage in Canada varies on some items. For full details call Sears Canada at 1-800-361-6665.

Sears Installation Service

For Sears professional installation of home appliances, garage door openers, water heaters, and other major home items, in the U.S.A. call 1-844-553-6667, , and in Canada call 1-800-469-4663.

WARNING

CALIFORNIA PROPOSITION 65

This product contains chemicals, including lead and lead compounds in brass fittings. It also produces combustion by-products when used. These substances are known to the State of California to cause cancer, birth defects or other reproductive harm.

Wash your hands after handling this product.

46372-407F0063 • 3

WARRANTY

KENMORE LIMITED WARRANTY

WITH PROOF OF SALE, the following warranty coverage applies when this appliance is correctly installed, operated and maintained according to all supplied instructions.

FOR ONE YEAR from the date of sale this appliance is warranted against defects in material or workmanship. A defective appliance will receive free repair or replacement at option of seller.

FOR FIVE YEARS from the date of sale, any stainless steel burner that rusts through or burns through will be replaced free of charge. If rust through or burn through occurs within the first year, a new burner will be installed at no charge. If rust through or burn through occurs after the first year, a new burner will be supplied but not installed at no charge. You are responsible for the labor cost of burner installation after the first year from the date of sale.

For warranty coverage details to obtain free repair or replacement, visit the web page: www.kenmore.com/warranty

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 appliance is ever used for other than private household purposes. This warranty covers ONLY defects in material and workmanship, and will NOT pay for:

1.Expendable items that can wear out from normal use within the warranty period, including but not limited to batteries, screw-in base light bulbs and surface coatings or finishes.

2.A service technician to clean or maintain this appliance, or to instruct the user in correct appliance installation, operation and maintenance.

3.Service calls to correct appliance installation not performed by Sears authorized service agents, or to repair problems with house fuses, circuit breakers, house wiring, and plumbing or gas supply systems resulting from such installation.

4.Damage to or failure of this appliance resulting from installation not performed by Sears authorized service agents, including installation that was not in accord with electrical, gas or plumbing codes.

5.Damage to or failure of this appliance, including discoloration or surface rust, if it is not correctly operated and maintained according to all supplied instructions.

6.Damage to or failure of this appliance, including discoloration or surface rust, resulting from accident, alteration, abuse, misuse or use for other than its intended purpose.

7.Damage to or failure of this appliance, including discoloration or surface rust, caused by the use of detergents, cleaners, chemicals or utensils other than those recommended in all instructions supplied with the product.

8.Damage to or failure of this appliance resulting from natural or other catastrophe, such as flood, fire or storm..

9.Damage to or failure of parts or systems resulting from unauthorized modifications made to this appliance.

10.Service to an appliance if the model and serial plate is missing, altered, or cannot easily be determined to have the appropriate certification logo..

Disclaimer of implied warranties; limitation of remedies

Customer’s sole and exclusive remedy under this limited warranty shall be product repair or replacement as provided herein. Implied warranties, including warranties of merchantability or fitness for a particular purpose, are limited to one year on the appliance and five years on the burners, or the shortest period allowed by law. Seller shall not be liable for incidental or consequential damages. Some states and provinces do not allow the exclusion or limitation of incidental or consequential damages, or limitation on the duration of implied warranties of merchantability or fitness, so these exclusions or limitations may not apply to you.

This warranty applies only while this appliance 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 Brands Management Corporation, Hoffman Estates, IL 60179

4 • 46372-407F0063

OPD Hand Wheel

USE AND CARE

DANGER

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

•Never fill a cylinder beyond 80% full.

•If the information in the two points above is not followed exactly, a fire causing death or serious injury may occur.

•An overfilled or improperly stored cylinder is a hazard due to possible gas release from the safety relief valve. This could cause an intense fire with risk of property damage, serious injury or death.

•If you see, smell or hear gas escaping, immediately get away from the LP cylinder and appliance and call your fire department.

LP Tank Removal, Transport And Storage

• Turn OFF all control knobs and LP tank valve. Turn coupling nut counterclockwise by hand only - do not use tools to disconnect. Lift LP tank wire upward off of LP tank collar, then lift LP tank up and off of support bracket. Install safety cap onto LP tank valve. Always use cap and strap supplied with valve. Failure to use safety cap as directed may result in serious personal injury and/or property damage.

LP Tank Valve

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.

LP Cylinder

•The LP cylinder used with your grill must meet the following requirements:

•Use LP cylinders only with these required measurements: 12" (30.5cm) (diameter) x 18" (45.7 cm) (tall) with 20 lb. (9 kg.) Capacity maximum.

•LP cylinders must be constructed and marked in accordance with specifications for LP cylinders of the U.S. Department of Transportation (DOT) or for Canada, CAN/CSA-B339, cylinders, spheres and tubes for transportation of dangerous goods. Transport Canada (TC). See LP cylinder collar for marking.

•LP cylinder valve must have:

•Type 1 outlet compatible with regulator or grill.

•Safety relief valve.

•UL listed Overfill Protection

Device (OPD). This OPD safety

feature is identified by a unique triangular hand wheel. Use only LP cylinders equipped with this type of valve.

• LP cylinder must be arranged for vapor withdrawal and include collar to protect LP cylinder valve. Always keep LP cylinders in upright position during use, transit or storage.

LP cylinder in upright position for vapor withdrawal

LP (Liquefied Petroleum Gas)

•LP gas is nontoxic, odorless and colorless when produced. For Your Safety, LP gas has been given an odor (similar to rotten cabbage) so that it can be smelled.

•LP gas is highly flammable and may ignite unexpectedly when mixed with air.

LP Cylinder Filling

•Use only licensed and experienced dealers.

•LP dealer must purge new cylinder before filling.

•Dealer should NEVER fill LP cylinder more than 80% of LP cylinder volume. Volume of propane in cylinder will vary by temperature.

•A frosty regulator indicates gas overfill. Immediately close LP cylinder valve and call local LP gas dealer for assistance.

•Do not release liquid propane (LP) gas into the atmosphere. This is a hazardous practice.

•To remove gas from LP cylinder, contact an LP dealer or call a local fire department for assistance. Check the telephone directory under “Gas Companies” for nearest certified LP dealers.

46372-407F0063• 5

LP Tank Exchange

•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.

•Always keep new and exchanged LP tanks in upright position during use, transit or storage.

•Leak test new and exchanged LP tanks BEFORE connecting to grill.

LP Tank Leak Test

For your safety

•Leak test must be repeated each time LP tank is exchanged or refilled.

•Do not smoke during leak test.

•Do not use an open flame to check for gas leaks.

•Grill must be leak tested outdoors in a well-ventilated area, away from ignition sources such as gas fired or electrical appliances. During leak test, keep grill away from open flames or sparks.

•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.

WARNING

If “growing” bubbles appear do not use or move the LP tank. Contact an LP gas supplier or your fire department!

▲Do not use household cleaning agents. Damage to the gas train components (valve/hose/regulator) can result.

6 • 46372-407F0063

Connecting Regulator To The LP Tank

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.

4.Remove the protective cap from LP tank valve. Always use cap and strap supplied with valve.

OPD Hand Wheel

Type 1 outlet with thread on outside

Safety Relief Valve

Strap and Cap

Do not insert a POL transport plug (plastic part with external threads) into the type 1 valve outlet. It will defeat the Safety Relief Valve feature.

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 crossththread the connection.

Nipple has to be centered into the LP tank valve.

Hold coupling nut and regulator as shown for proper connection to LP tank valve.

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 1-844-553-6667.

4 .Brush soapy solution onto areas where bubbles are shown in picture below:

6.Turn the coupling nut clockwise and tighten to a full stop. The regulator will seal on the back-check feature in the LP tank valve, resulting in some resistance. An additional one-half to three-quarters turn is required to complete the connection. Tighten by hand only - do not use tools.

NOTE:

If you cannot complete the connection, disconnect regulator and repeat steps 5 and 6. If you are still unable to complete the connection, do not use this regulator!

Call 1-844-553-6667 for an identical replacement part.

DANGER

• Do not insert any tool or foreign object 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.

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

LP cylinder valve and call LP gas supplier or your fire department !

▲Never remove threaded orifice at end of valve.

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 for replacement

parts at 1-844-553-6667.

6.Always close LP tank valve after performing leak test by

turning hand wheel clockwise.

46372-407F0063• 7

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.

•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.

•Use grill at least 3 ft. from any wall or surface. Maintain 10 ft. clearance to objects that can catch fire, or to sources of ignition etc.

• 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.

8 • 46372-407F0063

Safety Tips

▲Before opening LP cylinder valve, check the coupling nut for tightness.

▲When grill is not in use, turn off all control knobs and LP cylinder valve.

▲Never move grill while in operation or still hot.

▲Use long-handled barbecue utensils and oven mitts to avoid burns and splatters.

▲Maximum load for sideburner and side shelf is 10 lbs.

▲The drip tray must be inserted into grill and emptied after each use Do not remove drip tray until grill has completely cooled.

▲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.

▲If you notice drip or other hot material dripping from grill, determine the cause, correct it, then clean and inspect valve. Keep ventilation openings in cylinder enclosure (grill cart) free and clear of debris.

▲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.

▲The regulator may make a humming or whistling noise during operation. This will not affect safety or use of grill.

▲If you have a grill problem see the "Troubleshooting Section".

▲If the regulator frosts, turn off grill and LP cylinder valve immediately. This indicates a problem with the cylinder and it should not be used on any product. Return to supplier!

CAUTION

•Putting out drip fires by closing the lid is not possible. Grills are well ventilated for safety reasons.

•Do not use water on a drip fire. Personal injury may result. If a drip 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 drip fire can occur that may damage the product.

Main Burner Igniter Lighting

▲Do not lean over grill while lighting.

1.Open lid during lighting.

2.Turn on valve from source or tank.

3. To ignite, turn Ignition Burner knob to

HI.

4.Push and hold electronic ignition button.

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

6.To ignite other main burners after ignition burner is lit,turn a

control knob that is adjacent to a lit burner to	Hi.
Ignite far left burner last.

7.To ignite the Side Burner, follow steps 3-5 using the Side Burner knob.

If igniter does not work, follow Match Lighting instructions.

Match Lighting

▲Do not lean over grill while lighting.

1.Open lid during lighting.

2.Place match into match holder (hanging on inside of Left Leg Frame panel).Light match, and insert match holder through lighting hole on left side of firebox. Align lit match with first burner on left.

3.Turn knob of first burner on left to HI position. Be sure burner lights and remains lit. Withdraw match holder from firebox and extinguish match if still lit.

4.To light other burners, turn each knob in succession to HI.

5.Once burners are lit, adjust knobs to desired flame setting.

Sideburner Match Lighting

1.Open sideburner lid. Turn on gas at LP cylinder.

2.Place lit match near burner.

3.Turn sideburner knob to HI. Be sure burner lights and stays lit.

Burner Flame Check

•Remove cooking grates and heat diffusers. Light burners, turn knobs from HI to LO. You should see a smaller flame in LO position than seen on HI. Perform burner flame check on sideburner, too. Always check flame prior to each use. If only low flame is seen refer to "Sudden flame drop or low flame" in the Troubleshooting Section.

Turning Grill Off

•Turn all knobs to OFF position. Turn LP cylinder off by turning

Igniter Check

•Turn gas off at LP cylinder. Press and hold electronic igniter button. "Clicking" should be heard and spark seen each time between collector box or burner and electrode. See "Troubleshooting" if no click or spark.

Valve Check

•Important: Make sure gas is off at LP cylinder before checking valves Knobs lock in OFF position. To check valves, first push in knobs and release, knobs should spring back. If knobs do not spring back, replace valve assembly before using grill. Turn knobs to LOW

position then turn back to OFF position. Valves should turn smoothly.

Hose Check

•Before each use, check to see if hoses are cut or worn. Replace damaged hoses before using grill. Use only valve/hose/regulator as specified in the parts list of this Use & Care Guide.

Cast Iron Grate Seasoning (if applicable)

First Use – Before first use, season cast iron grates as follows: Rinse cast iron grates with hot water. Do not use soap. Dry grates thoroughly with a cloth towel. Coat grates with vegetable oil or non-stick cooking spray. Place grates in grill. Start grill and slowly raise temperature to 350° - 400° F. Heat grates for one hour. Turn off grill and allow grates to cool completely before using to cook. Cleaning – Do not use soap when cleaning grates. Clean grates with a stiff brush and hot water. Dry grates thoroughly with a cloth towel. Re-seasoning – Re-season grates when rust spots appear on grate surface. When re-seasoning grates, soap may be used with hot water to clean grates. After cleaning, dry grates thoroughly with a cloth towel. Coat grates with vegetable oil or non-stick cooking spray. Place grates in grill. Start grill and slowly raise temperature

to 350° - 400° F. Heat grates for one hour. Turn off grill and allow grates to cool completely before using again.

General Grill Cleaning

•Do not mistake brown or black accumulation of drip 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.

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

46372-407F0063• 9

•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 drip 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.

•Drip Tray and Cup: Regularly clean the grease drippings from the Drip Tray and Drip Cup. When the grill has completely cooled down after use, remove the cup from the tray and slide the tray out of the grill. Clean the grease drippings from the cup and tray surfaces by washing with mild detergent or nonabrasive cleaner and warm soapy water. Wipe dry with a soft nonabrasive cloth. Slide the tray back into the grill and replace the cup back into the tray before using the grill again.

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.

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 venturi’s.

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 venturi 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 assembly should be removed from the grill and cleaned before use whenever the grill has been idle for an extended period.

10. 46372-407F0063

Storing Your Grill

•Clean cooking grates. •Store in dry location.

•When LP cylinder is connected to grill, store outdoors in a well-ventilated space and out of reach of children.

•Cover grill if stored outdoors. Choose from a variety of grill covers offered by manufacturer once available.

•Store. grill indoors ONLY if LP cylinder is turned off and Disconnected, remove from grill and stored outdoors.

• 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 cotter pin from rear of burners. See Fig. A next page.

4.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.

(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.

(C)Wear eye protection: Use an air hose to force air into

the burner tube and out the burner ports. Check each port to make sure air comes out each hole.

5.Wire brush entire outer surface of burner to remove food residue and dirt.

6.Clean any blocked ports with a stiff wire such as an open paper clip.

7.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 below.

8.Carefully replace burners.

9.Attach burners to brackets with cotter pin. See Fig. B next page.

10.Replace heat diffusers and cooking grates.

A B

Indirect Cooking

Poultry and large cuts of meat cook slowly to perfection on the grill by indirect heat. Place food over unlit burner(s); the heat from lit burners circulates gently throughout the grill, cooking meat or poultry without the touch of a direct flame. This method greatly reduces flare-ups when cooking extra fatty cuts because there is no direct flame to ignite the fats and juices that drip during cooking.

1 Burner Cooking

Cook with direct or indirect heat. Best for smaller meals or foods. Consumes less fuel.

Indirect Cooking Instructions

•Always cook with the lid closed.

•Due to weather conditions, cooking times may vary. During cold and windy conditions the temperature setting may need to be increased to insure sufficient cooking temperature.

•Place food over over unlit burner(s).

2 Burner Cooking

Great indirect cooking on low. Produces slow, even heating. Ideal for slow roasting and baking.

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.

WARNING: To ensure that it is safe to eat, food must be cooked to the minimum internal temperatures listed in the table below.

USDA* Recommended Safe Minimum Internal Temperatures

Beef, Veal,USDA*LambSafeand PorkMinimum– WholeInternalCuts**Temperatures145° F

Fish	145° F145°F

PorkBeef, Veal, Lamb and Pork – Ground	160° F160°F

Egg Dishes	160° F160°F

SteaksTurkey, andChickenRoasts& ofDuckBeef,– Whole, Pieces &	165° F
VealGroundor Lamb	145°F

Ground Beef, Veal or Lamb	160°F
* United States Department of Agriculture

Whole Poultry (Turkey,
**Allow meat to rest three minutes before carving or consuming.
Chicken, Duck, etc.)	165°F
Ground or Pieces Poultry	165°F
(Chicken Breast, etc.)

*United States Department of Agriculture

46372-407F0063 • 11

Key

Description

Qty

Part Number

Key

Description

Qty

Part Number

Side Burner Lid

407F0100

B18

Middle Panel, Left and Right Cart

41600049

Side Burner Grid

40800119

B19

Bottom Panel, Left and Right Cart

407F0038

Side Burner Base

40800063

B20

Door Magnet, Side Cabinet

61200128

Side Burner

40800121

B21

Bottom Rail Bracket

407F0081

Igniter Wire, Side Burner

40800120

B22

Left Side Door

407F0054

Right Side Shelf

407B0007

B23

Left Door

40700086

Fascia, Right Side Shelf

407B0009

B24

Right Door

40700095

Electronic Ignition Module

40800122

B25

Right Side Door

407F0049

A10

Control Panel

40900080

B26

Door Handle

40900076

A11

Bezel, Control Knob

40900036

Fascia, Left Side Shelf

407F0004

A12

Control Knob

40900206

Back Panel, Left and Right Cart

407B0036

A13

Gas Valve, Main Burner

40900205

Middle Cart Top Back Rail

41600054

A14

Gas Valve ,Side Burner

40900209

Door Rail

40700085

A15

Manifold, Main Burner

40800037

No.2 Middle Cart Bottom Back Rail

407F0071

A16

Side Burner Hose

40900210

No.1 Middle Cart Bottom Front Rail

407F0068

A17

Cotter Pin

110050

Back Panel

407B0037

A18

Regulator

40800115

Door Magnet Box

407F0099

Lid

40700004

Middle Cart Bottom Panel

407F0048

Temperature Gauge

40900201

C10

Gas Tank Holder

40800130

Logo

40800106

C11

No.1 Leg Frame

407F0009

Rotate Rod, Lid

50300207

C12

No.2 Leg Frame

407F0025

Silicone Rubber Bumper

40700103

C13

No.3 Leg Frame

407F0021

Bezel, Lid Handle

40900013

C14

No.4 Leg Frame

407F0030

Lid Handle

40900012

C15

No.2 Left Cart Bottom Back Rail

407F0018

Warming Rack

40900203

C16

No.1 Left Cart Bottom Front Rail

407F0015

Cooking Grate

40900204

C17

Left Cart Top Front Rail

407F0044

B10

Heat Diffuser

40800023

C18

Right Cart Top Front Rail

407F0040

B11

Flame Carry Over Tube

40800022

C19

Tank Baffle

407F0075

B12

Main Burner

40700125

C20

Top Back Rail, Left and Right Cart

41600053

B13

Firebox

40700021

C21

No.3 Right Cart Bottom Front Rail

407F0034

B14

Igniter Wire, Main Burner

40900207

C22

No.4 Right Cart Bottom Back Rail

41600042

B15

Drip Tray

407F0074

C23

Caster With Brake

40700100

B16

Drip Cup Clip

40800131

C24

Caster

40700101

B17

Drip Cup

40800026

If you are missing hardware or have

Not Pictured

damaged parts after unpacking grill,

call 1-888-287-0735 for replacement.

Hardware Pack

407F0062

Manual

407F0063A

To order replacement parts after using grill,

call 1-844-553-6667.

12 • 46372-407F0063

Permasteel PG-40407SOLF, 14646372610 Owner’s Manual

PARTS DIAGRAM

46372-407F0063• 13

BEFOREASSEMBLY

NOTICE: Once you have unpacked the grill according to the STOP SHEET instructions, check all grill parts against the pictures on this and the following two pages. If any parts are missing or damaged, call 1-888-287-0735.

14 • 46372-407F0063

BEFOREASSEMBLY

46372-407F0063• 15

BEFOREASSEMBLY

16 • 46372-407F0063

ASSEMBLY

CAREFULLY READ AND PERFORM ALL ASSEMBLY INSTRUCTIONS ON THE FOLLOWING PAGES.

Tools Required:

Adjustable wrench (not provided)

Screwdriver (not provided)

The following hardware is provided in blister pack for convenient use.

M4X10 screw	AAA Battery
Qty: 63 pcs	Qty: 1 pc

M5X12 screw	M5 flat washer
Qty: 2 pcs	Qty: 2 pcs

M6X15 screw	M6 compression washer
Qty: 8 pcs	Qty: 8 pcs

M5X12 Hex Screw	M6X15 Hex Screw
Qty: 4 pcs	Qty: 34 pcs

Wrench

Qty: 1 pc

46372-407F0063• 17

Bottom Rails to Leg Frames

IMPORTANT

-Assemble grill cart on an even, flat surface. Use a level to confirm that surface is even and flat.

-For ease of cart assembly Leg Frames and Bottom Rails are numbered.

-Unless instructed otherwise, securely tighten all screws in each assembly step before proceeding to the next step.

Use (5) M6X15 Hex Screws to attach one Bottom Rail Bracket to No. 1 Middle Cart Bottom Front Rail. Repeat for No. 2 Middle Cart Bottom Front Rail. See A.

Use (4) M6X15 Hex Screws to attach No. 1 Middle Cart Bottom Front Rail to No. 3 Right Leg Middle Frame and No. 2 Left Leg Middle Frame. Repeat for No. 2 Middle Cart Bottom Back Rail. Do not yet fully tighten screws. See B.

Use (4) M6X15 Hex Screws to attach No. 1 Left Cart Bottom Front Rail to No. 1 Left Leg Frame and No. 2 Left Leg Middle Frame. Repeat for No. 2 Left Cart Bottom Back Rail. Do not yet fully tighten screws. See C.

Bottom Rail Bracket

M6X15 Hex Screw

Qty: 26 pcs

No.1 Middle Cart Bottom Front Rail

No.3 Right Leg

Middle Frame

No. 1 Left Leg Frame

No.2 Left Leg

Middle Frame No.2 Middle Cart

Bottom Back Rail

	No. 1 Left Cart
	Bottom Front Rail
	No. 2 Left Cart
18 • 46372-407F0063	Bottom Back Rail

Bottom Rail Bracket

No.2 Left Leg

Middle Frame

No.3 Leg Frame

Use (4) M6X15 Hex Screws to attach No. 3 Right Cart Bottom Front Rail to No. 4 Right Leg Frame and No.3 Right Leg Middle Frame. Repeat for No. 4 Right Cart Bottom Back Rail. Do not yet fully tighten screws. See D.

Use the Wrench to fully tighten all the screws. See E.

Note: Make sure all sections of cart are square and level before fully tightening all screws.

No.4 Right Leg Frame
No.4 Right Leg Frame		No.3 Right Leg Middle Frame

M6X15 Hex Screw Qty: 8 pcs

No. 4 Right Cart

Bottom Back Rail

No. 3 Right Cart

Bottom Front Rail

46372-407F0063•19

Casters to Cart

Screw the casters into the No. 1 and No. 4 Leg Frames. Screw the casters with brakes into the No. 4 Leg Frame.

No.4 Right Leg Frame

No. 1 Left Leg Frame

20 •46372-407F0063

Bottom Panels

Turn the cart frame right side up to rest on the casters. Lock the casters with brakes to stabilize the cart for further assembly.

Remove the (2) M4x10 screws pre-assembled to the Middle Cart Bottom Panel and use them to attach the Middle Cart Door Magnet to the Middle Cart Bottom Panel. See A.

Lay the Middle Cart Bottom Panel onto the No. 2 and No. 3 Leg Frames.

Lay the Left Cart Bottom Panel onto the No. 1 and No. 2 Leg Frames. Lay the Right Cart Bottom Panel onto the No. 4 and No. 3 Leg Frames. The right edge of the Left panel and the left edge of the Right panel will overlay the left and right edges of the Middle Cart panel respectively.

Use (12) M4x10 screws to attach panel edges securely to the Leg Frames as shown in B.

M4X10 screw

Qty: 12 pcs

Front

46372-407F0063•21

Side Door Magnets, Top Rails to Leg Frames

Use (4) M4x10 screws each to attach the Left and Right Door Magnets to the Right and Left Cart Bottom Panels as shown in A.

Use (4) M4x10 screws to attach the No. 2 Right Cart Top Front Rail to the No. 4 and No. 3 Leg Frames. See B. Repeat for Right Cart Top Back Rail with using (2) M4x10 screws. See C.

Use (4) M4x10 screws to attach the No. 1 Left Cart Top Front Rail to the No. 1 and No. 2 Leg Frames. See B. Repeat for Left Cart Top Back Rail with using (2) M4x10 screws. See C.

M4X10 screw
Qty: 16 pcs	A
	A

22 •46372-407F0063

Door Rail, Left and Right Cart Middle Panels

Use (4) M4x10 screws to attach the Door Rail to the top of the No. 2 Leg Frame and No. 3 Leg Frame. See A.

Insert (4) M4x10 screws into the No. 4 Leg Frame and No. 3 Leg Frame. Repeat for No. 1 Leg Frame and No. 2 Leg Frame. See B. Do not fully tighten screws down, but leave a small gap between the screw head and frame surface for middle panel attachment.

Mount the middle panels onto the (8) M4x10 screws. See C.

NOTE: DO NOT fully tighten down the screws. The panels will fit securely without further screw tightening. Fully tightening the screws may cause the panels to become tilted or possibly fall down.

M4X10 screw Qty: 12pc

46372-407F0063• 23

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