PRODUCT GUIDE
Kenmore Model No. 415.16121801
Kmart Item No. 640-174667113
IMPORTANT: Fill out the product record information below.
Serial Number
See rating label on grill for serial number.
Date Purchased
For support and to register your
grill, please visit us at
www.charbroil.com
If you have questions or need
assistance during assembly,
please call 1-800-241-7548.
Estimated assembly time: 35-40 minutes
The following are trademarks registered by W.C. Bradley Co. in the U.S. Patent and Trademark Office: Char-Broil®; America's Legendary Barbeque Company®;
American Gourmet®; Bandera®; BrushHawg®; CB940®; Char-Diamonds®; Char-Broil Charcoal/Gas®; DiamondFlame®; Everybody Grills®; Everybody Outside®;
FastStart®; Fireball®; Firenzy®; FlavorMaster®; Grill2Go®; Grill2Go® Express®; Grill Lovers®; H20 Smoker®; Keepers of the Flame®; New Braunfels Smoker
Company®; Oklahoma Joe's®; Patio Bistro®; Patio Caddie®; Patio Kitchen®; Precision Flame®; Quantum®; Santa Fe®; Sear and Grill®; Sierra®; Signature
Series®; The Big Easy®; The Minute Grill®; Trentino®; Wild West Tradition®; and the following marks:
®
®
The following are trademarks of W.C. Bradley Co.: Commercial Series™; Designer Series™; Grill2Go® Advantage™; Longhorn™; Double Chef™; QuickSet™;
Ready When You Are™; Hog and Yard Bird™; You Bring the Party™; SureFire™; Universal Grill Parts™
TEC™ is a trademark of Tec Infrared Grills.
Protected under one or more of the following U.S. Patents: 4,989,579; 5,421,319; 5,458,309; 5,579,755; 5,996,573; 6,114,666; 6,135,104; 6,209,533; 6,279,566; 6,331,108; 6,484,900; 6,526,876; 6,595,197; 6,640,799; 6,640,803; 6,729,873; 6,739,473; 6,749,424;
6,863,100; 6,935,327; 6,951,213; 6792,935; 7,047,590; D364,535; D372,637; D373,701; D377,735; D383,035; D397,910; D405,643; D406,005; D406,009 ; D413,043; D413,229; D414,982; D415,388; D416,164; D416,441; D417,587; D417,588; D422,516; D423,876;
D428,303; D430,772; D435,396; D436,004; D438,059; D438,060; D438,427; D439,110; D442,505; D443,179; D443,354; D443,464; D447,384; D447,385; D447,909; D448,610; D448,614; D448,615; D448,616; D448,975; D449,492; D450,544; D451,759; D454,028;
D454,031; D455,205; D455,206; D456,202; D456,222; D456,223; D457,789; D458,520; D458,760; D458,802; D459,088; D459,148 D459,149; D459,161; D459,163; D459,586; D459,943; D460,312; D460,313; D460,318; D461,359; D465,123; D465,693; D466,307;
D466,439; D466,752; D473,414; D474,371; D477,498; D477,501; D477,504; D477,506; D477,746; D478,471; D478,472; D480,914; D491,410; D494,009; D494,413; D498,523; D500,359; D504,048; D530,098; D535,000; Canada: 87,743; 87,744; 97,504; 99,355;
102,037; 104,200; 2,315,567; 2,336,036; France: 010,231; 010,422; 010,590; 010,849; 1,089,646; Germany: 1,089,646; South Korea: 384,565; China: 99,127,066.5; United Kingdom: 2,099,402; 1,089,646. Other Patents Pending.
© 2008 W.C. Bradley Company
TM REVISION 00
© 2008 Char-Broil, LLC Columbus, GA 31902
Printed in China
Assembly instructions © 2008
Model 463612509 • 463612709
10/29/08 • 80018033
TABLE OF CONTENTS
DANGER
For Your Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Use and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Grilling Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14
Limited Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Parts Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-28
If you smell gas:
1.
2.
3.
4.
Shut off gas to the appliance.
Extinguish any open flame.
Open lid.
If odor continues, keep away from the
appliance and immediately call your gas
supplier or your fire department.
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-30
Registration Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Safety Symbols
The symbols and boxes shown below explain what each heading
means. Read and follow all of the messages found throughout
the manual.
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.
WARNING
WARNING: Indicates an potentially hazardous situation
which, if not avoided, could result in death or serious injury.
CAUTION
CAUTION: Indicates a potentially hazardous situation or
unsafe practice which, if not avoided, may result in minor
or moderate injury.
DANGER
DANGER: Indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
CAUTION
For residential use only. Do not use for commercial
cooking.
THIS GRILL IS FOR OUTDOOR USE ONLY.
CAUTION:
Read and follow all safety statements, assembly
instructions, and use and care directions before attempting
to assemble and cook.
INSTALLER/ASSEMBLER:
Leave this manual with consumer.
CONSUMER:
Keep this manual for future reference.
WARNING:
Failure to follow all manufacturer’s instructions could result
in serious personal injury and/or property damage.
CAUTION:
Some parts may contain sharp edges – especially as noted
in the manual! Wear protective gloves if necessary.
2
WARNING
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.
CAUTION
Using pots larger than 6 quarts in capacity could
exceed weight limit of the
side burner shelf,
resulting in failure
of grill cart
components.
Installation Safety Precautions
• Use grill, as purchased, only with LP (propane) gas and the
regulator/valve assembly supplied. A conversion kit must be
purchased for use with natural gas.
• 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.
WARNING
Do not attempt to repair or alter the
hose/valve/regulator 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.
3
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 two points above is not
followed exactly, a fire causing death or serious
injury may occur.
• 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.
LP Cylinder Removal, Transport and Storage
•Turn OFF all control knobs and LP cylinder valve. Turn coupling
nut counterclockwise by hand only - do not use tools to
disconnect. Loosen cylinder screw beneath bottom shelf, then
lift LP cylinder up and out of cart. Install safety cap onto LP
cylinder 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.
•A disconnected LP cylinder in LP Cylinder Valve
storage or being transported
must have a safety cap installed (as shown).
Do not store an LP cylinder in enclosed spaces
such as a carport, garage, porch, covered
Safety
patio or other building. Never leave an LP cylinder
Cap
inside a vehicle which may become overheated
Retainer Strap
by the sun.
•Do not store an LP cylinder in an area where children play.
4
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.
OPD Hand Wheel
•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.
LP Cylinder Exchange
Connecting Regulator to the LP Cylinder
•Many retailers that sell grills offer you the option of replacing
your empty LP cylinder through an exchange service. Use only
those reputable exchange companies that inspect, precision fill,
test and certify their cylinders. Exchange your cylinder only
for an OPD safety feature-equipped cylinder as described
in the "LP Cylinder" section of this manual.
1.LP cylinder must be properly secured onto grill. (Refer to
assembly section.)
•Always keep new and exchanged LP cylinders in upright
position during use, transit or storage.
4.Remove the protective cap from LP cylinder valve. Always use
cap and strap supplied with valve.
2.Turn all control knobs to the OFF position.
3.Turn LP cylinder OFF by turning hand-wheel clockwise to a
full stop.
•Leak test new and exchanged LP cylinders BEFORE
connecting to grill.
Off
Clockwise
LP Cylinder Leak Test
For your safety
OPD Hand Wheel
•Leak test must be repeated each time LP cylinder is exchanged
or refilled.
Type 1 outlet with
thread on outside
•Do not smoke during leak test.
•Do not use an open flame to check for gas leaks.
Safety Relief Valve
•Grill must be leak tested outdoors in a well-ventilated area,
away from ignition sources such as gas fired or electrical
appliances. During leak test, keep grill away from open flames
or sparks.
Strap and Cap
•Use a clean paintbrush and a 50/50 mild soap and water
solution. Brush soapy solution onto areas indicated by arrows
in figure below.
Do not use a POL transport plug
(plastic part with external threads)!
It will defeat the safety feature of
the valve.
s
Do not use household cleaning agents. Damage to gas
train components can result.
5.Hold regulator and insert nipple into LP
cylinder valve. Hand-tighten the
coupling nut, holding regulator in a
straight line with LP cylinder valve so
as not to cross-thread the connection.
Nipple has to be centered
into the LP cylinder valve.
WARNING
If “growing” bubbles appear do not use or move the LP
cylinder. Contact an LP gas supplier or your fire
department!
5
Leak Testing Valves, Hose and Regulator
1.Turn all grill control knobs to OFF.
2.Be sure regulator is tightly connected to LP cylinder.
Str
a
igh
3.Completely open LP cylinder valve by turning hand wheel
counterclockwise. If you hear a rushing sound, turn gas off
immediately. There is a major leak at the connection. Correct
before proceeding.
t
Hold coupling nut and regulator
as shown for proper connection
to LP cylinder valve.
4.Brush soapy solution onto areas circled 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 cylinder
valve, resulting in some resistance. An additional one-half to
three-quarters turn is required to complete the
connection. Tighten by hand only – do not use tools.
NOTE:
If you cannot complete the connection, disconnect regulator and
repeat steps 5 and 6. If you are still unable to complete the
connection, do not use this regulator!
DANGER
• Do not insert any tool or foreign 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
LPcylinder valve and call LP gas supplier or your fire
department!
6
NOTE: Sideburner
shelf fascia not
shown for clarity.
5.If “growing” bubbles appear, there is a leak. Close LP
cylinder valve immediately and retighten connections. If leaks
cannot be stopped do not try to repair. Call for replacement
parts.
6.Always close LP cylinder valve after performing leak test by
turning hand wheel clockwise.
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 bottom 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.
(Unless briquets are supplied with your grill.)
•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.
•Apartment Dwellers:
Check with management to learn the requirements and fire
codes for using an LP gas grill in your apartment complex. If
allowed, use outside on the ground floor with a three (3) foot
clearance from walls or rails. Do not use on or under
balconies.
•NEVER attempt to light burner with lid closed. A buildup
of non-ignited gas inside a closed grill is hazardous.
•Never operate grill with LP tank out of correct position
specified in assembly instructions.
•Always close LP tank valve and remove coupling nut
before moving LP tank from specified operation
position.
Safety Tips
s
Before opening LP cylinder valve, check the coupling nut for
tightness.
s
When grill is not in use, turn off all control knobs and LP
cylinder valve.
s
If the outdoor cooking gas appliance is not in use, the gas
must be turned off at the supply cylinder. Storage of an
outdoor cooking gas appliance indoors is permissible only if
the cylinder is disconnected and removed from the appliance.
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 side shelves is 10 lbs.
s
The grease cup must be inserted into grease clip and
emptied after each use. Do not remove grease 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, hose or regulator, turn off gas supply at once.
Determine the cause, correct it, then clean and inspect valve,
hose and regulator before continuing. Perform a leak test.
s
The regulator may make a humming or whistling noise during
operation. This will not affect safety or use of grill.
s
Only use the pressure regulator and hose assembly supplied
with this grill. Replacement pressure regulator and hose
assemblies must be specified or supplied by Char-Broil, LLC.
s
If you have a grill problem see the "Troubleshooting Section".
s
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 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.
7
Ignitor Lighting
Sideburner Ignitor Lighting
1.
2.
3.
4.
s
Do not lean over grill while lighting.
1. Turn OFF gas burner control valves.
2. Turn ON gas source or tank.
3. Open lid during lighting.
4. To ignite, turn left knob to
HIGH.
5. Push IGNITOR button rapidly.
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 right burner, turn knob to
.
If ignitor does not work, follow match lighting instructions.
After Lighting: Turn knobs to HI position for warm-up.
Turn OFF gas burner control valves.
Turn ON gas source or tank.
Turn sideburner knob to HI. and push IGNITOR button rapidly.
If sideburner does NOT light, turn knob to OFF,
wait 5 minutes, then repeat lighting procedure.
Sideburner Match Lighting
1. Turn on gas at LP tank.
2. Hold lit match to any port on
the burner. Push in and turn
sideburner knob to
. Be
sure burner lights and stays lit.
Before Your First Cookout
CAUTION
If burner does not light, turn knobs to OFF, wait 5
minutes, and try again. Always close valve during the 5
minute waiting period. If the burner does not ignite with
the valve open, gas will continue to flow out of the burner
and could accidentally ignite with risk of injury.
Match-Lighting
•Light burners, check to make sure they are lit, close the lid and
warm up grill on HIGH for 15 minutes. This curing of paint and
parts will produce an odor only on first lighting.
Burner Flame Check
•Light burner, rotate knobs from HIGH to LOW. You should see
a smaller flame in LOW position than seen on HIGH. Always
check flame prior to each use. If only low flame is seen refer to
"Sudden drop or low flame" in the Troubleshooting Section.
s
Do not lean over grill while lighting.
HI
1.Open lid during lighting.
LO
2.Place match into match holder (hanging from side of cart).
3.Push in and turn left knob to
burner lights and stays lit.
HIGH position. Be sure
4.Light right burner by pushing knob in and turning to
position.
Hose Check
HIGH
•Before each use, check to see if hoses are cut, worn or kinked.
Replace damaged hoses before using grill. Use only
valve/hose/regulator specified in the Parts List.
Normal
Hose
8
Kinked
Hose
Turning Grill Off
CAUTION
•Turn all knobs to OFF position. Turn LP tank off by turning
OPD hand wheel clockwise to a full stop.
Ignitor Check
•Turn gas off at LP tank. Press and hold ignitor button. "Click"
should be heard and spark seen each time between collector
box or burner and electrodes. See "Troubleshooting" if no click
or spark.
SPIDER ALERT!
GAS COLLECTOR
BOX & IGNITOR
BURNER
CONTROL PANEL
Valve Check
•Important: Make sure gas is off at LP tank before checking
valves. Knobs lock in OFF position. To check valves, first
push in knobs and release, knobs should spring back. If knobs
do not spring back, replace valve assembly before using grill.
Turn knobs to LO position then turn back to OFF position.
Valves should turn smoothly.
General Grill Cleaning
•Keep the outside of your grill looking new by cleaning it once a
month with warm soap and water or a non-abrasive cleaner. If
you don’t have a grill cover, wipe off dust and grime before
starting your grill.
• Coating the cooking grids with spray-on cooking oil will keep the
food from sticking and make clean up easier. After cooking,
scrape the grates with a long handled, brass wire bristle brush.
•Check inside the grill bottom for grease build up and clean
often, especially after cooking fatty meat.
•Do not mistake brown or black accumulation of grease and
smoke for paint. 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.
•Plated wire grates: Wash grates with concentrated grill
cleaner or use soap and water solution. Dry thoroughly and
store indoors between cookouts.
• Plastic parts: Wash with warm soapy water and wipe dry.
s
Do not use citrisol, abrasive cleaners, degreasers or a
concentrated grill cleaner on plastic parts. Damage to and
failure of parts can result.
•Porcelain grates: Because of glass-like composition, most
residue can be wiped away with baking soda/water solution or
specially formulated cleaner. Use non-abrasive scouring
powder for stubborn stains.
•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.
SPIDER WEBS
INSIDE VENTURI
VALVE
VENTURI
AIR
SHUTTER
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.
LIFT OUT
BURNER ASSEMBLY
REMOVE
BURNER
CLIPS
CLEAN OUT
VENTURI
SPIDER WEBS
INSIDE VENTURI
In some areas of the country, 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.
9
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 grate and heat tent.
3. Under grill remove grease cup, disconnect ignitor wire from
burner.
4. Inside grill remove burner assembly (A), clean ceramic
portion of electrode with rubbing alcohol and a swab.
5. Clean outside of burner with soap and water. Lay burner
upside down on flat surface, insert garden hose to force
water through tubes. Make sure water comes out of all
burner holes. Open clogged holes with a thin wire. Shake
out excess water and examine holes. Due to normal wear
and corrosion some holes may become enlarged. If any
large cracks or holes are found replace burner.
6. If grill is to be stored, coat burner lightly with cooking oil.
Wrap in protective cover to keep insects out.
7. If not storing grill after cleaning, replace burner into grill
bottom.
VERY IMPORTANT: Burner tubes must re-engage valve
openings. See illustration (A).
8. Reattach ignitor wire to electrode.
9. Reposition heat tent and cooking grate. Reattach clean
grease cup to grease clip.
10. Before cooking again on grill, perform a “Leak Test” and
“Burner Flame Check”.
Correct burner-to-valve engagement
A
Burner Tube
Valve
B
10
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 15-20 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
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.
Note: Since 1995, all regulators (the part that attaches to the gas
tank to regulate the flow of gas) have included a safety feature
that restricts gas flow in the event of a gas leak. You can
inadvertently activate this safety feature without having a gas
leak. This typically occurs when you turn on the gas using the
grill control knob before you turn on the LP tank valve. If the gas
regulator safety feature activates, the grill will only reach
temperatures between 250°F and 300°F even with all burners on
the high setting.
Regulator
Coupling Nut
If your grill is not getting hotter than 250°F to 300°F these
steps should be taken first to reset the gas regulator safety
device:
1. Open the grill lid.
2. Turn off all knobs on the control panel in front.
3. Turn off the tank knob.
4. Disconnect the regulator from the LP tank.
5. Wait 30 seconds.
6. Reconnect the regulator to the LP tank.
7. Slowly open the LP tank knob all the way. Do not put
excessive force on the valve at the full open position to avoid
damaging the valve.
8. Turn on the appropriate control knob and light the grill per the
instructions on the control panel.
An illustration of this process is included in this Product Guide.
See Troubleshooting section for additional information.
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 1015 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 match-light chain and
hole is provided for your convenience.
11
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.
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.
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.
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
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.
12
GRILLING GUIDE – Tips & Tricks
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.
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.
USDA Recommended Safe Minimum
Internal Temperatures
Beef, Veal, Lamb, Steaks, & Roasts
Fish
Pork
Beef, Veal, Lamb Ground
Egg Dishes
Turkey, Chicken & Duck Whole,
Pieces & Ground
145° F
145° F
160° F
160° F
160° F
165° F
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.
Please refer to the USDA for complete, up-to-date information.
Our internal temperature chart is based on USDA standards for
meat doneness. Check it out at www.isitdoneyet.gov
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
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.
13
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 non-abrasive 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.
14
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.
LIMITED WARRANTY
This warranty only applies to units purchased from an authorized retailer. Manufacturer warrants to the original consumer-purchaser only that this
product shall be free from defects in workmanship and materials after correct assembly and under normal and reasonable home use for the periods
indicated below beginning on the date of purchase*. The manufacturer reserves the right to require that defective parts be returned, postage and or
freight pre-paid by the consumer for review and examination.
SCOPE OF COVERAGE
All Parts
PERIOD OF COVERAGE
1 year from date of purchase*
TYPE OF FAILURE COVERAGE
PERFORATION, MANUFACTURING,
AND MATERIAL DEFECTS ONLY
*Note: A dated sales reciept WILL be required for warranty service.
The original consumer-purchaser will be responsible for all shipping charges for parts replaced under the terms of this limited warranty.
This limited warranty is applicable in the United States and Canada only, is only available to the original owner of the product and is not transferable.
Manufacturer requires proof of your date of purchase. Therefore, you should retain your sales slip or invoice. Registering your product is not a
substitute for proof of purchase and the manufacturer is not responsible for or required to retain proof of purchase records.
This limited warranty applies to the functionality of the product ONLY and does not cover cosmetic issues such as scratches, dents, corrosions or
discoloring by heat, abrasive and chemical cleaners or any tools used in the assembly or installation of the appliance, surface rust, or the
discoloration of stainless steel surfaces. RUST is not considered a manufacturing or materials defect.
This limited warranty will not reimburse you for the cost of any inconvenience, food, personal injury or property damage.
ITEMS MANUFACTURER WILL NOT PAY FOR:
1. Shipping cost, standard or expedited, for warranty and replacement parts
2. Service calls to your home.
3. Repairs when your product is used for other than normal, single-family household or residential use.
4. Damage, failures, or operating difficulties resulting from accident, alteration, careless handling, misuse, abuse, fire, flood,
acts of God, improper installation or maintenance, installation not in accordance with electrical or plumbing codes, or use
of products not approved by the manufacturer.
5. Any food loss due to product failures or operating difficulties.
6. Replacement parts or repair labor costs for units operated outside the United States or Canada.
7. Pickup and delivery of your product.
8. Repairs to parts or systems resulting from unauthorized modifications made to the product.
9. The removal and/or reinstallation of your product.
DISCLAIMER OF IMPLIED WARRANTIES and LIMITATION OF REMEDIES
Repair or replacement of defective parts is your exclusive remedy under the terms of this limited warranty. Manufacturer will not be responsible for
any consequential or incidental damages arising from the breach of either this limited warranty or any applicable implied warranty, or for failure or
damage resulting from acts of God, improper care and maintenance, grease fire, accident, alteration, replacement of parts by anyone other than
Manufacturer, misuse, transportation, commercial use, abuse, hostile environments (inclement weather, acts of nature, animal tampering), improper
installation or installation not in accordance with local codes or printed manufacturer instructions.
THIS LIMITED WARRANTY IS THE SOLE EXPRESS WARRANTY GIVEN BY THE MANUFACTURER. NO PRODUCT PERFORMANCE
SPECIFICATION OR DESCRIPTION WHEREVER APPEARING IS WARRANTED BY MANUFACTURER EXCEPT TO THE EXTENT SET
FORTH IN THIS LIMITED WARRANTY. ANY IMPLIED WARRANTY PROTECTION ARISING UNDER THE LAWS OF ANY STATE,
INCLUDING IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR USE, IS HEREBY
LIMITED IN DURATION TO THE DURATION OF THIS LIMITED WARRANTY.
Neither dealers nor the retail establishment selling this product has any authority to make any additional warranties or to promise remedies
in addition to or inconsistent with those stated above. Manufacturer's maximum liability, in any event, shall not exceed the purchase price of the
product paid by the original consumer.
NOTE: Some states do not allow an exclusion or limitation of incidental or consequential damages, so some of the above limitations or exclusions
may not apply to you. This limited warranty gives you specific legal rights as set foth herein. You may also have other rights which vary from state
to state. In the state of California only, if refinishing or replacement of the product is not commercially practicable, the retailer selling this product or
the Manufacturer will refund the purchase price paid for the product, less the amount directly attributable to use by the original consumer-purchaser
prior to discovery of the nonconformity. In addition, in the state of California only, you may take the product to the retail establishment selling this
product in order to obtain performance under this limited warranty.
If you wish to obtain performance of any obligation under this limited warranty, you should
write to:
Consumer Relations
P. O. Box 1240
Columbus, GA 31902-1240
Consumer returns will not be accepted unless a valid Return Authorization is first acquired. Authorized returns are clearly marked on the outside of
the package with an RA number and the package is shipped freight/postage pre-paid. Consumer returns that do not meet these standards will be
refused.
15
PARTS LIST
Key Qty Description
A
1 CART LEG, UPPER LEFT, W/O TANK BRACE
B
1 SIDE BRACE F/ TANK RETAINER
C
1 MATCH HOLDER
D
2 TANK SUPPORT BRACKET
E
1 LEG (WHEEL), LEFT, BACK, STRAIGHT
F
1 LOWER LEG, CART, REAR, W/LEG EXTENDER
G
1 CART LEG, UPPER RIGHT, W/O TANK BRACE
H
1 LOWER LEG, CART, FRONT, W/ LEG EXTENDER
I
1 LEG (WHEEL), LEFT, FRONT, CURVED
J
2 EXTENDER, LEG
K
1 FRONT PANEL, LOWER
L
1 FRONT PANEL, UPPER
M
2 BACK BRACE
N
2 WHEEL
O
1 AXLE ROD
P
1 CONTROL PANEL, MAIN
Q
1 HOSE/VALVE/REGULATOR ASSY
R
1 GENERATOR, SPARK IGNITOR
S
2 CONTROL KNOB
T
2 TANK EXCLUSION WIRE
U
1 TANK RETAINER BRACKET
V
1 BURNER
W
1 ELECTRODE/COLLECTOR BOX
X
1 FIREBOX BOWL
Y
1 HEAT SHIELD, TANK
Z
1 SIDEBURNER SHELF
AA
2 MOUNTING BRACKET, RF/ LB
BB
2 MOUNTING BRACKET, LF/ RB
CC
1 SIDEBURNER DRIP PAN
DD
1 SIDEBURNER
EE
1 ELECTRODE F/ SIDEBURNER
FF
1 CONTROL KNOB, F/ SIDEBURNER
GG 1 CLIP F/ SIDEBURNER
HH
1 SIDEBURNER GRATE
II
1 SIDE SHELF
JJ
2 LOWER HINGE KIT
KK
1 GRILL LID
LL
1 LOGO PLATE
MM 1 HANDLE, F/ LID
Key Qty Description
NN
2 UPPER HINGE KIT
OO 1 HEAT TENT, VAPORIZER BAR
PP
1 COOKING GRATE
QQ 1 SWING AWAY
RR
1 CLIP, F/ GREASE CUP
SS
1 GREASE CUP
NOT Pictured
...
1 HARDWARE PACK
...
1 ASSEMBLY MANUAL, ENGLISH
...
1 ASSEMBLY MANUAL, SPANISH
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.
16
PARTS DIAGRAM
KK
LL
QQ
NN
PP
MM
OO
CC
HH
V
JJ
W
SS
FF
Z
II
JJ
X
RR
AA
A
G
B
DD
GG
EE
BB
R
U
S
Y
P
Q
BB
C
M
T
AA
L
E
I
F
H
D
K
J
N
O
J
D
N
17
ASSEMBLY
1
Left leg
Place upper left leg as shown. In front, attach upper left leg, side brace and left front leg (curve) with #10-24x1-1/4" screw
and #10-24 flange nut. Tighten screws. In back, attach upper left leg, side brace and left rear leg (straight) with #1024x1-1/4" screw and #10-24 flange nut. Do not tighten.
NOTE: Lower left leg assembly has notches on tank support
Upper Left Leg
Side Brace
Left Rear Leg
(Straight)
#10-24x1-1/4”
Machine Screw
Qty.2
Left Front Leg
(Curve)
Support Bracket
#10-24
Flange Nut
Qty. 2
2
Right Leg
Place upper right leg as shown. Attach upper right leg and right front leg (curve) with #10-24x1-1/4" screw and #10-24
flange nut. Tighten screws. Then attach upper right leg and right rear leg (straight) with #10-24x1-1/4" screw and #1024 flange nut . Do not tighten.
Upper Right Leg
Right Rear Leg
(Straight)
#10-24x1-1/4”
Machine Screw
Qty.2
Right Front Leg
(Curve)
Support Bracket
#10-24
Flange Nut
Qty. 2
Leg Extender
18
3
Front Panel
Lay front legs down on the floor
Fit upper front panel and lower front panel between legs. Attach with #10-24x2 machine screws” and #10-24 flange nuts.
Left Leg
Right Leg
#10-24
Flange Nut
Qty. 8
Upper
Front Panel
#10-24x2”
Machine Screw
Qty.8
Lower Front Panel
4
Back Braces to Cart
Remove previously attached screws and nuts from upper legs as shown. Attach back braces with #10-24x1-1/4" screws
and #10-24 flange nuts.
Wheels
Turn assembly upside down.
Insert axle rod into wheel, legs and other wheel. Secure with wheel bushing and hitch pin.
Axle Rod
Wheel
Back Brace
Wheel
#10-24x1-1/4”
Machine Screw
Qty.6
Hitch Pin
Hitch Pin
Qty.1
Wheel Bushing
Back Brace
#10-24
Flange Nut
Qty. 6
“Cone” side of wheel against leg
NOTE:
Wheel Bushing
Qty.1
Remove previously installed
screws and nuts to attach
upper back brace
19
5
Control Panel
Stand cart upright.
In front, fit control panel between left and right legs, attach control panel with #10-24X2’’ machine screws and #10-24 flange
nuts.
Control Panel
#10-24
Flange Nut
Qty. 4
f cart
o
Back
#10-24x2”
Machine Screw
Qty.4
6
Valve/Hose/Regulator and Ignitor
Attach valve/hose/regulator assembly to control panel with #10-24x1/2’’ machine screws.
Attach ignitor to control panel using the stamped nut that’s provided. NOTE: if your grill comes with Snap-in ignitor, please
see Option.
Snap-in ignitor
Option: Snap the
ignitor into the
control panel
Ignitor
Valve/Hose/Regulator
Stamped nut
#10-24X1/2”
Machine Screw
Qty.2
20
Main burner
valve
7
Tank Exclusion Wire
Hook tank exclusion wires onto front panel brackets, secure other end to back brace using #8-32X3/8’’ Sheet metal screws.
Tank Exclusion Wire
#8-32X3/8’’
Sheet Metal Screw
Qty.2
8
Heat Shield
Attach heat shield with #10-24x1/2’’ machine screws and #10-24 flange nuts.
Tank Retainer
Insert tank retainer through side brace and secure with #10-24x3/8’’ Wing nut.
Heat Shield
#10-24
Flange Nut
Qty. 2
#10-24X1/2”
Machine Screw
Qty.2
#10-24x3/8’’
Wing Screw
Qty.1
Tank Retainer
21
9
Burner ,Firebox and Control Knob
Place burner assembly into firebox. Fasten the burner assembly to the firebox using 5x15 fiber washers and #10-24x1/2’’
machine screws. Insert #10-24x1-1/4’’ machine screws from outside firebox, then fasten with #10-24 flange nuts and 5x15
fiber washers from the inside( A ).
Place firebox on cart. Make sure burner tubes are correctly engaged with valves. If burner is not level from left to right,
adjust the two screws attaching valve to control panel. Attach ignitor wire to ignitor( B ).
Attach firebox with #10-24x2’’ machine screws, 5x15 Fiber washers and #10-24 flange nuts( C) .
Push control knobs onto valve stems ( C ).
Burner Assembly
A
Firebox
#10-24
Flange Nut
#10-24X1/2”
Machine Screw
Qty.2
#10-24x1-1/4"
Machine Screw
Qty.4
9
#10-24x1-1/4’’
Machine Screw
5x15
Fiber Washer
5x15
Fiber Washer
#10-24x1/2’’
Machine Screw
#10-24
Flange Nut
Qty. 8
5x15
Fiber Washer
Qty.10
B
#10-24x2’’ Machine Screw
5x15 Fiber Washer
#10-24x2”
Machine Screw
Qty.4
Heat Shield
For Tank
C
Valve
Venturi tube
Ignitor wire
Make sure the Venturi tubes are located
underneath Heat Shield
Control Knob
#10-24
Flange Nut
22
10 Sideburner
Attach mounting brackets to sideburner shelf support with #8-32-3/8’’ sheet metal screws and 4x12 flat washers (A).
Attach mounting brackets to front of leg with 1/4’’-20x1/2’’ machine screws. Back of leg with 1/4’’-20x1-1/4’’ machine
screws and 1/4’’-20 flange nuts (B).
Attach sideburner valve to mount cup with #8-32X3/8'' machine screws . Place sideburner into side burner drip pan. Make
sure sideburner valve is inside sideburner tube. Fasten sideburner with 5x9 fiber washer and #8-32 wing nut .
Hook burner clip to sideburner tube and around manifold (D). Attach sideburner ignitor wire.
Place sideburner grate onto sideburner shelf. Push sideburner knob onto sideburner valve stem (E).
#8-32X3/8’’
Sheet Metal Screw
4x12
Flat Washer
A
Sideburner
Shelf Support
1/4’’-20x1-1/4"
Machine Screw
Qty.2
#8-32
Wing Nut
Qty.1
1/4’’-20x1/2”
Machine Screw
Qty.2
#8-32X3/8’’
#8-32X3/8''
Machine Screw Sheet Metal Screw
Qty.4
Qty.2
1/4’’-20
Flange Nut
Qty. 2
5x9
Fiber Washer
Qty.1
4x12
Flat Washer
Qty.4
Sideburner Clip
Qty.1
Sideburner
Mounting Bracket
B
C
#8-32X3/8''
Machine Screw
1/4’’-20x1-1/4’’
Machine Screw
1/4’’-20
Flange Nut
5x9 Fiber
Washer
1/4’’-20x1/2’
Machine Screw
Mount Cup
#8-32 Wing Nut
D
Sideburner Grate
Sideburner Knob
E
Sideburner ignitor wire
Sideburner Clip
23
Side Shelf
11 LeftAttach
mounting brackets to left side shelf with #8-32-3/8’’ sheet metal screws and 4x12 flat washers.
Attach mounting brackets to front of leg with 1/4’’-20x1/2’’ machine screws. Back of leg with 1/4’’-20x1-1/4’’ machine
screws and 1/4’’-20 flange nuts.
#8-32X3/8’’
Sheet Metal Screw
4x12 Flat Washer
#8-32X3/8’’
Sheet Metal Screw
Qty.4
4x12
Flat Washer
Qty.4
Mounting Bracket
Left Side Shelf
1/4’’-20x1-1/4"
Machine Screw
Qty.2
24
1/4’’-20x1/2”
Machine Screw
Qty.2
1/4’’-20
Flange Nut
Qty. 2
12
Lower Hinges
Attach lower hinges to back of firebox using #10-24x1/2’’ machine screws, 5x15 fiber washer and #10-24 flange nuts. The
center flat portion of the hinge should be at the bottom (see insert).
#10-24X1/2”
Machine Screw
Qty.4
#10-24
Flange Nut
Qty. 4
5x15
Fiber Washer
Qty.8
Center flat portion
of hinge on bottom
13
Lid Handle and Upper Hinges
Attach handle to lid with 7x15 fiber washers and 1/4’’-20 wing nut (A).
Attach upper hinges to back of lid using #10-24x1/2’’ machine screws, 5x15 fiber washers and #10-24 flange nuts. Hinge
should curve downward when properly installed (B).
1/4’’-20
Wing nut
Qty.2
7x15
Fiber Washer
Qty.4
#10-24X1/2”
Machine Screw
Qty.4
5x15
Fiber Washer
Qty.8
#10-24
Flange Nut
Qty. 4
B
A
25
Place lid assembly onto firebox, aligning hinges. Hinges on lid fit inside hinges on firebox. Secure using two hinge pins and
14 hitch
pins.
Hitch Pin
Qty.2
Hinge Pin
Qty.2
15
Place heat tent inside firebox onto support screws.
Place cooking grate onto firebox.
Cooking Grate
Heat Tent
26
16
Insert ends of Swing Away pivot wire into holes in sides of grill lid. Insert ends of Swing Away 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, swing away is installed upside-down.
Swing Away
17
Hang grease cup clip from bottom of firebox and place grease cup into grease clip.
CAUTION
Failure to install grease cup clip
and cup will cause hot grease to
drip from bottom of grill with risk
of fire or property damage.
Grease Cup Clip
Grease Cup
27
18
Tank collar opening must face to front of grill. Loosen wing nuts from tank retainer bracket. Set bottom of tank into notches of
tank bracket. Place tank retainer bracket onto tank collar and tighten wing nuts.
LP CYLINDER IS SOLD SEPARATELY. Fill and leak check the cylinder before attaching to grill and regulator (see Use &
Care section). Once cylinder has been filled and leak checked, place cylinder into notches in tank support bracket.Make sure
cylinder valve is facing front of grill. See Use & Care section of this manual to perform the “Burner Flame
Check” and for important safety instructions before using.
Regulator
LP Tank
LP Cylinder
( not included)
Correctly Installed
LP cylinder
CAUTION
Cylinder valve must face to front of cart once
tank is attached. Failure to install cylinder
correctly may allow gas hose to be damaged
in operation, resulting in the risk of fire.
Always keep LP cylinders in
upright position during use,
transport, and storage.
28
EMERGENCIES: If a gas leak cannot be stopped, or a fire occurs due to gas leakage, call the fire department.
Emergencies
Possible Cause
Prevention/Solution
Gas leaking from
cracked/cut/burned
hose.
•Damaged hose.
•Turn off gas at LP cylinder or at source on natural gas systems. If
anything but burned, replace valve/hose/regulator. If burned,
discontinue use of product until a plumber has investigated cause
and corrections are made.
Gas leaking from LP
cylinder.
•Mechanical failure due to rusting or
mishandling.
•Replace LP cylinder.
Gas leaking from LP
cylinder valve.
• Failure of cylinder valve from
mishandling or mechanical failure.
• Turn off LP cylinder valve. Return LP cylinder to gas supplier.
Gas leaking between
LP cylinder and
regulator connection.
•Improper installation, connection not
tight, failure of rubber seal.
•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.
Fire coming through
control panel.
• Fire in burner tube section of burner due
to blockage.
•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. See Natural Hazard
and Cleaning the Burner Assembly pages.
Grease fire or
continuous excessive
flames above cooking
surface.
• Too much grease buildup in burner area.
• 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 cup, and other
surfaces.
Possible Cause
Prevention/Solution
GAS ISSUES:
• Trying to light wrong burner.
• See instructions on control panel and in Use and Care section.
• Burner not engaged with control valve.
• Make sure valves are positioned inside of burner tubes.
• Obstruction in burner.
• Ensure burner tubes are not obstructed with spider webs or other
matter. See cleaning section of Use and Care.
• No gas flow.
• Make sure LP cylinder is not empty. If LP cylinder is not empty,
refer to “Sudden drop in gas flow.”
• Vapor lock at coupling nut to LP cylinder.
• Turn off knobs and disconnect coupling nut from LP cylinder.
Reconnect and retry.
• Coupling nut and LP cylinder valve not
fully connected.
• Turn the coupling nut approximately one-half to three-quarters
additional turn until solid stop. Tighten by hand only - do not use
tools.
Troubleshooting
Problem
Burner(s) will not light
using ignitor.
Continued on next
page.
ELECTRICAL ISSUES:
•Electrode cracked or broken; “sparks at
crack.”
• Replace electrode(s).
•Electrode tip not in proper position.
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.
Sideburner (if featured):
• Tip of electrode should be pointing toward gas port opening on
burner. the distance should be 1/8” to 3/16”. Adjust if necessary.
•Wire and/or electrode covered with
cooking residue.
•Clean wire and/or electrode with rubbing alcohol and clean swab.
•Wires are loose or disconnected.
•Reconnect wires or replace electrode/wire assembly.
•Wires are shorting (sparking) between
ignitor and electrode.
•Replace ignitor wire/electrode assembly.
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Troubleshooting (continued)
Problem
Possible Cause
Prevention/Solution
Burner(s) will not light
using ignitor.
PIEZO PUSH-BUTTON AND ROTARY:
•Push-button sticks at bottom.
•Replace ignitor.
•Rotary knob rotates without clicking.
•Replace knob.
•Sparking between ignitor and electrode.
•Inspect wire insulation and proper connection. Replace wires if
insulation is broken.
Burner(s) will not
match light.
•See “GAS ISSUES:” on previous page.
•Match will not reach.
•Use long-stem match (fireplace match).
•Improper method of match-lighting.
•See “Match-Lighting” section of Use and Care.
•Out of gas.
•Check for gas in LP cylinder.
•Excess flow valve tripped.
•Turn off control and tank knobs, wait 30 seconds, turn tank knob on
slowly, light grill. If flames are still low, turn off control and tank
knobs and disconnect regulator. Reconnect regulator, turn tank knob
on slowly, light grill.
•Vapor lock at coupling nut/LP cylinder
connection.
•Turn off control and tank knobs and disconnect regulator. Reconnect
regulator, turn on tank knob slowly, light grill.
•High or gusting winds.
•Turn front of grill to face wind or increase flame height.
•Low on LP gas.
•Refill LP cylinder.
•Excess flow valve tripped.
•Refer to “Sudden drop in gas flow” above.
•Grease buildup.
•Clean burners and inside of grill/firebox.
•Excessive fat in meat.
•Trim fat from meat before grilling.
•Excessive cooking temperature.
•Adjust (lower) temperature accordingly.
Persistent grease fire.
•Grease trapped by food buildup around
burner system.
•Turn knobs to OFF. Turn gas off at LP cylinder. Leave lid in position
and let fire burn out. After grill cools, remove and clean all parts.
Flashback...
(fire in burner tube(s)).
•Burner and/or burner tubes are blocked.
•Turn knobs to OFF. Clean burner and/or burner tubes. See burner
cleaning section of Use and Care.
Unable to fill LP
Cylinder.
•Some dealers have older fill nozzles
with worn threads.
•The worn nozzles don’t have enough “bite” to engage the valve. Try
a second LP dealer.
One burner does not
light from other
burner(s).
• Grease buildup or food particles in
end(s) of carryover tube(s).
• Clean carry-over tube(s) with wire brush.
Low flame, drop in gas
flow.
Flames blow out.
Flare-up.
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