Kenmore PG-A4030400LD-MO 3-Burner Outdoor BBQ Grill User Guide

Liquid Propane Gas Grill
Model : PG-40409S0LB

PG-A4030400LD-MO 3-Burner Outdoor BBQ Grill

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

Please Contact Permasteel Customer Service
For Help & Parts
If you have any questions or need assistance during assembly, please call 1-888-287-0735. M-F 8:00AM – 5:00PM PST. You will be speaking to a Representative of thegrill manufacturer. Or visit us at Kenmoregrill.com

Product Record
IMPORTANT: Fill out the product record information below.

Model Number __
Serial Number _ __
See rating label on grill for serial number.
Date Purchased __

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

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 may result in a safety hazard and will void the warranty for this grill.

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 a 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.

WARNING
Combustion by products produced when using this product include carbon monoxide, a chemical  nown to the State of California to cause birth  defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov

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. Note: Consumer is responsible for Shipping & Handling of all warranty replacement parts.
FOR ONE YEAR: from the date of sale this grill is warranted against defects in material or workmanship, consumer will receive free replacement parts with proof of purchase, consumer is responsible for Shipping & Handling cost.
FOR FIVE YEARS: from the date of sale, any stainless-steel burner that rusts through or burns through will be replaced, proof of purchase must be provided, consumer is responsible for Shipping & Handling cost.
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 or normal use, accident or improper maintenance.
All warranty coverage is void if this appliance is ever used for other than private household purposes.
For warranty coverage details to obtain replacement parts, visit the web page: Kenmoregrill.com

This warranty covers ONLY defects in material and workmanship, and will NOT pay for:

1. Service calls to correct appliance installation, or to repair problems with house fuses, circuit breakers, house wiring, and plumbing or gas supply systems resulting from such installation.
2.  Service to an appliance if the model and serial plate is missing, altered, or cannot easily be determined to have the appropriate certification logo.
3.  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.
4. A service technician to clean or maintain this appliance, or to instruct the user in correct appliance installation, operation and maintenance.
5. Damage to or failure of this appliance resulting from installation, including installation that was not in accord with electrical, gas or plumbing codes.
6. 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.
7.  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.
8. 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.
9.  Damage to or failure of this appliance resulting from natural or other catastrophe, such as flood, fire or storm.
10. Damage to or failure of parts or systems resulting from unauthorized modifications made to this appliance.

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 gives you specific legal rights, and you may also have other rights which may vary from state to state.
Product distributed by Permasteel, 100 Exchange Place, Pomona, CA 91768. Made in China.

USE AND CARE

DANGER

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

• Never fill a tank 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 tank 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 tank and appliance and call your fire department.

LP Tank Removal, Transport and Storage

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

• 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 Tank

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

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

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

• LP tank 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. Only use the LP tanks equipped with this type of valve.

• The LP tank must be arranged for vapor withdrawal and include collar to protect LP tank valve. Always keep the LP tanks in an upright position during use, transit or storage.

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 Tank Filling

• Use only licensed and experienced dealers.
• LP dealer must purge new tank before filling.
• Dealer should NEVER fill the LP tank more than 80% of LP tank volume. Volume of propane in tank will vary by temperature.
• A frosty regulator indicates gas overfill. Immediately close the LP tank valve and call your local LP gas dealer for assistance.
• Do not release the liquid propane (LP) gas into the atmosphere. This is a hazardous practice.
• To remove gas from the LP tank, contact a LP dealer or call a local fire department for assistance. Check the telephone directory under “Gas Companies” for your nearest certified LP dealers.

LP Tank Exchange

• Many propane retailers offer the option of replacing your empty LP tank through an exchange service. Only use reputable exchange companies that inspect, precision fill, test and certify their tanks. Exchange your tank only for an OPD safety feature-equipped tank as described in the “LP Tank” section of this manual.
• Always keep your new and exchanged LP tanks in the upright position during use, transportation or storage.
• Leak test new and exchanged LP tanks BEFORE connecting to the grill.

LP Tank Leak Test For your safety:

• Leak test must be repeated each time a LP tank is exchanged or refilled.
• Do not smoke during a leak test.
• Do not use an open flame to check for gas leaks.
• The grill must be leak tested outdoors in a wellventilated area, away from ignition sources such as gas or electrical appliances. During the leak test, keep the 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 a LP gas supplier or your fire department!
Do not use household cleaning agents. Using Cleaning agents can result in damage to the gas train components (valve/hose/regulator).

Connecting Regulator to the LP Tank

1. The LP tank must be properly secured onto the grill. (Refer to assembly section.)

2. Turn all control knobs to the OFF position.

3. Turn the LP tank OFF by turning the OPD hand wheel clockwise to a full stop.

4. Remove the protective cap from the LP tank valve. Always use cap and strap supplied with the valve.
   Do not insert a POL transport plug (plastic part with external threads) into the type 1 valve outlet. It will remove the Safety relief valve feature.

5. Hold the regulator and insert the nipple into LP tank valve. Hand- tighten the coupling nut, holding the regulator in a straight line with the LP tank valve so as not to cross-thread the connection.
   
   

6. Turn the coupling nut clockwise until it is fully tightened.
   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 the regulator and repeat steps 5 and 6. If you are still unable to complete the connection, do not use this regulator!
• Call for replacement parts at 1-888-287-0735.

DANGER

• Do not insert any tools or foreign objects into the valve outlet or safety relief valve. You may damage the valve and cause a leak. Leaking propane may result in an 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 a selfcontained LP gas system of a camper trailer or motor home.
• Do not use the grill until a leak test is performed.
• If a leak is detected at any time, STOP and call the fire department.
• If you cannot stop a gas leak, immediately close the LP tank valve and call a LP gas supplier or your fire department!

Leak Testing Valves, Hose and Regulator

1. Turn all grill control knobs to OFF.

2. Be sure regulator is tightly connected to the LP tank.

3. Completely open the LP tank valve by turning the OPD hand wheel counterclockwise. If you hear a rushing sound, turn the gas off immediately. There is a major leak at the connection. Correct before proceeding. Call for replacement parts at 1-888-287-0735.

4. Brush soapy solution onto areas where bubbles are.
   

5. If “growing” bubbles appear, there is a leak. Close the LP tank valve immediately and retighten connections. If leaks cannot be stopped do not try to repair. Call for replacement parts at 1-888-287-0735.

6. Always close the LP tank valve after performing the 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 the grill.

• Keep the grill area clear and free from materials thatburn.

• Do not block the holes on the insides and back of the grill.

•  Use the grill only in well-ventilated space. NEVER use the grill in an enclosed space such as a carport, garage, porch, covered patio, or under an overhead structure of any kind.

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

• Use the 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 the lid closed.
  A buildup of non-ignited gas inside a closed grill is hazardous.

• Never operate the grill with a LP tank out of position specified in the assembly instructions.

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

Safety Tips

Before opening the LP tank valve, check the coupling nut for tightness.
When the grill is not in use, turn off all control knobs and LP tank valve.
Never move the grill while in operation or still hot.
Use long-handled barbecue utensils and oven mitts to avoid burns and splatters.
The maximum load for the side burner and side shelf is 10 lbs.
The drip tray must be inserted into the grill and emptied after each use. Do not remove the drip tray until the grill has completely cooled.
Clean the 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 the cooking surfaces prior to grilling. It is not recommended to clean cooking surfaces while the grill is hot.
If you notice grease or other material dripping from the grill; determine the cause correct it, then clean and inspect the valve. Keep ventilation openings and tank 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 the grill.
If you have a grill problem, see the “Troubleshooting Section”.
If the regulator frosts, turn off the grill and LP tank valve immediately. This indicates a problem with the tank, 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 tank off.

• Do not leave the grill unattended while preheating or burning off food residue on HI. If the grill has not been regularly cleaned, a drip fire can occur that may damage the product.

Electronic Ignition Lighting Instructions
▲ Do not lean over the grill while lighting.

1. Open the lid during lighting.
2.  Turn ON the gas valve on the tank.
3.  To ignite, turn the Ignition Burner knob to HI.
4.  Push and hold the 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 the Ignition Burner is lit, turn a control knob that is adjacent to a lit burner to HI. Ignite the far left burner last.
7. Once burners are lit, adjust the knobs to the desired flame setting. To extinguish an individual burner, turn its knob to OFF.
8. To ignite the Searing Burner, follow steps 3-5 using the Searing Burner knob.

If the igniter does not work, follow the Match Lighting instructions on page 9.

WARNING
Turn your controls, gas source or tankOFF when not in use.
CAUTION
If ignition does NOT occur in 5 seconds, turn the burner controls OFF, wait 5 minutes and repeat the lighting procedure. If the burner does not ignite with the valve open, gas will continue to flow out of the burner and could accidently ignite with risk of injury.
Match Lighting Instructions
▲ Do not lean over the grill while lighting.

1. Open the lid during lighting.
2.  Place the match into the match holder (hanging on the left of the side panel).
3.  Light the match and insert the match holder through the lighting hole in the left side of the firebox. Align the lit match with the first burner on the left.
4. Turn the knob of the first left burner to HI position. Be sure the burner lights and stays lit. Withdraw the match holder from the firebox and extinguish the match
5. To light the other burners, turn each knob in succession to HI.
6. Once the burners are lit, adjust the knobs to the desired flame setting. To extinguish any individual burner, turn its knob to OFF.

Searing Burner Match Lighting

1. Open the searing burner lid. Turn on the LP tank.
2. Place the lit match near the burner.
3. Turn the searing burner knob to HI. Be sure the burner lights and stays lit.

Burner Flame Check

• Remove the cooking grates and heat diffusers. Light the burners and rotate the knobs from HIGH to LOW. You should see a smaller flame on the LOW setting and a higher flame on the HI setting. Always check the flame prior to each use. If only low flame is seen, refer to the “Sudden drop or low flame” in the Troubleshooting Section on page 30.

Turning Grill Off

• Turn all knobs to the OFF position. Turn the LP tank off. When you are finished grilling, raise the grill lid to allow the grill to fully cool. If the grill lid is closed while the grill is cooling, condensation may occur on the interior grill surfaces which can cause the interior parts to rust.

Igniter Check

• Turn the LP tank off. Press and hold the electronic igniter button. “Click” should be heard and sparks should be seen each time between the collector box or burner and electrode. See the Troubleshooting Section on pages 29-31 if there are no clicks or sparks.

Valve Check

• Important: Be sure the gas in the LP tank is turned off before checking the valve and the knobs are in the Off Setting. To check the valves, first push in the knobs and release. The knobs should spring back. If the knobs do not spring back, replace the valve assembly before using the grill. Turn the knobs to the LOW position then turn back to the OFF position. Valves should turn smoothly.

Hose Check

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

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

General Grill Cleaning

• Do not mistake brown or black accumulation of grease and smoke for paint. Interiors of the 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 a scrub brush to clean the inside of the grill. Rinse and allow the grill to completely dry. Do not apply a caustic grill/oven cleaner to the painted surfaces.
•  Porcelain surfaces: Because of the glass-like composition, most residue can be wiped away with baking soda/water solution or a specially formulated cleaner. Use a nonabrasive scouring powder for stubborn stains.
• Painted surfaces: Wash with a mild detergent or nonabrasive cleaner and warm soapy water. Wipe dry with a soft nonabrasive cloth.
• Stainless steel surfaces: To maintain your grill’s highquality appearance, wash with a mild detergent and warm soapy water. Then wipe dry with a soft cloth. 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 the 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 the cooking surfaces prior to grilling. It is not recommended to clean the cooking surfaces while the grill is hot.
• Drip Tray and Cup: When the grill has completely cooled down after use, remove the drip tray and drip cup for cleaning.

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.
Storing Your Grill

• Clean the cooking grates.
• Store in dry location.
• When the LP tank is connected to the grill, store outdoors in a well-ventilated space and out of reach from children.
• Cover the grill if stored outdoors. Choose from a variety of grill covers offered by the manufacturer. Available at Kenmoregrill.com.
•  Store the grill indoors ONLY if the LP tank is turned off and disconnected. Remove the LP tank from the grill and store the cylinder outdoors.
• When removing the grill from storage, follow the “Cleaning the Burner Assembly” instructions before starting the grill.

Cleaning the Burner Assembly
Follow these instructions to clean and/or replace parts of the burner assembly or if you have trouble igniting the grill.

1. Turn the gas OFF by turning the control knobs to the off setting and close the valve of the LP tank.
2. Remove the cooking grates and heat diffusers.
3. Remove the attachment cotter pin from the rear of each burner. See Fig A on page 11.
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 lightweight 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) and 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 of each hole.

5. Use a wire brush to scrub the entire outer surface of the burner to remove food residue and dirt.

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

7.  Check the burner for damage. Due to normal wear and corrosion, some holes may become enlarged. If there are any large cracks or holes found on the burner, please replace them.
   VERY IMPORTANT : Burner tubes must re-engage the valve openings. See illustrations below.

8. Carefully replace the burners. See Fig. A and B on page 11.

9. Attach the rear of each burner to the bracket and reconnect the cotter pin. See Fig. A on page 11.

10.  Replace the heat diffusers and cooking grates.

Indirect Cooking
Poultry and large cuts of meat cook slowly to perfection on the grill by indirect heat. Place food over the unlit burner(s); the heat from the lit burners circulates gently throughout the grill, cooking the 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.

Indirect Cooking Instructions

• Always cook with the lid closed.

• Once the burners are lit, extinguish any individual burner by turning its knob to OFF.

• 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 heat.

• Place food over unlit burner(s).

2 Burner Cooking
Great indirect cooking on low. Produces slow and 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-toeat 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 the food to check for visual signs of doneness.
• Whole poultry should reach 180° F; breasts, 170° F. Juices should run clear, and the 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.

SDA *Recommended Safe Minimum Internal Temperatures

Beef, Veal, Lamb, and Pork: Whole Cuts**| 145°F
Fish| 145°F
Beef, Veal, Lamb, and Pork: Ground| 160°F
Egg Dishes| 160°F
Turkey, Chicken, and Duck: Whole, Pieces, and Ground| 165°F

• United States Department of Agriculture
  ** Allow meat to rest for three minutes before carving or consuming.

PARTS LIST (1/2)

Li

| 1| 40900221| 19| Control Knob Bezel| 5| 40920036
3| Side Burner Grid| 1| 40900222| 20| Control Knob, Main Burner| 4| 40900206
4| Searing Burner| 1| 40900142| 21| Control Knob, Searing Burner (Copper Chrome)| 1| 40900224
5| Searing Burner Wire| 1| 40900220| 22| Bottom Shelf| 1| 40900137
6| Searing Burner Base| 1| 40900114| 23| Standard Caster| 1| 40900214
7| Drip Box, Searing Burner| 1| 40900116| 24| Swivel Caster| 1| 40900213
8| Right Side Shelf| 1| 40900145| 25| Swivel Caster With Brake| 2| 40900212
9| Fascia, Right Side Shelf| 1| 40920046| 26| Door Magnet Box| 1| 40200072
10| Side Shelf Support Angle Bar| 2| 40900109| 27| Door Magnet| 4| 40200094
11| Electronic Ignition Module (Black)| 1| 40820122| 28| Hole Bushing| 1| 40400005
12| Control Panel| 1| 40900032| 29| Right Side Panel| 1| 40900121
13| Gas Valve, Main Burner| 4| 40900205| 30| Tank Baffle| 1| 40200070
14| Side Burner Hose| 1| 40900216| 31| Tank Holder| 1| 40800130
15| Gas Valve, Searing Burner| 1| 40900219| 32| Right Door (Black)| 1| 40900132B
16| Manifold, Searing Burner| 1| 40200045| 33| Door Handle (Copper Chrome)| 2| 40900076
17| Manifold, Main Burner| 1| 40800037| 34| Left Door (Black)| 1| 40900127B

Not Pictured

https://www.kenmoregrill.com

If you are missing hardware or have damaged parts after unpacking grill, call 1-888-287-0735 for replacement.
To order replacement parts after using grill, call 1-888-287-0735.
Or visit Kenmoregrill.com

NOTE: Some grill parts shown in the assembly steps may differ slightly in appearance from those on your particular grill. However, the method of assembly remains the same.

PARTS LIST (2/2)

50300205
37| Left Side Panel| 1| 40900119| 53| Temperature Gauge| 1| 40900218
38| Back Panel| 1| 40900056| 54| Logo| 1| 40800106
39| Match Holder| 1| 40800128| 55| Rotate Rod, Lid| 2| 50300207
40| Match Holder Bracket| 1| 40800129| 56| Insulation Spacer, Lid| 2| 40700022
41| Lighting Rod Chain| 1| 41100105| 57| Bezel, Lid Handle| 2| 40900013
42| Door Bracket| 1| 40900124| 58| Lid (Black)| 1| 40700004B
43| Right Door Bracket| 1| 40200126| 59| Lid Handle| 1| 40900012
44| Left Door Bracket| 1| 40200125| 60| Warming Rack| 1| 40900203
45| Back Rail| 1| 40900057| 61| Cooking Grate| 2| 40900204
46| Drip Cup| 1| 40800026| 62| Heat Diffuser| 4| 40800023
47| Drip Cup Clip| 1| 40800131| 63| Flame Carry Over Tube| 3| 40800022
48| Drip Tray| 1| 40900106| 64| Firebox| 1| 40900104
49| Fascia, Left Side Shelf| 1| 40900040| 65| Electrode, Main Burner| 1| 40900207
50| Left Side Shelf| 1| 40900143| 66| Main Burner| 4| 40900030

Not Pictured

https://www.kenmoregrill.com

If you are missing hardware or have damaged parts after unpacking grill, call 1-888-287-0735 for replacement.
To order replacement parts after using grill, call 1-888-287-0735.
Or visit Kenmoregrill.com

NOTE: Some grill parts shown in the assembly steps may differ slightly in appearance from those on your particular grill. However, the method of assembly remains the same.

PARTS DIAGRAM

BEFORE ASSEMBLY

NOTICE: Once you have unpacked the grill, check all grill parts against the pictures on page 15-1 7.
If any parts are missing or damaged, call 1-888-287-0735.

BEFORE ASSEMBLY

ASSEMBLY

CAREFULLY READ AND PERFORM ALL ASSEMBLY INSTUCTIONS ON THE FOLLOWING PAGES.
Tools Required:

• Adjustable wrench (not provided)
• Screwdriver (not provided)
• The following hardware is provided in the blister pack for convenient use.

1. Bottom Shelf
   • Turn the bottom shelf upside down. Attach the casters to the bottom shelf with (16) M6x13 screws.
   Note: Install each caster into the correct position as shown in the figure below. The standard caster (non-swiveling) will only install in one direction.
   • Turn the bottom shelf right side up. Attach the door magnets to the bottom shelf with (2) M4x10 screws.
   

2. Cart
   •  To attach the side panels, align the side panel holes with the leg holes on each side of the bottom shelf.
   Note: Left side panel has the match holder attachment.
   •  Attach the left and right side panels to the sides of the bottom shelf with (4) M6x13 screws. (A)
   • Attach the back panel to the bottom shelf and the two side panels with (6) M4x10 screws. (B)
   • Attach the tank baffle bar to the back panel and bottom shelf with (2) M4x10 screws. (C)
   • Align the door bracket holes with the holes on the side panels. Attach the door bracket to the side panels with (4) M4x10 screws. (D) Note: Attach the bracket so that magnets are on top.
   •  The tank baffle bar will be found underneath the left side shelf (40900143).
   • Align the holes in the cart support angle bars with the holes on the bottom shelf and the side panels.
   Attach the angle bars with (8) M4x10 screws. (E)
   

3. Front Door
   •  Remove the (4) M5x15 screws pre-assembled from the door handle ends, and use them to attach the handles to the doors. (A)
   • Insert the pin at the bottom of each door into the hole on the bottom panel. Insert the pin at the top of each door through the hole in the door bracket hinge. (B)
   IMPORTANT: If the doors do not line up when closed or do not close freely, the hinges may need to be adjusted. Loosen the hinge screws, adjust the hinge position as necessary, and retighten the screws.
   

4. Grill Head to Cart
   IMPORTANT: Remove the tie wraps and packing material from the regulator hose, searing burner valve and igniter wire. Pull the hose and igniter wire out to the right side of the grill head.
   • This step requires two people to lift and to position the grill head onto the cart.
   • Carefully lower the grill head onto the cart. Make sure the regulator hose and igniter wire are hanging outside the cart. Open the lid and attach the head to the cart with (4) M6x13 screws and M6 compression washers. (A & B)
   • Align the back rail holes with the holes on the side panels and the firebox. Attach the back rail with (4) M4x10 screws. (C)
   

5. Left Side Shelf
   • Attach the fascia to the left side shelf with (2) M5x10 screws and (2)M5 flat washers. (A)
   • Attach the shelf support angle bar to the side shelf and fascia with (4) M4x10 screws. (B)
   • Hang the left side shelf onto the brackets on left side of the firebox. (C)
   • Attach the shelf to the firebox as follows:
   • From the inside to the outside of the firebox with (2) M6x13 screws and (2) M6 compression washers. (D)
   • IMPORTANT: Be sure the side panel of the firebox and control panel are in alignment before placing the side shelf.
   • From the outside to the inside of the firebox with (2) M6x13 screws and (1) M4x10 screw. (E)
   

6. Right Side Shelf
   • Attach the fascia to the right side shelf with (2) M5x10 screws and (2)M5 flat washers. (A)
   • Attach the shelf support angle bar to the side shelf and the fascia with (4) M4x10 screws. (B)
   • Hang the right side shelf onto the brackets on the left side of the firebox. (C)
   • Attach the shelf to firebox as follows:
   • From the inside to the outside of the firebox with (2) M6x13 screws and (2) M6 compression washers. (D)
   • IMPORTANT: Be sure the side panel of the firebox and control panel are in alignment before placing the side shelf.
   • From the outside to the inside of the firebox with (2) M6x13 screws and (1) M4x10 screw. (E)
   

7. Searing Burner
   • Remove the plastic packaging from the searing burner valve. Remove the searing burner grate from the searing burner shelf.
   • Remove the 2 pre-installed screws from the valve control stem and set them aside. (A & B)
   • Loosen the searing burner to insert the gas valve. First, loosen and remove the screw attaching the electrode (C) to the shelf and set it aside, then loosen and remove the 2 screws holding the searing burner in place. (D)
   • Insert the gas valve into the searing burner. (E) Insert the valve control stem through the hole in the fascia. (F) Install the 2 previously removed valve control stem screws, but do not fully tighten until the bezel has been attached to the fascia.
   • Reattach the searing burner to the shelf with the 2 previously removed screws. (G)
   Reattach the electrode to the shelf with the previously removed screw from the searing burner. (H)
   • Insert the bezel openings over the valve control stem and the 2 screws. (I) Slide the bezel down onto the screws. Make sure that the black mark on bezel is vertical.
   Tighten the 2 screws to secure the bezel to the fascia. (J)
   • Push the control knob onto searing burner valve stem. (K)
   • Place back the searing burner grid. (L)
   • Connect both igniter wires to the igniter module on the left side of the searing burner shelf fascia.
   To connect, push the igniter wire tips into the slots on the pins in igniter module. (M)
   • Slide the searing burner drip box into the drip box bracket. (N)
   • Unscrew the igniter cap from the control panel. Insert (1) AA battery (provided in the blister pack) into the battery slot with the positive end (+) facing outward. Screw the igniter cap back onto the fascia. (O)
   
   

8. Heat Diffuser, Cooking Grates and Warming Rack
   •  Place the heat diffusers over the burners. Diffusers will fit in the firebox in either direction. Fit the tabs in the firebox’s front end through the slots in the diffuser’s tips. Fit the diffuser’s tips in between the tabs in the firebox’s rear end. (A & B)
   • Place the cooking grates onto the grate rests at the front and rear of the firebox. (C)
   • Insert the warming rack into the brackets at the top of the firebox with the upcurved edge in the front as shown. (D)
   

9. Drip Tray, Drip Cup and LP Tank
   • Slide the drip tray into the bottom of the firebox from the back. (A)
   • Hang the drip cup clip from the bottom of the drip tray. Make sure the drip drainage hole is on the right side, as seen from the back of the grill. Place the drip cup into the drip cup clip. (B)
   • Feed the regulator hose through the hole in the right side panel. (C)
   • Place the LP tank into the hole on the bottom shelf with the tank collar opening facing to the right as shown. Raise the tank holder to hold the LP tank securely in place. (C)
   • When the grill is in the desired location, lock the caster brakes; this will help the grill stay in place for safe operation. (D)

CAUTION
Failure to install the drip cup and the drip cup clip will cause hot fall into the bottomof the grill with a risk of fire and property damage.
CAUTION
Failure to install the tank correctly may allow the gas hose to be damaged during operation.
EMERGENCIES: If a gas leak cannot be stopped, or a fire occurs due to gas leakage, call the fire department.

gas from your LP tank or your natural gas system.
If the hose is cracked or cut but not burned, simply replace the valve / hose / regulator. If the hose is burned, the cause could be something other than a faulty valve/hose/regulator. Do not use of grill until a plumber or gas technician has investigated and corrected the problem.
Gas leaking from the LP tank.| • Mechanical failure due to rusting or mishandling.| • Replace the LP tank.
Gas leaking from the LP tank valve.| • Failure of the tank valve through mishandling or mechanical failure.| • Turn off the LP tank valve. Return the LP tank to the gas supplier.
Gas leaking between the LP tank and the regulator
connection.| • Improper installation, connection not being tight, or failure of the rubber seal.| • Turn off the LP tank valve. Remove the regulator from the tank and visually inspect the rubber seal for any damage. See the Leak test on page 7 for instructions on finding leaks in your regulator.
Fire coming through the control panel.| • Fire in the burner tube section due to blockage.| • Turn the control knobs and the LP tank valve off. Leave the lid open to allow the flames to die down. After the fire is out and the grill is cold, remove the burner and inspect for spider nests or rust. See the Spider Alert and Cleaning the Burner Assembly sections on page 10 of this Use & Care Guide.
Drip fire or continuous excessive flames above the cooking surface.| • Too much drip buildup in firebox or grease tray area.| • Turn the control knobs and LP tank valve off. Leave the lid open to allow the flames to die down. After the grill has cooled, clean any food particles and excess Drip from inside the firebox area, grease tray, and any other surface that may come into contact with food particles and excess Drip.
Problem| Possible Cause| P r e v e n ti o n / S o l uti o n
---|---|---

Burner(s) will not light using the igniter. (Also view the Electronic ignition Troubleshooting) Continued on next page.

| GAS ISSUES:
•       Trying to light the wrong burner.
•       Burner is not engaged with the control valve.
•       Obstruction in the burner.
•       No gas flow.
•       Coupling nut and LP tank valve not fully connected. ELECTRICAL ISSUES:
•       Electrode cracked or broken; sparks at crack.
•       Electrode tip is not in the proper position.
•       Wire and/or electrode covered with cooking residue.
•       Wires are loose or disconnected.
•       Wires are shorting (sparking) between igniter and electrode.
•       Dead battery.|

•       See instructions on the control panel and in the Use and Care section.
•       Make sure the valves are positioned inside of the burner tubes.
•     Ensure the burner tubes are not obstructed with spider webs or other matter. See the cleaning section on page 10 of the Use and Care.
•       Make sure the LP tank is not empty. If the LP tank is not empty, refer to the “Sudden drop in gas flow section on page 30”.
•       Turn off the knobs and disconnect the coupling nut from LP tank. Reconnect and retry.
•       Turn the coupling nut approximately one-half to three-quarters additional turn until solid stop. Tighten by hand only – do not use tools.
•       Replace the electrode(s). Main Burners:
•       Tips of the electrode should be pointing toward the gas port opening on the burner. The distance should be 1/8” to 1/4”. Adjust if necessary.

Side Burner:
•       Tip of the electrode should be pointing toward the gas port opening on the burner. The distance should be 1/8” to 3/16”. Adjust if necessary.
•       Clean the wire and/or electrode with rubbing alcohol with a clean swab.
•       Reconnect the wires or replace the electrode/wire assembly.
•       Replace with a new AA-size alkaline battery.

Troubleshooting (continued)

Burner(s) will not light using igniter.
(Also view the Electronic ignition Troubleshooting.)| ELECTRONIC IGNITION:
•     No spark, no ignition noise.
•     No spark, some ignition noise.
•     Sparks, but not at the electrode or at full strength.| •     See Section I of the Electronic Ignition System.
•     See Section II of the Electronic Ignition System.
•     See Section III of the Electronic Ignition System.
Burner(s) will not light with match.| •     See “GAS ISSUES :” on the previous page.
•     Match will not reach.
•     Improper method of match- lighting.| •     Use a long-stem match (fireplace match).
•     See “Match-Lighting” section on page 9 of the Use and Care.
Sudden drop in gas flow or low flame.| •     Out of gas.
•     Excess flow valve tripped.
•     Vapor lock at the coupling nut/LP tank connection.| •     Check for gas in the LP tank.
•     Turn off the knobs, wait 30 seconds and light the grill. If the flames are still low, turn off the knobs and LP tank valve. Disconnect the regulator. Reconnect the regulator and perform a leak-test. Turn on the LP tank valve, wait 30 seconds and then light the grill.
•     Turn off the knobs and the LP tank valve. Disconnect the coupling nut from the tank. Reconnect and retry.
Flames blow out.| •     High or gusting winds.
•     Low on LP gas.
•     Excess flow valve tripped.| •     Turn the grill so that the front of the grill faces the wind or increase the flame height.
•     Refill the LP tank.
•     Refer to the “Sudden drop in gas flow” section above.
Flare-up.| •     Drip buildup.
•     Excessive fat in meat.
•     Excessive cooking temperature.| •     Clean the burners and the inside of the grill/firebox.
•     Trim the fat from the meat before grilling.
•     Adjust to a lower temperature.
Persistent drip fire.| •     Drip trapped by food buildup around the burner system.| •     Turn the knobs to OFF. Turn the gas in the LP tank off. Leave the lid in position and let the fire burn out. After the grill cools, remove and clean all parts.
Flashback… (fire in burner tube(s)).| •     Burner and/or burner tubes are blocked.| •     Turn the knobs to OFF. Clean the burner and/or burner tubes. See the burner cleaning section on page 10 of the Use and Care.
Unable to fill the LP tank.| •     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).| •     Drip buildup or food particles in the end(s of carryover tube(s).| •     Clean the carry-over tube(s) with a wire brush.

Troubleshooting – Electronic Ignition

Problem| Possible Cause| Check Item| P r e v e n ti o n / S o l uti o n
---|---|---|---
SECTION I
No sparks appear at any electrodes when control knob are turned to HI: no noise can be heard from the spark module.| •  The battery is not installed properly.
• Dead battery.
• The wire assembly is not installed properly.
• Faulty spark module.| • Check that the battery has the positive side facing the outside.
• Has the battery been used previously?
• Check to ensure the threads are properly engaged.
• If no sparks are generated with the new battery and the wires are connected properly, the module is faulty.| •  Install the battery, making sure that the positive end is facing outward, and the negative end is facing inward.
• Replace the battery with a new AA-size alkaline battery.
• Unscrew the ignition module assembly and be sure that all the wires are installed properly before reinstalling the ignition module assembly.
•  Replace the ignition module assembly by calling customer service at 1-888-287-0735.
SECTION II

No sparks appear at any electrodes when control knob is turned to HI; noise can be heard from the spark module.

| • The Electrodes are not connected properly.| • Are the electrodes tightly connected?| • Remove and reconnect all electrode wires from the module sockets.
SECTION III

Sparks are present but not at all electrodes and/or not at full strength.

| • The electrodes are not connected properly.
• Electrical arc between the output wires and burner tube.
• Weak battery.
• Electrodes are wet.
• The electrode(s) are cracked or broken; sparks appear where cracked.| • Are the electrodes tightly connected?
• If possible, observe grill a in dark location. Operate the ignition system and look for arcing between the output wires and burner tube.
• All sparks are present but have a weak or slow rate.
• Has moisture accumulated on the electrode and/or in burner ports?
• Inspect the electrodes for cracks.| • Remove and reconnect all electrode wires from the module sockets.
• If sparks are seen in places other than the burner tube area, the wire insulation may be damaged. Replace wires.
• Replace the battery with a new AA-size alkaline battery.
• Use a paper towel to remove any moisture.
• Replace the cracked or broken electrodes by calling customer service at 1-888-287- 0735.
SECTION IV
Grill is not getting hot and is only reaching 250 – 300 degrees| • This typically occurs when you turn on your control knobs before you turn on the LP tank valve. If so, this will activate the gas regulator safety device, the grill will only reach temperatures between 250 and 300F even with all burners on the high setting.| • Are the regulator on and tight?
• Make sure the regulator is connected properly to the tank, and control knobs are all in the off position.| • Open the grill lid.
• Turn off all knobs on the control panel.
• Turn off the tank knob.
•  Disconnect the regulator from the LP tank. Wait 30 seconds.
• Reconnect the regulator to the LP tank.
• Slowly open the LP tank knob all the way. Do not put excessive force on the valve when in the fully open position to avoid damaging the valve.
• Turn on the appropriate control knob and light the grill per the lighting instructions on page 9.

P/N 4 0 9 0 0 3 4 2 A

Documents / Resources

| Kenmore PG-A4030400LD-MO 3-Burner Outdoor BBQ Grill [pdf] User Guide
PG-A4030400LD-MO 3-Burner Outdoor BBQ Grill, PG-A4030400LD-MO, 3-Burner Outdoor BBQ Grill
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