Charbroil 415.16657900 Owner's Manual

Use and Care Guide

®

LiquidPropaneGasGrill withinfraredCooking System

Sears ModelNo. 4t5.t6657900

This Grill isfor Outdoor Use Only

• Read and follow all Safety, Assembly,
and Use and Care instructions in this

Guide before assemblingand cooking
with this grill.

• Failure to follow all instructions inthis
Use and Care Guide may lead to fire or

explosion, which could result in property
damage, personal injuryor death.

SAVETHESEINSTRUCTIONS!

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

©2008Sears,RoebuckandCo.,AllRightsReserved PrintedinChina

• Safety

• Parts

• Use and Care

• Assembly

Assembly Questions?

Call t-800-241-7548

Tools needed for assembly:
Adjustable wrench (not provided)

Screwdriver (not provided)
7/16" Combinationwrench (not provided)

Model464261709 80019155,02-23-09

ifyou 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.

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

this or any other appliance.

2. An LP Tank not connected for use shall not

be stored in the vicinity of this or any other

appliance.

Call Grill Service Center For Help And Parts
If you have questions or need assistance during assembly,

please call 1-800-241-7548. You wilt be speaking to a
representative ofthe grill manufacturer and not a Sears

employee. To order new parts call Sears at 1-800-4-MY-HOME®.

Product Record
IMPORTANT:Fillouttheproductrecordinformationbelow.

Model Number

Serial Number

Seeratinglabelongrillfor serialnumber.

CALIFORNIA PROPOSiTiON 65

1. Combustion by-products produced when using

this product contain chemicals known to the State of

California to cause cancer, birth defects, and other
reproductive harm.

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

reproductive harm.

Wash your hands after handling this product.

installation Safety Precautions

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

• Grill installation must conform with local codes, orin the

absence of local codes, with either the National Fuel Gas

Code,ANSI Z223.1/NFPA 54, Natural Gas and Propane

Installation Code, CSAB149.1, orPropane Storage and
Handling Code, B149.2, or the Standardfor Recreational

Vehicles,ANSI A 119.2/NFPA1192,and CSAZ240 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 70or Canadian
Electrical Code, CSA C22.1. Keepany electrical cords and/or

fuel supply hoses away from any hot surfaces.

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

• This grill issafety certified for use inthe United States and/or

Canada only. Do not modify for use in any other location.
Modification wilt result in a safety hazard.

Safety Symbols
The symbols and boxes shown below explain what each heading

means. Read and follow all of the messages found throughout
the manual.

Date Purchased

To InstalledAssembler: Leave these instructionswith

consumer.

To Consumer: Keep this manual for future reference.

CAUT,o. /K

, Some parts may contain sharp edges,

especially as noted in these instructions.
Wear protective gloves if necessary.

CAUTION

For residential use only. Do not use for commercial

cooking.

2,464261709

DANGER: Indicates an imminently hazardous situation
which, if notavoided, will result in death or serious injury,

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

carefully follow all of the messages.

CAUTION

CAUTION: Indicates a potentially hazardoussituation which,
if not avoided, may result in minoror moderate injury,

ForYourSafety...................................... 2

GrillServiceCenter................................... 2

KENMORE GRILL WARRANTY

ProductRecordInformation............................ 2

SafetySymbols...................................... 2

InstallationSafetyPrecautions.......................... 2

KenmoreEliteGrillWarranty........................... 3

UseandCare.................................... 4-10

PartsList.......................................... 11

PartsDiagram...................................... 12

Assembly....................................... 13-23

Troubleshooting.................................. 24-26

RepairProtection Agreements

Congratulations on making a smart purchase. Your new
Kenmore® productis designed and manufacturedfor years of

dependable operation. But like all products, it may require repair
from time to time. That'swhen having a Repair Protection

Agreement cansave you money and aggravation.
Here's what the Repair Protection Agreement* includes:

[] Expert service by our 10,000professional repair specialists
[] Unlimited service and no charge for parts and labor on all

covered repairs

[] Product replacement up to $1500 if your covered product

can't be fixed

[] Discount of 10% from regular price of service and related

installed parts notcovered by the agreement; also, 10% off
regular price of preventive maintenance check

[] Fast help by phone - we call it Rapid Resolution -

phone support from a Sears representative. Think of us

as a "talking owner's manual."

Once you purchase the Repair ProtectionAgreement, a
simple phone call is all that ittakes for you to schedule service.

You can call anytime day or night, or schedule a service
appointment online.

The Repair ProtectionAgreement is a risk-free purchase. If
you cancel for any reason during the product warranty period,

wewilt provide a full refund. Or, a prorated refund anytime after
the product warranty period expires. Purchase your Repair

ProtectionAgreement today!
Some limitations and exclusions apply. For prices and

additional information in the U.S.A. call 1-800-827-6655.
*Coverage in Canada varies on some items. For full details

call Sears Canada at 1-800-361-6665.
Sears Installation Service

For Sears professional installation of home appliances, garage
door openers, water heaters, and other major home items, in the

U.S.A. or Canada call 1-800-4-MY-HOME®.

One Year Full Warranty on Kenmore Grill
If this grill fails due to a defect in material or workmanship

within one year from the date of purchase, call 1-800-4-MY-

HOME% arrange for free repair (or replacement if repair
proves impossible).

Ten-Year Limited Warranty on Burners
Forten years from the date of purchase, any burner that

ruststhrough wilt be replaced free of charge.After the first
yearfrom the date of purchase,you payfor labor ifyou wish

to have it installed.

All warranty coverage excludes ignitor batteries and grill part

paint loss, discoloration or surface rusting,which areeither
expendable parts that can wear out from normal use within

thewarranty period, orare conditions that can bethe result
of normal use, accident or improper maintenance.

All warranty coverage is void if this grill is ever used for

commercial or rental purposes.

All warranty coverage applies only if this grill is used in the

United States.

This warranty gives you specific legal rights, and you may
also have other rights which vary from state to state.

Sears, Roebuck and Co., Hoffman Estates, IL 60179

CONVERSION-READY

Easily converts from (LP) liquid

propane to (NG) natural gas

Contact I-8OO4-MY-HOME or

a natura_ gas conversion kff,

Request Part number 41&4584609

Dual FuerrMand SureFireTM are registered trademarks of
the W. C. Bradley Company and used, with permission,

by Sears Holding Corporation. All rights reserved.

_parts to purchase

464261709• 3

• NEVERstore a spare LP cylinder under or near the
appliance or in an enclosed area.

• Never fill a cylinder beyond 80%full.

• If the informationin two points above is not
followed exactly, afire causing death or serious
injury may occur.

• An over filled or improperlystored 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 cylindedappliance and call

your fire department.

LP Tank

• The LP Tank used with your grill must meet the following

requirements:

• Use LP Tanksonly with these required measurements: 12"

(30.5cm) (diameter) x 18" (45.7 cm) (tall) with 20 lb. (9 kg.)
capacity maximum.

• LPTanks must be constructed and marked in accordance with
specifications for LP Tanks 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 compatiblewith

regulatoror grill.

• Safety relief valve.

• ULlisted Overfill Protection

Device (OPD). This OPD safety OPDHandWheel

feature is identified by a unique triangular hand wheel. Use

only LP Tanks equipped with this type of valve.

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

LP Tank in upright position for vapor withdrawal

LP Tank Removal, Transport And Storage

• Turn OFFall control knobs and LPtank valve. Turn coupling
nut counterclockwise by hand only - do not use tools to

disconnect. Lift LP tank wire upward offof LP tank collar, then
lift LP tank up and off of support bracket. Install safety cap onto

LP tank valve.Always use cap and strap supplied withvalve.
Failure to use safety cap as directed may result in serious

personal injury and/or property damage.

LP Tank Valve,

SafetyCap

RetainerStrap

• A disconnected LP tank in storage or being transported must
have a safety cap installed (as shown). Do not store an LPtank
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 bythe sun.

• Do not store an LPtank in an area where children play.

4,464261709

LP (Liquefied Petroleum Gas)

• LPgas is nontoxic, odorless and colorless when produced. For

Your Safety, LPgas has beengiven an odor (similar to rotten
cabbage) so that it can be smelled.

• LPgas is highly flammable and may ignite unexpectedly when
mixedwith air.

LP Tank Filling

• Use only licensed and experienced dealers.

• LPdealer must purge new tank before filling.

• Dealershould NEVER fill LPTankmore than 80% of LPTank

volume. Volume of propane in tank will vary by temperature.

• A frosty regulator indicates gas overfill. Immediately close LP

Tankvalve and call local LP gas dealer for assistance.

• Do not releaseliquid propane (LP) gas into the atmosphere.

This is a hazardous practice.

• Toremove gas from LPTank, contactan LP dealer or call a

local fire department for assistance. Check the telephone
directory under "Gas Companies" for nearest certified LP

dealers.

LP Tank Exchange

Connecting Regulator To The LP Tank

• Many retailers that sell grills offer you the option of replacing
your empty LP tank through an exchange service. Use only

those reputable exchange companies that inspect, precision fill,
test and certify their tanks. Exchange your tank only for an

OPB safety feature-equipped tank as described in the "LP
Tank" section of this manual.

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

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

LP Tank Leak Test
For your safety

• Leak test mustbe repeated each time LP tank isexchanged or
refilled.

* Do not smoke during leak test.

• Do not use an openflame to check for gas leaks.

• Grill must beleak tested outdoors ina well-ventilated area,

away from ignition sources such as gas fired or electrical
appliances. During leak test, keep grill away from open flames
or sparks.

• Use a clean paintbrush anda 50/50 mild soap and water
solution. Brush soapy solution onto areas indicated byarrows

in figure below. Leaks are indicated by growing bubbles.

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

2. Turn all control knobs to the OFF position.

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

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

OPDHandWheel

j Type1outlet with

threadon outside

Safety Relief Valve

/

Strapand Cap

Do not use a POL transport plug
(plastic part with external threads)!

It will defeat the safety feature of
the valve.

If "growing" bubbles appeardo not use or movethe LP tank.

Contact an LP gas supplier or your fire department!

A Do not use household cleaning agents. Damage to gas

train components can result.

5. Hold regulator and insert nipple into LP
tank valve. Hand-tighten the coupling

nut, holding regulator in a straight line

with LP tank valve so as not to cross-

thread the connection.

Nipplehas to be centered
intothe LPtankvalve.

464261709• 5

Holdcoupling nut andregulator
asshown for properconnection

to LP tank valve.

6. Turn the coupling nut clockwise and tighten to a full stop. The
regulatorwill seal onthe back-checkfeature inthe 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:

Leak Testing Valves, Hose and Regulator

1. Turn all grill control knobs to OFF.

2. Be sure regulator istightly connected to LP tank.

3. Completely open LP tank valve by turning OPD hand wheel
counterclockwise. If you hear a rushing sound, turn gas off

immediately.There is a major leak at the connection. Correct
before proceeding by calling Sears for replacement parts at

1-800-4-MY-HOME®.

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

A Neverremovethreaded

orificeatend of valve.

If you cannot complete the connection, disconnect regulator and
repeat steps 5 and 6. If you are still unable to completethe

connection, do not use this regulator!

_z

• Do not insert any tool or foreign objects into the valve outlet
or safety reliefvalve. You may damage the valve and cause

a leak. Leaking propane may result in explosion, fire, severe

personal injury,or death..

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

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

• Never attempt to attach this grill to the self-contained LP gas
system of a camper trailer or motor home.

5. If "growing" bubblesappear, there is a leak. Close LP tank
valve immediately and retighten connections. If leaks cannot

be stopped do not try to repair. Call Sears for replacement
parts at 1-800-4-MY-HOME®.

6. Always close LP tank valve after performing leak test by
turning hand wheel clockwise.

• Do not use grill until leak-tested.

6,464261709

For SafeUse of Your Grill and to Avoid Serious
Injury:

• Do not letchildrenoperateor play neargrill.

• Keepgrill area clear andfreefrom materials that burn.

• Do not block holes in sides or back of grill.

• Check burnerflames regularly.

• Use grill only inwell-ventilated space. NEVERuse in
enclosedspace such as carport,garage, porch,

covered patio,or under an overhead structureof any
kind.

Do not use charcoal or ceramic briquetsin a gasgrill.
(Unlessbriquets are supplied with your grill.)

Usegrill at least 3 ft. from any wall or surface.
Maintain 10 ft. clearanceto objects that cancatch fire

or sourcesof ignition such as pilot lightsonwater

heaters,liveelectrical appliances,etc.

Safety Tips
A Beforeopening LP cylindervalve, check the coupling nutfor

tightness.

A When grill is not in use, turn off all control knobs and LP

cylinder valve.

,A, Never move grill while in operation or still hot.
A Use long-handled barbecue utensils and oven mitts to avoid

burnsand splatters.

,A, Maximum load for sideburner and side shelf is 10 Ibs.
A The grease tray must be insertedinto grill and emptied after

each use. Do not remove grease tray until grill has

completely cooled.

A Clean grill often, preferably aftereach 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.

A If you noticegrease or other hot material dripping from grill

onto valve, hoseor regulator,turn off gas supplyat once.

Determinethe cause, correct it, then clean and inspect valve,
hoseand regulator before continuing. Perform a leak test.

A Keep ventilation openings in cylinder enclosure (grill cart) free

and clear of debris.

A Donot store objects or materials inside the grill cart

enclosure that would block the flow of combustion air to the

undersideof either the control panel or the firebox bowl.

A The regulator may make a humming or whistling noise during

operation. This will not affect safety or use of grill.

,A, If you have a grill problem see the "Troubleshooting Section".
A If the regulator frosts, turn off grill and LP cylinder valve

immediately.This indicates a problemwith the cylinder and it

should not be used on any product. Returnto supplier!

• Apartment Dwellers:
Checkwith managementto learn the requirements

and fire codes for using an LPgasgrill in your
apartmentcomplex.If allowed, useoutside on the

ground floorwith a three (3)foot clearance from walls
or rails. Do not use on or under balconies.

• NEVERattempt to light burner with lid closed. A
buildup of non-ignited gas insidea closed grill is

hazardous.

• Never operate grill with LP cylinder out of correct
position specified in assembly instructions.

• Always close LP cylinder valve and remove
coupling nut before moving LP cylinder from

specified operation position.

tAuT,oN

• 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.

Main Burner ignitor Lighting
A Do not lean over grill while lighting.

1. Open lid during lighting.

2. Turn on gas Tank valve.

3. Push and turn any burner control knob to HI and
immediately press and hold ELECTRONIC IGNITION button.

4. If ignition does NOT occur in 5 seconds, turn burner control
knob OFF, wait 5 minutes for gas to clear away,and repeat

the lighting procedure.

5. Repeat above steps to lighteach burner individually.

if ignition still does not occur, follow match-lighting

instructions.

464261709.7

Turn controls and gas source or tank OFF when not
in use.

CAUTIo.

Sideburner Match Lighting

1. Turn OFF all burner control valves.

2. Open the sideburner lid.
Turn on gas at LP cylinder.

3. Place lit match near burner.

4. Turn sideburner knob to HI_ .

Be sure burner lights and stays lit.

if ignition does NOToccur in 5 seconds, turn the burner
controls OFF, wait 5 minutes for gas to clear away 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.

Main Burner Match-Lighting
A Do not lean over grill while lighting.

1. Turn OFF all burner control valves.

2. Open lid during lighting. Turn on gas at LP cylinder.

3. Light match, and place into lighting holefor desired burnerto
light. The lighting holesare locatedat the front of the cooking

grates between the emitter plate mounting brackets.

4. Push in and turn control knob to HI ._ position for desired
burner to light. Be sure burner lights and stays lit.

5. If ignition does NOT occur in 5 seconds, turn the burner

Control knob off, wait 5 minutes for gas to clear away, and
repeatthe match lighting procedure.

6. Ignite remaining burners by repeating steps 3 through 5 for
each burner.

WARNING: Sideburner top cover must be openwhen

sideburner is in operation.

Before YourFirst Cookout

• Lightburners, check to make sure they are lit, close the lidand
warm up grill on HIGHfor 15 minutes. This curing of paint and

partswill produce an odor only on first lighting.

Burner Flame Check

• Lightburner, rotate knobs from HIGHto 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 dropor low flame" in the Troubleshooting Section.

Hose Check

• Beforeeach use, check to see if hoses are cut, worn or kinked.

Replace damaged hoses before usinggrill. Use only

valve/hose/regulator specified in the Parts List.

Warning:
Top cover must be open

when side burner(s) is in

operation.

Side Burner Ignitor Lighting

,& Do not lean over grill while lighting.

1. Open lid during lighting.

2. Turn ON gas tank valve.

3. Push and turn sideburner control knobto_1:: HI and
immediately press and hold ELECTRONIC IGNITION button.

4. If ignition does NOT occur in 5 seconds, turn burner control
knob OFF,wait 5 minutes for gas to clear away, and repeatthe

lighting procedure.

5. Repeat above steps to light each burner individually.

Normal
Hose

Kinked
Hose

Turning Grill Off

• Turn allknobs to OFF position.Turn LPtank off byturning
OPD hand wheel clockwise to a full stop.

Ignitor Check

• Turn gas off at LP tank. Push and turn burner control to _ .
"Clicking" should be heard and sparking seen each time

between collector box or burner and electrodes. See

"Troubleshooting" if no click or spark occurs.

Valve Check

• Important: Make sure gas is off at LP tank before checking
valves. Knobslock in OFF position. To check valves, first
push in knobs and release, and knobs should spring back. If
knobs do not spring back, replace valve assembly before using

grill. Turn knobs to LO position then turn backto OFF position.
Valves should turn smoothly.

8. 464261709

General Grill Cleaning

•Do not mistake brown or black accumulation of grease and
smoke for paint. Interiors of gas grills are notpainted at the
factory (and should never be painted). Apply a strong solution

of detergent and water or use a grill cleanerwith scrub brush
on insides of grill lid and bottom. Rinse and allow to completely
air dry. Do not apply a caustic grill/oven cleaner to painted

surfaces.

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

failure of parts can result.

•Porcelain surfaces: Because of glass-like composition, most

residuecan be wiped away with baking soda/water solution or

specially formulated cleaner. Use nonabrasive scouring powder
for stubborn stains.

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

nonabrasive cloth.

•Stainless steel surfaces: To maintain your grill's highquality
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 useof an abrasive plastic cleaning

pad.Use only in direction of brushed finish to avoid damage.
Donot use abrasive pad on areas with graphics.

• Cooking surfaces: If a bristle brush is usedto cleanany of

the grill cooking surfaces, ensure no loose bristles remain on
cooking surfaces prior to grilling. It isnot recommendedto
clean cooking surfaces while grill is hot.

Storing Your Grill

•Clean cooking grates.

•Store in dry location.

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

•Cover grill ifstored outdoors. Choose froma variety of grill
covers offered by Sears or other qualified dealers.

•Store grill indoors ONLY if LP cylinder isturned off and
disconnected, removed from grill and stored outdoors.

•When removing grill from storage, follow "Cleaning the Burner
Assembly" instructions beforestarting grill.

CAUTION

/ SPIDER ALERT!

If you notice that your grill isgetting hard tolight or thatthe
flame isn't asstrong asit should be, takethe timeto checkand

clean the venturi's.

CONTROLPANEL

Insomeareasofthe country,spidersorsmallinsectshavebeen
knowntocreate"flashback"problems.Thespidersspinwebs,build

nestsandlayeggsin the grill'sburnertube(s)obstructingtheflowof
gasto theburner.Thebacked-upgascanigniteinthetubebehind
thecontrolpanel.Thisisknownas aflashbackand itcandamage

yourgrillandevencauseinjury.
Topreventflashbacksandensuregoodperformancetheburner

assemblyshouldberemovedfromthegrillandcleanedbeforeuse

wheneverthegrillhas beenidleforan extendedperiod.

SPIDERWEBS

INSIDE TUBE

BURNER

464261709• 9