Charbroil 463731203 Owner's Manual

Assembly Instructions/Use and Care Manual

Liquid Propane Gas Grill

with VapoRISER Smoking Tray
Model No. 415.162060

This Grill Is For
Outdoor Use Only

N

NO TOOLS

ASSEMBLY

WARNING

• Read this manual before cooking on
grill. Failure to follow all
manufacturer's instructions could
result in fire or explosion which could
cause property damage, personal
injury or death.

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

CAUTION

• Read and follow all Safety
Statements, Assembly Instructions
and Use & Care Directions before
attempting to assemble and cook.

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

• Parts

• Assembly

• Use and Care

• Troubleshooting

• Safety Rules

Assembly Questions?
Call 1-800-4-MY-HOME

Parts Ordering:
Call 1-800-366-PART (7278)

To Installer/Assembler: Leave
these instructions with
consumer.

To Consumer: Keep this
manual for future reference.

®

463731303 / 1-4165292 (04-03-03)

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

WARNING

FOR YOUR SAFETY

1. Do not store or use gasoline or other
flammable vapors and liquids 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.

FOR YOUR SAFETY
If you smell gas:

1. Shut off gas to the appliance.

2. Extinguish any open flame.

3. Open lid.

4. If odor continues, immediately call your

gas supplier or your fire department.

Call Grill Service Center For Help And Parts

If you have questions or need assistance during assembly,
please call . You will be speaking to a
representative of the grill manufacturer and not a Sears
employee. To order new parts call Sears at .

Product Record

IMPORTANT: Fill out the product record information below.

Model Number

UPC (on carton) Label Lot # GG

Serial Number

1-800-241-7548

1-800-4-MY-HOME

Installation Safety Precautions

•

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

•

Grill installation must conform with local codes, or in their
absence with

Z223.1

LP Gas Code Grill is not for use in or on
recreational vehicles and/or boats.

• All electrical accessories (such as rotisserie) must be
electrically grounded in accordance with local codes, or

National Electrical Code, ANSI / NFPA 70.

electrical cords and/or fuel supply hoses away from any hot
surfaces.

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

Safety Symbols

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

®

DANGER: Indicates an imminently hazardous situation

which, if not avoided, will result in death or serious injury.

National Fuel Gas Code, NFPA 54 / ANSI

. Handling and storage of LP cylinders must conform to

NFPA/ANSI 58.

Keep any

DANGER

WARNING

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

Date Purchased

CAUTION

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

WARNING

CARBON MONOXIDE HAZARD

Burning charcoal releases carbon monoxide which has no
odor and can cause serious injury or death. Never burn
charcoal inside homes, vehicles or tents.

2 • 463731303

CAUTION

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

TABLE OF CONTENTS WARRANTY

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

Grill Service Center...................................2

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

Installation Safety Precautions ..........................2

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

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

Parts List...........................................4

Parts Diagram.......................................5

Assembly ........................................6-14

Use and Care ...................................15-23

VapoRISER Smoking Tray .....................21

Cooking Chart...............................22

Troubleshooting .............................23

KENMORE GRILL WARRANTY

Full 1-Year Warranty on Grill

For one year from the date of purchase Sears will repair or
replace, at our option, any grill part (except for paint finish)
that is defective in material or workmanship.

Limited Warranty on Selected Grill Parts

From one year after the date of purchase for the designated
time periods listed below, Sears will replace the following grill
parts if they are defective in material or workmanship. You
will be charged for labor.

• Lifetime of Grill: Aluminum Top and Bottom Castings

(except for paint finish)

• 2 years: Burner Assembly

WARRANTY SERVICE

Warranty service is available by contacting Sears at

®

1-800-4-MY-HOME

.

WARRANTY RESTRICTIONS

This warranty is void if grill is used for commercial or rental
purposes.

This warranty applies only when the 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., Dept. 817WA,

Hoffman Estates, IL 60179

463731303 • 3

PARTS LIST – Model No. 415.162060

Key Qty Description Part #

1 2 Leg Assembly.......................4503198

2 1 Base ..............................4503196

3 8 #10-24x2” Carriage Bolt ...............4080064

4 10 #10-24 Plastic Tee Knob...............4080091

5 1 Midshelf ...........................4151034

6 2 Wheel Assembly.....................4310003

7 4 1” Hitch Pin.........................4080062 STD624001

8 2 Leg Extender .......................4154556

9 1 Grill Bottom.........................4580578

10 1 Burner Assembly ....................4505074

11 1 Collector Box .......................4500278

12 1 Electrode ..........................5156119

13 1 #10-16x1/2” Self-Tap Screw ............4080059 STD611005

14 1 Control Panel .......................4526173

15 1 Valve/Hose/Regulator Assembly ........4524165

16 2 Valve Clip ..........................4151043

17 4 #10x1/2”, T-20, Self-Tap Screw .........4080043

18 2 Control Knob........................4154559

19 1 Ignitor .............................4153713

20 1 Ignitor Wire .........................4153720

21 2 1/4-20x1-1/4” Carriage Bolt ............4080615 STD532512

22 2 1/4-20 Wing Nut .....................4080221 STD541625

23 2 #10-24x1-1/4” Carriage Bolt ............4080074

Key Qty Description Part #

24 1 Tank Wire ..........................4151019

25 1 Vaporiser Bar Wire ...................4151036

26 2 Vaporiser Bar .......................4500268

27 1 Front Panel.........................4503199

28 1 Front Panel Shelf ....................4154518

29 4 Push-Fastener ......................4080679

30 1 Panel Wire .........................4151040

31 4 EndCap...........................4080065

32 2 Side Shelf ..........................4154373

33 8 #10-12x1-7/8” Wing Screw.............4080096

34 1 Grill Lid ............................4580586

35 2 1/4x1-1/8” Hinge Pin..................4156513

36 1 Handle ............................4154473

37 2 #10-24x1” Machine Screw .............4080302 STD511010

38 2 #10-24 Wing Nut.....................4080063 STD541610

39 1 Heat Indicator with Bracket.............4156800

40 1 #10-24 Hex Nut (keps) ................4080208 STD541410

41 1 Logo Plate .........................4156081

42 2 3/16” Pal Nut........................4153096

43 1 SwingAway.........................4152124

44 1 Cooking Grate ......................4152739

45 1 Grease Clip.........................5156607

4 • 463731303

PARTS DIAGRAM – Model No. 415.162060

34

42

44

38

26

36

26

25

11

10

21

7

35

9

13

12

7

21

35

40

39

37

43

41

32

31

22

1

32

31

6

33

33

3

4

7

3

4

4

3

24

22

45

1

3

2

5

7

3

6

4

8

33

33

23

4

3

43

4

3

29

20

28

14

17

16

19

27

17

17

15

23

4

16

18

17

29

30

463731303 • 5

ASSEMBLY – Model No. 415.162060

Cart Assembly Step 1

Position base on edge with tank hole to left side.

1

Leg Assembly

Insert legs into base and attach with carriage bolts
and plastic wing nuts. Use top holes on left side.
DO NOT FULLY TIGHTEN.
Insert midshelf wire into holes on insides of legs,
long wires toward left side. Fully tighten carriage
bolts and plastic wing nuts.

4

Qty. 8

3

Qty. 8

Long midshelf wire
to left side.

IMPORTANT!

USE TOP HOLE

3

4

Base

6 • 463731303

Cart Assembly Step 2

Insert wheel/hubcap assemblies into

2

Wheel/Hubcap Assembly

bottom holes on left legs.
Secure beneath base with hitch pins.
See inset below.
Push leg extenders into right legs.

7

Qty. 2

7

Leg Extender

Completed assembly with
hitch pin in axle bolt.

463731303 • 7

3

Grill Bottom/Control Panel Assembly And Tank Wire

Carefully place grill bottom/control panel
assembly onto cart, so as not to scratch paint
on legs. Make sure control panel bracket fits over
support bar on each side.
Insert carriage bolts through grill bottom and
center hole in support bar. Thread metal wing nuts
onto bolts but do not fully tighten.
Insert carriage bolts through control panel bracket
and front holes in support bar. Secure with plastic
wing nuts.
Fully tighten metal wing nuts.
Insert ends of tank wire into
slots on each side of tank
hole in grill base. Lean tank
wire toward midshelf.

21
p/n 4080615

22

Qty. 2

4

Qty. 2

21
p/n 4080615

21

p/n 4080615

Qty. 2

23

p/n 4080074

Qty. 2

23
p/n 4080074

Grill Bottom/Control
Panel Assembly

Tank Wire

23
p/n 4080074

Support Bar
Center Hole

Support Bar
Front Hole

Control Panel
Bracket

22

4

8 • 463731303

NOTE: Wheels are to left side.