Charbroil 463742304 Owner's Manual

Assembly Instructions/Use and Care Manual

Liquid Propane Gas Grill

Model No. 415.162100

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 1-800-241-7548

Parts Ordering:
Call 1-800-4-MY-HOME

To Installer/Assembler: Leave
these instructions with
consumer.

To Consumer: Keep this
manual for future reference.

®

463742304 / 1-4165355 (01-23-04)

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.

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: 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

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

Serial Number

Date Purchased

1-800-241-7548

1-800-4-MY-HOME

See rating label on grill for serial number.

CAUTION

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

®

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.

National Fuel Gas Code, NFPA 54 / ANSI

. Handling and storage of LP cylinders must conform to

NFPA/ANSI 58.

Keep any

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 • 463742304

TABLE OF CONTENTS WARRANTY

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

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

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

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

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

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

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

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

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

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

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

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

Repair Protection Agreements

Congratulations on making a smart purchase.

Kenmore product is designed and manufactured for years of

®

dependable operation. But like all products, it may require repair
from time to time. That’s when having a Repair Protection
Agreement can save you money and aggravation.

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

Here’s what’s included in the Agreement:

Expert service

by our 12,000 professional repair specialists

Unlimited service and no charge

covered repairs

Product replacement
Discount of 10%

if your covered product can’t be fixed

from regular price of service and service­related parts not covered by the agreement; also, 10% off
regular price of preventive maintenance check

Fast help by phone

– phone support from a Sears
technician on products requiring in-home repair, plus
convenient repair scheduling

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

Sears has over 12,000 professional repair specialists, who have
access to over 4.5 million quality parts and accessories. That’s
the kind of professionalism you can count on to help prolong the
life of your new purchase for years to come. Purchase your
Repair Protection Agreement today!

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

Your new

for parts and labor on all

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

.

Sears Installation Service

For Sears professional installation

door openers, water heaters, and other major home items, in the
U.S.A. call

1-800-4-MY-HOME

of home appliances, garage

®

463742304 • 3

PARTS LIST – Model No. 415.162100

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.....................4310002

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

8 2 Leg Extender .......................4154577

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 ........4524198

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

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

18 1 Ignitor .............................4153713

19 1 Ignitor Wire .........................4153196

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

21 2 1/4-20 Wing Nut .....................4080221 STD541625

22 2 #10-24x1-1/4” Carriage Bolt ............4080074

Key Qty Description Part #

23 1 Tank Wire ..........................4151019

24 2 V-bar..............................4500326

25 2 Control Knob........................4154559

26 1 Front Panel.........................4503199

27 1 Front Panel Shelf ....................4154518

28 4 Push-Fastener ......................4080679

29 1 Panel Wire .........................4151040

30 4 EndCap...........................4080065

31 2 Side Shelf ..........................4154373

32 8 #10-12x1-7/8” Wing Screw.............4080096

33 1 Grill Lid ............................4580652

34 2 1/4x1-1/8” Hinge Pin..................4156513

35 1 Handle ............................4154473

36 2 #10-24x1” Machine Screw .............4080302 STD511010

37 2 #10-24 Wing Nut.....................4080063 STD541610

38 1 Temperature Gauge with Wing Nut ......4157171

39 1 Temperature Gauge Bezel .............4157169

40 1 Logo Plate .........................4156081

41 2 3/16” Pal Nut........................4153096

42 1 SwingAway.........................4152124

43 1 Cooking Grate ......................4152739

44 1 Grease Clip.........................5156607

4 • 463742304

PARTS DIAGRAM – Model No. 415.162100

33

41

43

37

38

35

24

13

11

10

20

7

34

9

12

7

20

34

36

39

38

42

40

31

30

21

1

31

30

6

32

32

3

4

7

3

4

4

3

23

21

44

1

3

2

5

7

3

6

4

8

32

32

22

4

3

43

4

3

28

19

27

14

17

16

18

26

17

17

15

22

4

16

25

17

28

29

463742304 • 5

ASSEMBLY – Model No. 415.162100

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 • 463742304

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.

463742304 • 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.

20
p/n 4080615

21

Qty. 2

4

Qty. 2

20
p/n 4080615

20

p/n 4080615

Qty. 2

22

p/n 4080074

Qty. 2

22
p/n 4080074

Grill Bottom/Control
Panel Assembly

Tank Wire

22
p/n 4080074

Support Bar
Center Hole

Support Bar
Front Hole

Control Panel
Bracket

21

4

8 • 463742304

NOTE: Wheels are to left side.