Char-Broil 464220110 Owner’s Manual

Use& CareGuide
®
LiquidPropaneGasGrill
Sears Model No. 4t5.t6t280t0
Safety
Parts
Use and Care
Assembly
Read and follow all Safety, Assembly,
and Use & Care instructions in this Guide before assembling and cooking
with this grill.
Failure to follow all instructionsinthis Use & Care Guide may lead to fire or
explosion, which could result in property damage, personal injury or death.
Grill InformationCenter
MissingParts?Assembly Questions? OperationProblems? Before returning grill to store,call 1-800-241-7548
Tools needed for assembly:
Adjustable wrench (not provided) Screwdriver (not provided)
7/16" Combinationwrench (not provided)
SAVETHESEiNSTRUCTiONS!
See our extensiveassortment of outdoorliving products on-lineat
www.sears.comand www.kmart.com
Sears Brands Management Corporation, Hoffman Estates, IL 60179 U.S.A.
©2010SearsBrands,LLC PrintedinChina Model 464220110 G550-001-010801 Nov-%-09
_l|_mmmm_l! / " _
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 immediatelycall 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 informationCenter for Help and Parts
Missing Parts? Assembly Questions? Operation Problems? Before returning grill to store, call 1-800-241-7548
Product Record IMPORTANT:Fill outtheproductrecordinformationbelow.
Model Number
Serial Number
Seeratinglabelongrillfor serialnumber.
CALIFORNIA PROPOSITION65
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 handlinq 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, or in the absence of local codes, witheither the National Fuel Gas
Code,ANSI Z223.1/NFPA 54, Natural Gas andPropane Installation Code, CSA B149.1, or Propane Storage and Handling Code, B149.2, or the Standardfor Recreational
Vehicles,ANSI A 119.2/NFPA1192,and CSAZ240 RV Series,
Recreational VehicleCode, 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. Keep any electrical cords and/or
fuel supply hoses away fromany hot surfaces.
Grill is not for use in or on recreational vehicles and/or boats.
This grill issafety certified for use in the United States and/or Canada only. Donot modify for use in any other location.
Modification will result in a safety hazard.
Safety Symbols The symbols and boxes shownbelow explain what each heading
means. Read and follow all of the messagesfound throughout the manual.
Date Purchased
To installedAssembler: Leave these instructions with
consumer.
To Consumer: Keep this manual for future reference.
CAUTioN/K
Some parts may contain sharp edges, especially as noted in these instructions.
Wear protective gloves if necessary.
CAUT'O.
For residential use only. Do not use for commercial
cooking.
2. 464220110
DANGER: Indicatesan imminently hazardous situation which, if notavoided, will result in death orserious injury.
WARNING: Bealert to the possibility of serious bodily injury if the instructions are not followed. Be sureto read and
carefully follow all of the messages.
CAUTION
CAUTION: Indicates a potentially hazardoussituation which, if notavoided, may result in minoror moderate injury.
ForYourSafety...................................... 2
GrillInformationCenter................................ 2
KENMORE GRILL WARRANTY
ProductRecordInformation............................ 2
SafetySymbols...................................... 2
InstallationSafetyPrecautions.......................... 2
KenmoreGrillWarranty............................... 3
UseandCare.................................... 4-10
PartsList.......................................... 11
PartsDiagram...................................... 12
Assembly....................................... 13-22
Troubleshooting.................................. 23-25
RepairProtectionAgreements
Congratulations onmaking a smart purchase. Yournew Kenmore®product isdesigned and manufactured for yearsof
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 purchasethe Repair ProtectionAgreement, a simple phonecall is all that ittakes for you to schedule service.
You can call anytime day or night,or schedule aservice appointment online.
The Repair ProtectionAgreement is a risk-free purchase. If you cancel for any reason during the product warranty period,
wewill provide afull refund. Or, aprorated 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®to arrange for free repair (or replacement if repair proves impossible).
Five-Year Limited Warranty on Burners Forfive years fromthe date of purchase,any burner that
ruststhrough will be replaced free of charge.After the first yearfrom the date of purchase,you pay for labor ifyou wish
to have it installed.
All warranty coverage excludes ignitor batteries and grillpart
paint loss, discoloration or surface rusting,which are either expendable parts that can wear out from normal usewithin
thewarranty period, orare conditions that can be the 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 legalrights, andyou may also have other rights which vary from state to state.
Sears, Roebuck and Co., Hoffman Estates, IL 60179
464220110.3
NEVERstore a spare LP cylinderunder or near the appliance or in an enclosed area.
Never fill a cylinder 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 improperlystored cylinder is a hazard due to possible gas release from the safety
relief valve. This could cause an intensefire with risk of property damage, serious injury or death.
If you see, smell or hear gas escaping, immediately get away from the LP cylinder and appliance and
call your fire department.
LP Tank
The LP Tank used with your grill must meet the following requirements:
UseLP Tanksonly with these required measurements: 12"
(30.5cm) (diameter) x 18" (45.7 cm) (tall) with 20 lb. (9 kg.) capacity maximum.
LPTanksmust be constructed andmarked in accordance with
specifications for LP Tanksof the U.S. Department of Transportation (DOT)or for Canada, CAN/CSA-B339, tanks,
spheres andtubes for transportation of dangerous goods. Transport Canada (TC). See LPTank collarfor marking.
LPTankvalve must have:
Type 1 outlet compatiblewith regulatoror grill.
Safety relief valve.
UL listed 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.
LPTankmust be arranged for vapor withdrawal and include collar to protect LPTank valve.Always keep LPTanks in upright position during use, transit orstorage.
LP Tank in upright position for vapor withdrawal
LP Tank Removal, Transport And Storage
Turn OFF all control knobs and LPtank valve. Turn coupling nut counterclockwise by hand only - do not use tools to
disconnect. Lift LP tank wire upward off of LP tank collar, then lift LPtank up and offof support bracket. Installsafety cap onto
LP tank valve.Always use cap andstrap supplied with valve. Failure to use safety cap as directed may result in serious
personal injury and/or property damage.
LPTankValve ..
SafetyCap
RetainerStrap
A disconnected LP tank in storage or beingtransported must have a safety cap installed (as shown). Do notstore an LPtank in enclosedspaces such as acarport, garage, porch, covered
patio or other building. Never leavean LP tank inside a vehicle which may becomeoverheated bythe sun.
Do not store an LP tank in an area where children play.
4,464220110
LP (Liquefied Petroleum Gas)
LPgas is nontoxic,odorless and colorless when produced. For Your Safety, LP gas 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
Useonly licensed and experienced dealers.
LPdealer must purge new tank before filling.
Dealershould NEVER fill LPTank more than 80% of LP Tank volume. Volume of propane in tank will vary by temperature.
A frosty regulator indicatesgas overfill. Immediately close LP Tankvalve and call local LP gas dealer for assistance.
Do not release liquid propane (LP) gas into the atmosphere. This is a hazardous practice.
To removegas from LP Tank,contact an LP dealer or call a local fire department for assistance. Check the telephone
directory under "Gas Companies" for nearest certified LP dealers.
LPTank Exchange
Connecting Regulator To The LP Tank
Manyretailers that sell grills offer you the option of replacing your empty LPtank through an exchange service. Useonly
those reputable exchange companiesthat 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 new andexchanged LP tanks in upright position during use,transit or storage.
Leak test new and exchanged LPtanks BEFORE connecting to grill.
Placedust cap on cylinder valve outlet whenever the cylinder is
not in use. Only install the type of dust cap on the cylinder valve
outlet that is providedwith the cylinder valve. Other types of caps
or plugs may result inleakage of propane.
LP Tank Leak Test For your safety
Leak test must be repeated each time LPtank is exchanged or refilled.
Do not smoke duringleak test.
Do not use anopen flame to check for gas leaks.
Grillmust be leak tested outdoors ina well-ventilated area, away from ignition sources such as gas fired or electrical
appliances. Duringleak test, keep grillaway from open flames or sparks.
Usea clean paintbrush and a 50/50 mildsoap and water solution. Brush soapy solution onto areas indicated byarrows
in figure below. Leaks are indicated bygrowing bubbles.
If "growing" bubbles appeardo not use or move the LP tank.
Contact an LP gas supplier or your fire department!
1. LP tank must be properlysecured onto grill. (Refer to assembly section.)
2. Turn allcontrol knobs to the OFF position.
3. Turn LPtank OFF byturning OPD hand wheel clockwise to a full stop.
4. Remove the protective cap from LPtank valve.Always use cap and strap supplied with valve.
OPDHandWheel
//- Type1outlet with
threadon outside
SafetyReliefValve
/
Strapand Cap
Do not insert a POLtransport plug (plastic part with external threads)
into the Type I tank valve outlet. It will defeat the Safety Relief Valve
feature.
,& Do not use household cleaning agents. Damageto gas
train components (valve/hose/regulator) can result.
5. Hold regulator and insertnipple into LP tank valve. Hand-tightenthe coupling
nut, holding regulator ina straight line
with LP tank valve so as not to cross-
thread the connection.
Nipplehasto be centered intothe LPtank valve.
464220110.5
Holdcoupling nutand regulator asshownfor properconnection
to LPtank valve.
6. Turnthe coupling nut clockwise and tighten to a full stop. The regulatorwill seal onthe 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:
Leak Testing Valves, Hose and Regulator
1. Turn all grill control knobs to OFF.
2. Be sure regulator is tightly connected to LP tank.
3. Completely open LPtank valve byturning OPD handwheel counterclockwise. Ifyou heara 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:
Neverremovethreaded orificeatend of valve.
If you cannot complete the connection, disconnect regulatorand repeat steps 5 and 6. If you arestill unable to completethe
connection, do not use this regulator! Call ®
1-800-4-MY-HOME for identical replacement part.
/L /L
Do not insert any tool or foreign objects into the valve outlet or safety reliefvalve. Youmay damage the valveand cause
a leak. Leaking propane may result in explosion, fire, severe
personal injury,or death.
Ifa leak is detected at any time, STOP and callthe fire department.
Ifyou cannot stop a gas leak, immediately close LPtank valve andcall LP gas supplier or your fire department!
Neverattempt to attach this grill to the self-contained LPgas system of a camper trailer or motorhome.
5. If "growing" bubbles appear, there is a leak. CloseLP 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' 464220110
For SafeUse of YourGrill and to Avoid Serious injury:
Do not letchildren operate or play near grill.
Keepgrill area clear andfree from materials that burn.
Do not blockholes in sides or backof grill.
Check burnerflames regularly.
Use grill only inwell-ventilated space. NEVERuse in enclosedspace suchas carport, garage, porch,
covered patio,or under an overhead structure of any kind.
Do not usecharcoal or ceramic briquetsin a gas grill. (Unlessbriquets aresupplied with your grill.)
Usegrill at least 3 ft. from any wall or surface. Maintain 10ft. clearanceto objects that cancatch fire
or sourcesof ignition such as pilot lights onwater
heaters,live electrical appliances,etc.
Safety Tips A Beforeopening LP cylinder valve, check the coupling nutfor
tightness.
A When grill is not in use,turn off all control knobs and LP
cylinder valve.
,I, Never move grill while in operation or still hot.
A Uselong-handled barbecue utensils andoven mitts to avoid
burnsand splatters.
A Maximumload for sideburner and side shelf is 10 Ibs. A The grease tray must be inserted into grill and emptied after
each use. Do not removegrease tray until grill has
completely cooled.
A Clean grill often, preferably after each cookout. If a bristle
brush is used to clean any of the grill cooking surfaces,
ensure no loose bristles remain on cooking surfaces priorto grilling. It is not recommendedto clean cooking surfaces
while grill is hot.
A Ifyou noticegrease or other hot material dripping from grill
onto valve, hose or regulator,turn off gas supplyat once.
Determinethe cause, correct it, then clean and inspect valve, hoseand regulator before continuing. Perform a leak test.
A Keepventilation openings in cylinderenclosure (grill cart) free
and clear of debris.
A Donot store objects or materials inside the grill cart
enclosure thatwould block the flow of combustion air to the
undersideof either the control panel or the firebox bowl.
A The regulator maymake a humming orwhistling noise during
operation. Thiswill notaffect safetyor use of grill.
,I, If you have agrill problem see the "Troubleshooting Section".
A Ifthe regulator frosts, turn offgrill and LP cylinder valve
immediately.This indicates a problemwith the cylinder and it
should not be used onany product. Return to supplier!
Apartment Dwellers: Checkwith managementto learn the requirements
and fire codes for using an LPgas grill in your apartmentcomplex. If allowed, useoutside onthe
ground floorwith a three (3)foot clearance fromwalls or rails. Donot use onor under balconies.
NEVERattempt to light burner with lid closed.A buildup of non-ignited gas inside a closed grill is
hazardous.
Never operate grillwith LP cylinder out of correct positionspecified in assembly instructions.
Always close LP cylinder valve and remove coupling nut before moving LPcylinder 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, agrease fire can occur that may damage the
product.
Ignitor Lighting the Grill ,I, Do not lean over grill while lighting.
1. Turn OFF gas burner control valves.
2. Turn ONgas at LP cylinder.
3. Open lid during lighting.
4. To ignite,push and turn the iGNITiON BURNER knob to HI.
5. Push andhold ELECTRONIC IGNITION buttonuntil the IGNITION BURNER lights.
6. If ignitiondoes NOT occur in 5 seconds,turn the burner controls OFF, wait 5 minutes for gas to clear away,and repeat
the lighting procedure.
7. Toignite remaining burners, turn each burner knob in sequence to the HI position, starting with the burner closest to the
IGNITION BURNER.
8. Once each burner has ignited,turn knobs to desired setting. If ignitor does notwork, follow match lighting instructions.
Lighting instructions are continued on the next page
464220110,7
Turncontrols and gas source or tank OFF when not in use.
c.uT,o.
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
A Do not lean over grill while lighting.
1. Open lid. Turn ON gas at LP cylinder.
2. Place match into match holder (hanging from side panel of grill). Light match; then light burner by placing matchthrough
the match light holeon right or left side of grill.
3. Push inand turn far right or far left burner knob to the HI
position, depending on match light hole selected. Be sure burner lights and stays lit.
4. Light adjacent burners insequence by pushing knobs inand
turning to the HI position.
Sideburner ignitor Lighting ,A Do not lean over grill while lighting.
1. Open sideburner lid. Turn ON gas at LP cylinder.
2. Turnsideburner knob to the Hi position, push and hold
ELECTRONIC IGNITION button.
3. Ifsideburner does NOT light within 5 seconds, turn knob to OFF, wait 5 minutes,then
repeat lighting procedure.
Sideburner Match Lighting
1. Open sideburner lid. Turn ON gas at LP cylinder.
2. Place lit match near burner.
3. Turnsideburner knob to the
HI position. Be sure burner lightsand
stays lit.
8' 464220110
Burner Flame Check
Remove cooking grates and flame tamers. Light burners, rotate knobs from HI to LOW. Youshould see a smaller flame in
LOW position than seen on HI. Perform burnerflame check on sideburner,also.Always check flame prior to each use. If
only low flame is seen refer to "Suddendrop or low flame" in the TroubleshootingSection.
Turning Grill Off
Turn all knobs to the OFF position. Turn LP cylinder OFF by turning hand-wheel clockwise to a full stop.
Ignitor Check
Turn gas off at LP cylinder. Press and hold electronic ignitor button. "Click" should be heard and spark seen each time
between each collector box orburner and electrode. See
"Troubleshooting" if no click orspark.
Valve Check
important: Makesure gas is off at LPcylinder before checking valves. Knobs lock in OFF position. To check
valves, first push in knobs and release, knobs should spring back. If knobs do not spring back, replace valve assembly
before using grill. Turn knobs to LOW position then turn back to OFF position.Valves should turn smoothly.
Hose Check
Beforeeach use, check to see if hoses arecut or worn. Replace damaged hoses before usinggrill. Use only
identical replacement partvalve/hose/regulator as specified in the Parts List of this Use and Care Guide.
General Grill Cleaning
Do not mistake brown or black accumulation of grease and smoke for paint. Interiorsof gas grills are not painted at the
factory (and should never be painted). Apply a strong solution of detergent and water or usea grill cleanerwith scrub brush
on insidesof 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.
,A.Do not use citrisol, abrasive cleaners, degreasers or a concentrated grillcleaner on plastic parts. Damage to and failure of parts can result.
Porcelain surfaces: Because of glass-like composition, most residue can bewiped away with baking soda/water solution or
specially formulated cleaner. Use nonabrasive scouring powder for stubborn stains.
Painted surfaces: Washwith mild detergent or nonabrasive cleaner and warm soapy water. Wipe dry with a soft
nonabrasive cloth.
Stainless steel surfaces: Tomaintain your grill's high quality appearance, wash with mild detergent and warm soapy water and wipe dry with a soft cloth after each use. Baked-on grease
deposits may require the use of an abrasive plastic cleaning pad. Use only in direction of brushed finishto avoid damage.
Do not use abrasive padon areas with graphics.
Cooking surfaces: If a bristle brushis usedto clean any of
the grill cooking surfaces, ensure no loose bristles remain on cooking surfaces prior to grilling. It is not recommendedto
clean cooking surfaces while grill is hot.
cAuTioN
3. Remove carryover tubes and burners.
4. Detach electrodefrom burner.
f
SPIDER ALERT!
If you notice that your grill is getting hard tolight or thatthe flame isn't as strong as it should be, takethe time to check and
clean theburner tubes.
iiiiiiii
CONTROLPANEL
'k _ i!
Insomeareasof the country,spidersor smallinsectshavebeen knowntocreate"flashback"problems.Thespidersspinwebs,build
nestsandlayeggs inthegrill'sburnertube(s)obstructingthe flowofgastothe burner.Thebacked-upgascanigniteintheburner tubebehindthecontrolpanel.Thisisknownasa flashbackand it
candamageyourgrillandevencauseinjury.
SPIDERWEBS
INSIDE BURNER TUBE
BURNER
NOTE: Removal/Detachment method will depend on the burner configuration. See different configurations in
illustrations below.
,
Carefully lift each burner up and away fromvalve openings.
We suggest three ways to clean the burner tubes. Use the one
easiest for you.
(A) Benda stiff wire (a light weight coat hangerworks well)
into a small hook. Run the hook through each burner tube several times.
r.,_,,.,. -__-
(B) Usea narrow bottle brushwith a flexible handle (do not
use a brass wire brush), 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 makesure air comes out each hole.
6. Wire brush entire outer surface of burner to removefood
residue and dirt.
7. Clean any blocked ports with a stiff wire such as an open
paper clip.
8. Check burner fordamage, due to normal wear and corrosion
some holes may become enlarged. Ifany large cracks or holes are found replace burner.
VERY IMPORTANT:Burner tubes must reengage valve
openings. See illustration at right. Correct
9. Attach electrode to burner, burner-to-valve
10. Carefully replace burners, enc
11. Attach burners to brackets on firebox.
12. Reposition carryover tubes and attach to burners. Replace flame tamers and
cooking grates.
Topreventflashbacksandensuregoodperformancetheburnerand burnertubeassemblyshouldberemovedfromthegrillandcleaned beforeusewheneverthegrill hasbeenidleforanextendedperiod.
\ J
Storing Your Grill
Clean cooking grates.
Store in dry location.
When LP cylinder is connected to grill, storeoutdoors in a well-
ventilated space and out of reach of children.
Covergrill ifstored outdoors. Choose from a variety of grill covers offered by manufacturers.
Store grill indoorsONLY if LP cylinder isturned off and disconnected, removed from grill andstored outdoors.
When removing grill from storage, follow "Cleaning the Burner Assembly" instructions before starting grill.
Cleaning the Burner Assembly
Follow these instructionsto cleanand/or replace partsof burner
assembly or ifyou have trouble ignitinggrill.
1. Turn gas OFF at control knobs and LP cylinder,
2. Remove cooking grates and flame tamers.
Firebox burner bracket
Electrode
screwdriver
464220110.9
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