Kenmore 41516103 Owner’s Manual
/_ CAUTION:
Read and follow all safety statements, assembly
instructions, and use and care directions before
attempting to assemble and cook.
/_ WARNING:
Failure to follow all manufacturer's instructions
could result inserious personal injury and/or
property damage.
INSTALLER/ASSEMBLER:
Leave this manual with consumer.
CONSUMER:
Keep this manual for future reference.
CAUTION:
Some parts may contain sharp edges -
especially as noted in the manual! Wear
protective gloves if necessary.
Printed n China• 463720607 • 463720807. 80009263 • 1121 06
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.
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 cylinder not connected for use shall not
be stored in the vicinity of this or any other
appliance,
Installation Safety Precautions
Use grill only with LP(propane) gas and the regulator/valve
assembly supplied.
Grill installation must conformwith localcodes, or in their
absence with National Fuel Gas Code, NFPA 54 / ANSI
Z223,1 and Natural Gas and Propane Installation Code,
CSA B149,1. Handling and storage of LP cylinders must
conform to LP Gas Code NFPA/ANSI 58, 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. Keep any
electrical cords and/or fuel supply hoses away from any hot
surfaces.
. This grill is safety certifiedfor use in the United Statesonly. Do
not modifyfor use in any other location. Modification will result
in a safety hazard.
CALIFORNIA PROPOSITION 65
Combustion by-products producedwhen using this
productcontain chemicals known to the State of
California to cause cancer, birth defects, and other
reproductive harm.
Call Grill Service Center for Help and Parts
. Ifyou need assistance with your product or warranty parts call
%800-241-7548, Hours of Service Center Operation are
8:00 A.M. To 6:00 P.M. EST Monday- Friday.
. Toorder non-warranty replacement parts or accessories
pleasevisit uson the web at www.charbroil, corn or call
1-800-241-7548 and one of our friendly and knowledgeable
agents will beglad to assist you.
IMPORTANT: Fill out the product record information below.
Model Number
Serial Number
See rating label on grill for serial number.
Date Purchased
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: Indicatesan imminentlyhazardous situation
which, if not avoided,will resultin deathor serious injury.
WARNING: Indicatesan potentially hazardoussituation
which, if not avoided, could result in death or serious
injury.
CAUTION
For residential use only. Do not use for commercial
cooking.
2 . 463720607. 463720807
CAUTION: Indicates a potentially hazardous situation or
unsafe practice which, if not avoided, may result in minor
or moderate injury.
ForYour Safety ...................................... 2
Grill Service Center................................... 2
Product Record information............................ 2
installationSafety Precautions .......................... 2
Safety Symbols...................................... 2
Use and Care .................................... 4-10
Parts List .......................................... 11
Parts Diagram...................................... 12
Assembly ....................................... 13-23
Troubleshooting.................................. 24-25
Limited Warranty.................................... 26
Registration Card ................................... 27
Do not attempt to repair or alter the
hose/valve/regulatorfor any "assumed" defect. Any
modification to this assembly will void your warranty
and create the risk of a gas leak and fire. Use only
authorized replacement partssupplied by
manufacturer.
CertifiedGrill PartsAnd Accessories@,Char-Broil and Design@,Char-Broil(GasGrilt Briquettes)@,Char-Diamonds@,CookingZoneand Design@,DiamondFlame®,ExecutiveChefQ,Faststart®,Flare
Fighter@,FlavorMaster_,Gas GritlSilouetteand Design@,H20 Smoker@,LavaFlame®,MasterFlame@,MasterFlamePrecision CookingSystem@,PowerSpark@,Quantum@,VIP@,PrecisionFlameand
Design@,SierraS, andTreFlame@are registeredTrademarksoftheW.C. BradleyCompany, Thermos@is a registeredtrademarkof the ThermosCompany and its affiliates,
Artisan Collectionby Char-BroilT,_C3and DesignTM, Cbar-Broitand DesignTM, FtameDesignTa,FlavorTects'rMGrill 2GoTM, Grillin'StickTM, Keeperof the FlameTM, Keepersof the FlameTM, NaturatGripTM,
OutdoorCooking Collectionand DecignTM, PatioBistroTM, PrecisionFlameTM, Pro-CheckTM, QuickSetGrills andDesignTM, SmokerTentsTM, The Big EasyTM, The MinuteGrilM'_, The EdgeTM, The Tuscan
CollectionTM, andThe UrbanGrittTM are Trademarksof the W,C,BradleyCompany, UniversalGrillParts and DesignTM isa trademarkof theThermos Companyandits affiliatec.
Protectedunderone or moreof the followingU,S. Patents: 4,598,692;4,624,240;4,747,391; 4,747,391;4,817,583;4,924,846;4,989,579; 5,003,960;5,078,256;5,078,257;5,090,398;5,109,834;5,224,676;
5,277,106;5,421,319;5,44t ,228;5,452,787;5,458,309;5,586,608;5,588,608;5,579,755;5,582,094;5,613,486;5,649,475;5,708,797;5,711,883;0,765,543;5,931,149;5,996,573;6,095,t32; &135,104;
6,173,844B1;6,279,566;6,397,731;6,410,923;6,439,222;6,523,461;8,935,327; D202,819;D339,714;D341,292;D343,337;D358,059;D381,468;D364,535;D372,637; D373,701;D377,735;D383,035;
D397,gt0; D405,643;D405,643;D406,085;D406,009;D413,043;D413,229;D413,229;D414,982;D415,380;D418,164;D416,441;D416,441;D417,587;D422,518;D423,274;D423,078;D42&303; D435,398;
D438,004;D438,059;D438,080;D438,427;D439,110;0442,505;D443,179;D443,354;D447,304;D447,385;D447,909;D440,610;D448,814;D440,615;D44&816; D448,975;D449,492;0451,759;D456,202S;
D480,313,D461,359and D504,048.Canada:87743;07744;92807;92808 and1,318,424.OtherPatentsPending,Assemblyinstructions@2008.
463720607• 463720807,3
T
• NEVERstore a spare LP tank underorneargrillorin
enclosed areas
Never fill the cylinder beyond 80% full.
• An overfllled or improperly stored tank is a hazard due
to possible gas release from the safety relief valve.
LP Tank
• The LP tank used with your grill must meet the following
requirements:
• Use LP tanks only with these required measurements: 12"
(30.5cm) (diameter) x 18" (45.7 cm) (tall) with 20 lb. (9 kg.)
capacity maximum.
, LP tanks must be constructed and marked in accordance with
specifications for LP tank of the U.S. Department of
Transportation (DOT). See LP tank collar for marking.
• LPtank valve must have:
, Type I outletcompatible with
regulator or grill.
, Safety relief valve.
, UL listed Overfill Protection
OPDHandWheel
Device (OPD). This OPDsafety
feature is identified by a unique triangular hand wheel. Use
only LP tanks equipped with this type of valve.
, LP tank must be arranged for vapor withdrawal and include
collar to protect LP tank valve.
LP (Liquefied Petroleum Gas)
• if you see, smell or hear escaping gas, immediately get
away from the LP tank/grill and call your fire
department.
If the above is not followed exactly, a fire causing
death or serious injury may occur.
LP Tank Removal, Transport And Storage
, Turn OFF all control knobs and LP tank valve. Turn coupling
nut counterclockwise by hand only - do not use tools to
disconnect. Lift LP tank wire upward off of LPtank collar, then
lift LP tank up and off of support bracket. Installsafety cap onto
LP tank valve.Always use cap and strap supplied with valve.
Failure to use safety cap as directed may result in serious
personal injury and/or property damage.
LP TankValve
Safety Cap
• LPgas is nontoxic, odorless and colorless when produced. For
Your Safety, LP gas has been given anodor (similar to rotten
cabbage) so that it can be smelled.
• LPgas is highly flammable and may ignite unexpectedly when
mixed with air.
LP Tank Filling
Use only licensedand experienced dealers.
• LPdealer must purge tank beforefilling.
• Dealer should NEVERfill 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 LP
tank valve and call local LP gas dealer for assistance.
, Do not release liquid propane (LP) gas into the atmosphere.
This is a hazardous practice.
, To remove gas 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.
Retainer Strap
, 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 leavean LP tank inside a vehicle
which may become overheated bythe sun.
, Do not store an LP tank in an area where children play.
4 . 463720607,463720807
LP Tank Exchange
Connecting Regulator To The LP Tank
, Many retailers that sell grills offer you the option of replacing
your empty LPtank through an exchange service. Use only
those reputable exchange companies that inspect, precision fill,
test and certify their cylinders. Exchange your tank only for
an OPD safety feature-equipped tank as described in the
"LP Tank" section of this manual,
Always keep new and exchanged LP tanks 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 must be repeated each time LP tank is exchanged or
refilled.
Do not smoke during leak test.
Do not use an open flame to check for gas leaks.
Grill must be leak tested outdoors in a well-ventilated area,
away from ignition sources such as gas fired or electrical
appliances. Duringleak test, keep grill away from open flames
or sparks.
1. LP tank must be properly secured onto grill. (Refer to
assembly section.)
2. Turnall 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.
, Usea 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 bygrowing bubbles.
If "growing" bubbles appear do not use or move the LP tank.
Contact an LP gas supplier or your fire department!
A Do not use household cleaning agents. Damageto gas
train components can result.
Do not use a POL transport plug
(plastic part with external threads)!
Itwill defeat the safety feature of
the valve.
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 soas not to cross-
thread the connection.
Nipplehas to becentered
intothe LPtank valve.
463720607 * 463720807.5
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 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.
Holdcoupling nut and regulator
asshownfor proper connection
to LP tank valve.
6. Turnthe coupling nut clockwise and tighten to a full stop.The
regulatorwill seal on the back-checkfeature 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 regulator and
repeat steps 5 and 6. if you are still unable to complete the
connection, do not use this regulator!
, Do not insert any tool or foreign objects into the valve outlet
or safety relief valve. Youmay 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 yourfire department!
4. Brush soapy solution onto areas where bubbles are shown in
picture below:
A Never remove threaded
orifice at end of valve.
,
If "growing" bubbles appear,there is a leak. Close LP tank
valve immediately and re-tighten connections. Ifleaks cannot
be stopped do not try to repair, Callfor replacement parts.
Order new parts by giving the serial, model number, name and
part numberof items needed (see parts list) to the Grill
Service Center at 1-800-241-7548.
,
Always close LPtank valve after performing leak test by
turning hand wheel clockwise.
, Never attempt to attach thisgrill to the self-contained LP gas
system of a camper trailer or motor home.
, Do not use grill until leak-tested.
6 . 463720607,463720807
For Safe Use Of Your Grill And To Avoid Serious
injury:
* Do not letchildren operate or play near grill.
Keep grill area clear and free from materials that burn.
Donot block holes in bottom or back of grill.
Check burnerflames regularly.
Use grill only in well-ventilated space. NEVER use in
enclosed space such as carport, garage, porch, covered
patio, or under an overhead structure of any kind.
Donot usecharcoal or ceramic briquets in a gas grill.
(Unlessbriquets are supplied with your grill.)
* Usegrill at least 3 ft. from any wall or surface. Maintain
10ft. clearance to objects that can catch fire or sources of
ignitionsuch as pilot lights on water heaters, live electrical
appliances, etc.
Safety Tips
A Before opening LP tank valve, check the coupling nut for
tightness.
A When grill is not in use, turn off all control knobs and LP tank
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 shelves is 10 Ibs.
A Do not use a cooking pot larger than 9" on grid.
A The grease cup must be attached to grease cup clip and
emptied after each use. Do not remove grease cup until grill
hascompletely cooled.
A If you notice grease or other hot material dripping from grill
onto valve, hose or regulator, turn off gas supply at once.
Determine thecause, correct it, then clean and inspect valve,
hoseand regulator before continuing. Perform a leak test.
A The regulator may make a humming or whistling noiseduring
operation. This will not affect safety or use of grill.
Apartment Dwellers:
Checkwith 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.
A If you have a grill problem see the "TroubleshootingSection".
ff the regulator frosts, turn off 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!
* NEVER attempt to light burner with lid closed. A buildup
of non-ignited gas inside a closed grill ishazardous.
Never operate grill with LP tank out of correct position
specified in assembly instructions.
Always close LP tank valve and remove coupling nut
before moving LP tank from specified operation
position.
463720607 * 463720807.7
ignitor Lighting
A Do not lean over grill while lighting.
1. Open lid during lighting.
2. Toignite, turn left knob to_ _ HIGH.
3. Push IGNITOR button rapidly.
4. If ignition does NOT occur in 5 seconds, turn the burner
controls off,wait 5minutes, and repeat the lighting procedure.
5. Ignite right burner,turn knob to _.
6. If ignitor does not work, wait 5 minutes, then follow match
lighting instructions.
CAUTION
If burner does not light, turn knobs to OFF,wait 5
minutes, and try again. Always close valve during the 5
minute waiting period. If the burner does not ignite with
the valve open, gas will continue to flow out of the burner
and could accidentally ignitewith risk of injury.
Match-Lighting
A Do not lean over grill while lighting.
1. Open lid during lighting.
* 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 tank
off.
* Do not leave grill unattended while preheating or
burning off food residue on high. if grill has not been
regularly cleaned, a grease fire can occur that may
damage the product. Follow instructions on General
Grill Cleaning and Cleaning The Burner Assembly to
prevent grease fires.
Before Your First Cookout
. Light burners, check to make sure they are lit, close the lid and
warm up grill on HIGH for 15 minutes. This curing of paint and
parts will produce an odor only on first lighting.
Burner Flame Check
. Light burner, rotate knobs from HIGHto LOW. Youshould see
a smaller flame in LOW positionthan seen on HIGH.Always
check flame prior to each use. If only lowflame is seen referto
"Sudden drop or low flame" in the TroubleshootingSection.
2. Place match into match holder (hanging from side of cart).
3. Push in and turn left knob to _ _ HIGHposition. Be sure
burner lights and stays lit.
4. Light right burner by pushing knob in and turning to _ HIGH
position.
Hose Check
* Before each use, check to see if hoses are cut, worn or kinked.
Replace damaged hoses before using grill. Useonly
valve/hose/regulator specified in the Parts List.
Normal Kinked
Hose Hose
8 . 463720607,463720807
Turning Grill Off
. Turn all knobs to OFF position. Turn LP tank off byturning
OPD handwheel clockwise to a full stop.
I1 ! c ,o. II !
Ignitor Check
• Turn gas off at LP tank. Press and hold ignitor button. "Click"
should be heard and spark seen each time between collector
box or burner and electrodes. See "Troubleshooting"if no click
or spark.
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, knobs should spring back. If knobs
do not spring back, replace valve assembly before using grill.
Turn knobs to LO position then turn back to OFF position.
Valves should turn smoothly.
General Grill Cleaning
, Keep the outside of your grill looking new by cleaning itonce a
month with warm soap and water or a non-abrasive cleaner. If
you don't havea grill cover, wipe off dust and grime before
starting your grill.
, Coating the cooking grids with spray-on cooking oil will keepthe
food from sticking and make clean up easier.After cooking,
scrape the grates with a long handled, brass wire bristle brush.
. Check insidethe grill bottom for grease build up and clean
often, especially after cooking fatty meat.
, Do not mistake brown or black accumulation of grease and
smoke for paint. Apply a strong solution ofdetergent and water
or use a grill cleaner with scrub brush on insides d grill lid and
bottom. Rinse and allow to completely air dry. Do not apply a
caustic grillloven cleaner to painted surfaces.
• Plated wire grates: Wash grates with concentrated grill
cleaner or use soap and water solution. Dry thoroughly and
store indoors between cookouts.
SPIDER ALERT!
GAS COLLECTOR
BOX & IGNITOR
CONTROL PANEl
VALVE AIR VENTURI
SHUTTER
/
If you notice that yourgrill is getting hard to light or that the
flame isn't as strong asit should be,take the timeto checkand
clean theventuri's.
LIFTOUT
BURNER ASSEMBLY
J
CLEAN OUT SPIDERWEBS
VENTURI INSIDEVENTURI
Insomeareasofthecountry,spidersorsmallinsectshavebeen
knowntocreate"flashback"problems.Thespidersspinwebs,build
nestsandlayeggsinthegrill'sventuritube(s)obstructingtheflowof
gasto theburner,Thebacked-upgas canigniteintheventuribehind
thecontrolpanel.Thisis knownasa flashbackanditcandamage
yourgrillandevencauseinjury.
BURNER
REMOVE
BURNER
CLIPS
SPIDER WEBS
INSIDEVENTURI
. 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 grates: Because of glass-like composition, most
residue can bewiped away with baking soda/water solution or
specially formulated cleaner. Use non-abrasive scouring
powder for stubborn stains.
Topreventflashbacksandensuregoodperformancethe burnerand
venturiassemblyshouldberemovedfromthe grillandcleaned
beforeusewheneverthegrillhasbeenidlefor anextendedperiod.
463720607,463720807,9
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