Kenmore 640-134892-116, 41516106 Owner’s Manual

Assembly instructions/Useand CareManual

LiquidPropaneGasGrill

Kenmore ModelNo.415.16106

Kmart Item No. 640-134892-116

This Grill is For
Outdoor UseOnly

®

, 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

• Safety Rules

Assembly Questions?

Call 1=800=241=7548
Parts Ordering:

Call 1=800=4=MY=HOIVlE®

To InstalledAssembler: Leave
these instructions with

consumer.
To Consumer: Keep this

manual for future reference.

• Use and Care

• Troubleshooting

• Espahol

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

(#2006 Sears, Roebuck and Co., All Rights Reserved Printed in China 464720707. 80004886 •11-21-06

Ifyou smellgas:

1. Shutoffgasto the appliance.

2. Extinguish any openflame.

3. Openlid.

4. Ifodorcontinues,keepawayfrom the
applianceand immediatelycallyour gas
supplieror yourfire department.

Safety Symbols

The symbolsand boxes shown below explain what each heading

means. Read and follow all of the messages found throughout

the manual.

DANGER: Indicatesan 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 instructionsare not followed. Be sureto read and

carefully follow allof the messages.

1. Donotstoreor use gasolineorother

flammableliquidsorvaporsin the vicinityof
thisor any otherappliance.

2. An LPcylindernotconnectedfor use shaftnot

bestoredin the vicinityof thisoranyother

appliance.

Carl Grifl Service Center For Help And Parts
Ifyou havequestions or need assistance during assembly,

please call 1.800.241.7548. Youwill be speaking to a
representative ofthe grill manufacturer and nota Sears

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

ProductRecord
IMPORTANT:Fillouttheproductrecordinformationbelow.

Model Number

cAo.

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

installation Safety Precautions

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

• Grill installation must conformwith localcodes, or in their
absence d local codes, with either the National Fuel Gas
Code, ANSI Z223.1/NFPA 54, Natural Gasand Propane

Installation Code, CSA B149.1, or Propane Storage and
Handling Code, B149.2,orthe Standard for Recreational

Vehicles,ANSI A 119.2/NFPA1192,and CSA Z240 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 70. Keep any electrical

cords and/orfuel supply hoses away from any hot surfaces.

• Grill is notfor use in or on recreationalvehicles and/or boats.

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

in a safety hazard.

Serial Number

Seeratinglabelongrillforserialnumber.

Date Purchased

m m

cAuT,o.

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

2,464720707

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

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

KENMORE GRILL WARRANTY

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

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

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

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

Use and Care .................................... 4-10

Parts List .......................................... 11

Parts Diagram...................................... 12

Assembly ....................................... 13-24

Troubleshooting.................................. 25-26

Repair Protection Agreements
Congratulations on making a smart purchase. Your new

Kenmore®product is designed and manufactured for years of
dependable operation. But like all products, it mayrequire repair

from time to time. That's when having a Repair Protection
Agreement can save you money andaggravation.

Purchase a Repair ProtectionAgreement now and protect
yourself from unexpectedhassle and expense.

Here's what's included inthe Agreement:

[] Expert service by our 12,000 professional repair specialists
[] Unlimited service and no charge for parts and laboron all

covered repairs

[] Product replacement if your covered product can't be fixed
[] Discount of 10%from regular price of service and service-

related parts not covered by the agreement; also, 10% off
regular price of preventive maintenance check

[] Fast help by phone- phonesupportfrom 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.Youcan 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 millionquality parts and accessories. That's
the kind of professionalism you can count on to help prolong the
life of your new purchase for yearsto come. Purchase your

Repair Protection Agreement today!
Some limitations and exclusions apply.

For prices and additional information call 1-800-827-6655.
Sears installation Service

One Year Full Warranty on Kenmore Grill
If this grill fails due toa defect in materialorworkmanship

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).

Two-Year Limited Warranty on Stainless Steel Burners
For two years from the date of purchase,any stainless steel

burner that rusts through will be replacedfree ofcharge.After
thefirst yearfrom the date of purchase,you payfor labor if

youwish to have it installed.

All warranty coverage excludes ignitor batteries and grill part

paint loss, discoloration or rusting, which are either
expendable parts that can wear out from normal usewithin

thewarranty period, or are conditions that can be the result
of normal use, accident or improper maintenance.

All warranty coverage is void if this grill is used for

commercial or rental purposes.

This warranty coverage applies only if this grill is used in the
United States.

This warranty gives you specific legalrights, and you may
have other rights which varyfrom state to state.

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

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

U.S.A. call 1-800-4-MY-HOME®

464720707.3

T

• NEVER store 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.

• LP tank valve must have:
, Type I outletcompatible with

regulator or grill.

, Safety reliefvalve.
, ULlisted 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 andinclude

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, afire causing

death or serious injury may occur.

LP Tank Removal, Transport And Storage
, Turn OFF all control knobsand LP tank valve. Turn coupling

nut counterclockwise by hand only - do not use tools to
disconnect. LiftLPtank wire upward off of LPtank collar,then

lift LP tank upand 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

• LP gas is nontoxic, odorless andcolorless when produced. For
Your Safety, LP gas has been given anodor (similar to rotten

cabbage) so that it can be smelled.

• LP gas is highly flammable and may ignite unexpectedly when
mixed with air.

LP Tank Filling

Use only licensedand experienced dealers.

• LP dealer must purge tank beforefilling.

• Dealer should NEVERfill LPtank more than 80% of LP tank
volume. Volume of propane in tank will vary by temperature.

• A frosty regulator indicates gas overfill, immediatelyclose 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.

, Toremovegas from LP tank, contact an LPdealer 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 instorage or being transported must

have a safetycap installed (as shown). Do not store an LP tank
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 anLPtank in an area where children play.

4 • 464720707

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 certifytheir 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 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 must be repeated each time LPtank 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 inawell-ventilated area,
away from ignition sources such as gas fired or electrical

appliances. Duringleak test, keep grill away fromopen flames
or sparks.

1. LPtank must be properly secured onto grill. (Refer to

assembly section.)

2. Turnall control knobs to the OFF position.

3. Turn LP tank OFFby 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 anda 50/50 mild soap and water

solution. Brush soapy solution onto areas indicated by arrows
in figure below.Leaksare indicated by growing 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. Damage to 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-tightenthe 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.

464720707• 5

Holdcoupling nut and regulator
asshownfor properconnection

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 insome 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. Besure regulator istightly connected to LPtank.

3. Completelyopen LP tank valve byturning 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-HONIE®.

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

A Never remove threaded

orifice at end of valve.

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

connection, do not use this regulator!

. Donot 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 resultin explosion, fire, severe

personal injury,or death..

. If a leak is detectedat any time, STOPand call the fire

department.

. If you cannot stop a gas leak, immediately close LPtank

valve and call LP gas supplier or yourfire department!

. Never attempt to attach thisgrill to the self-contained LPgas

system of a campertrailer or motorhome.

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

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

6. Always close LPtank valve afterperforming leak test by
turning hand wheel clockwise.

. Donot use grill until leak-tested.

6°464720707

For Safe Use Of Your Grill And To Avoid Serious

injury:

* Donot let children operate or play near grill.

Keep grill area clear and free from materials that burn.
Donot block holes in bottom or backof grill.
Check burnerflames regularly.

Use grill only inwell-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 agas grill.

(Unlessbriquets are supplied with your grill.)

* Use grill at least 3 ft. from any wall or surface. Maintain

10ft. clearanceto objects that can catch fire or sources of
ignitionsuch as pilot lights on water heaters, live electrical

appliances, etc.

Safety Tips
A Before opening LPtank valve, check the coupling nut for

tightness.

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

valve.

A Nevermove grill while in operation or still hot.
A Uselong-handled barbecue utensils and oven mitts to avoid

burnsand splatters.

A Maximumloadfor shelves is 10 Ibs.
A Do not usea cooking pot larger than 9" ongrid.

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 Ifyou notice grease or other hot material dripping from grill

onto valve, hose or regulator, turn off gas supply at once.

Determine the cause, correct it, then clean and inspect valve,
hoseand regulator before continuing. Perform a leaktest.

A The regulator may make ahumming 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 inyour apartment complex. If
allowed, use outside on the ground floor with a three (3) foot

clearance from walls or rails. Donot use on or under

balconies.

A Ifyou 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 LPtank valve and remove coupling nut

before moving LP tank from specified operation

position.

464720707o7

ignitor Lighting

A Donot lean over grill while lighting.

1. Open lid during lighting.

2. Toignite, turn left knob to4 _ HIGH.

Sideburner ignitor Lighting

1. To ignite SIDEBURNER, turn knob to ..€ _ HIGH.

2. Push IGNITOR button rapidly.

3. If sideburner does NOT light in 5 seconds,turn knob to OFF,
wait 5 minutes,then repeat lighting procedure.

3. Push IGNITOR button rapidly.

4. Ifignition does NOT occur in5 seconds, turn the burner
controls off, wait 5 minutes, and repeat the lighting procedure.

5. Ignite right burner,turn knob to _.

6. Ifignitor 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. Ifthe 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.

Sideburner Match Lighting

1. Turnon gas at LP tank.

2. Hold lit match to any port on the burner. Push in and turn
sideburner knob to._ _ HIGH. Be sure burner lightsand

stays lit.

-- m

cAu'r,o.

* 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, agrease fire can occur that may

damage the product. Follow instructions on General

Grill Cleaning and Cleaning The Burner Assembly to
prevent grease fires.

2. Place match into match holder (hangingfromside of cart).

3. Push in and turn left knob to _ _ HIGH position. Be sure
burner lights and stays lit.

4. Light right burner by pushing knob in and turning to _ HIGH
position.

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 inLOW position than seen on HIGH.Always
check flame priorto each use. If only lowflame is seen referto

"Sudden drop or low flame" in the TroubleshootingSection.

Hose Check

* Beforeeach use, check to see if hoses arecut, worn or kinked.

Replace damaged hoses before using grill. Useonly

valve/hose/regulator specified in the Parts List.

8• 464720707

Normal Kinked
Hose Hose

Turning Grill Off

. Turn all knobs to OFF position. Turn LP tank off byturning

OPD handwheel clockwise to a full stop.

I1 ! c Io. II i

ignitor Check

• Turn gas off at LP tank. Press and hold ignitor button. "Click"
should be heardand spark seen each timebetween collector

box or burnerand electrodes. See "Troubleshooting"if noclick
or spark.

Valve Check

Important: Make sure gas is off at LP tank before checking
valves. Knobslock in OFF position. Tocheck valves, first
push inknobsand 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 anon-abrasive cleaner. If
you don't have a grill cover, wipe off dust and grime before
starting your grill.

, Coatingthe cooking grids with spray-on cooking oil will keepthe

food from stickingand make clean up easier.After cooking,
scrape the grates with a longhandled, 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 blackaccumulation of grease and

smoke for paint. Apply astrong solution of detergent 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 thoroughlyand

store indoors between cookouts.

SPIDER ALERT!

GAS COLLECTOR

BOX & IGNITOR

CONTROL PANEl

VALVE AIR VENTURI

SHUTTER

If you notice thatyourgrill is getting hard to light or that the
flame isn't as strong as it should be,takethe timeto checkand

clean the venturi's.

LIFTOUT

BURNERABSEMBLY

CLEAN OUT SPIDERWEBS

VENTURI INSIDEVENTURI

Insomeareasofthecountry,spidersorsmallinsectshavebeen
knowntocreate"flashback"problems.Thespidersspinwebs,build

nestsandlayeggsin thegrill'sventuritube(s)obstructingtheflowof
gasto theburner,Thebacked-upgascanigniteintheventuribehind
thecontrolpanel.Thisis knownasa flashbackanditcan damage

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 solutionor

specially formulated cleaner. Use non-abrasive scouring
powder for stubborn stains.

Topreventflashbacksandensuregoodperformancetheburnerand
venturiassemblyshouldberemovedfromthegrillandcleaned

beforeusewheneverthegrillhasbeenidleforanextendedperiod.

464720707o9