Kenmore 41516109 Owner’s Manual

Assembly Instructions/Useand CareManual

LiquidPropaneGasGrill

Model No. 415.16109

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 e×plosion 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 464820907,80009273 * 12-06-06

Ifyou smellgas:

1. Shutoffgasto the appliance.

2. Extinguish any openflame.

3. Openlid.

4. Ifodorcontinues,keepawayfrom the
applianceand immediatelycallyourgas
supplieror yourfire department.

Safety Symbols

The symbolsand boxes shown below explain what each heading

means. Read and follow allof the messages found throughout

the manual.

DANGER: Indicatesan imminently hazardous situation
which, if notavoided, will result in death or serious injury.

WARNING: Bealertto 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 LP cylindernotconnectedfor useshaftnot

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:Filloutthe productrecordinformationbelow.

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 eitherthe 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 not for use in or on recreationalvehicles and/or boats.

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

in a safety hazard.

Serial Number

Seeratinglabelongrillfor serialnumber.

Date Purchased

m m

cAuT,o.

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

2,464820907

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 asmart purchase. Your new

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 andaggravation.

Purchase a Repair ProtectionAgreement now andprotect
yourself from unexpectedhassle andexpense.

Here's what's included inthe Agreement:

[] Expert service by our 12,000 professional repair specialists
[] Unlimited service and no charge for parts and labor on 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- phone support from a Sears

technician on products requiring in-home repair,plus
convenient repair scheduling

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

night, or schedule aservice appointment online.
Sears has over 12,000 professional repairspecialists,who have

access to over 4.5 millionquality parts and accessories. That's
the kind of professionalism you can count onto 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 homeappliances, garage
door openers, water heaters, and other major home items, in the

U.S.A. call 1-800-4-MY-HOME®

464820907.3

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 inaccordance 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 outlet compatible 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 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, afire 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. 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 and colorless when produced. For
Your Safety, LP gas has been given an odor (similarto 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 before filling.

• 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.

, Toremove gas from LP tank, contactan 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 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 an LP tank in an area where children play.

4 • 464820907

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 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 ina well-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 solutiononto 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. 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-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.

464820907 • 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 LP tank.

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 and6. 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 LP tank

valve and call LP gas supplier or yourfire department!

. Never attempt to attach thisgrill to the self-contained LP gas

system of a campertrailer or motor home.

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 after performing leak test by
turning hand wheel clockwise.

. Donot use grill until leak-tested.

6• 464820907

For Safe Use Of Your Grill And To Avoid Serious

injury:

* Donot letchildren 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 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 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 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 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 in your 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 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.

464820907.7

ignitor Lighting

A Do not 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 in 5 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. 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.

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. Besure 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, 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.

2. Place match into match holder (hangingfrom 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 ,i 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 low flame 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• 464820907

Normal Kinked
Hose Hose

Turning Grill Off

. Turn all knobsto OFF position. Turn LP tank off by turning

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 heardand spark seen each time between 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. To check valves, first
push inknobsand release, knobs should spring back. If knobs
do not spring back, replace valve assemblybefore using grill.

Turn knobs to LO positionthen 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 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 cookingfatty meat.

, Do not mistake brown or blackaccumulation of grease and

smoke for paint. Apply a strong 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 thatthe
flame isn't as strong as it should be, take the timeto checkand

clean the venturi's.

LIFTOUT

BURNER ASSEMBLY

J

CLEAN OUT SPIDERWEBS

VENTURI INSIDEVENTURI

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

nestsandlayeggsin thegrill'sventuritube(s)obstructingtheflowof
gasto theburner,Thebacked-upgascan igniteinthe venturibehind
thecontrolpanel.Thisis knownasa flashbackanditcandamage

yourgrillandevencauseinjury.

BURNER

REMOVE
BURNER

CLIPS

SPIDER WEBS

INSIDEVENTURI

. Plastic parts: Wash with warm soapywater 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. Usenon-abrasive scouring
powder for stubborn stains.

Topreventflashbacksandensuregoodperformancetheburnerand
venturiassemblyshouldberemovedfromthegrillandcleaned

beforeusewheneverthegrillhasbeenidleforanextendedperiod.

464820907,9