Kenmore 415.16117 Assembly Instructions/use And Care Manual
Assembly Instructions/Use and Care Manual
Liquid Propane Gas Grill
Kenmore Model No. 415.16117
Kmart Item No. 640-104261-110
This Grill Is For
Outdoor Use Only
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
• 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.
• Use and Care
• Troubleshooting
• Español
®
Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A.
©2006 Sears, Roebuck and Co., All Rights Reserved
Printed in China
4 2 7 • 6 2 0 8 0 0 846 32 10 4 43 19 7 • 00 9283 • 3-25-0
If you smell gas:
DANGER
Safety Symbols
The symbols and boxes shown below explain what each heading
means. Read and follow all of the messages found throughout
the manual.
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.
WARNING
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.
Call Grill Service Center For Help And Parts
If you have questions or need assistance during assembly,
please call 1-800-241-7548. You will be speaking to a
representative of the grill manufacturer and not a Sears
employee. To order new parts call Sears at 1-800-4-MY-HOME .
Product Record
IMPORTANT: Fill out the product record information below.
Model Number
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
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 conform with local codes, or in their
absence of local codes, with either the National Fuel Gas
Code, ANSI Z223.1/ NFPA 54, Natural Gas and Propane
Installation Code, CSA B149.1, or Propane Storage and
Handling Code, B149.2, or the Standard for Recreational
Vehicles, ANSI A 119.2/NFPA 1192, and CSA Z240 RV Series,
®
Recreational Vehicle Code, 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/or fuel supply hoses away from any hot surfaces.
• Grill is not for use in or on recreational vehicles and/or boats.
• 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.
Serial Number
See rating label on grill for serial number.
Date Purchased
CAUTION
For residential use only. Do not use for commercial
cooking.
2 • 464321907 • 464322107
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
Use and Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Parts Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-24
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-27
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 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:
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.
®
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
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 Stainless Steel Burners
For five years from the date of purchase, any stainless steel
burner that rusts through will be replaced free of charge. After the
first year from the date of purchase, you pay for labor if you wish 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 use within the warranty 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 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 legal rights, and you may have
other rights which vary from state to state.
Sears, Roebuck and Co., Hoffman Estates, IL 60179
®
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. call 1-800-4-MY-HOME
®
464322107 • 464321907 • 3
USE AND CARE
DANGER
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.
• NEVER store a spare LP tank under or near grill or in
enclosed areas
• Never fill the cylinder beyond 80% full.
• An overfilled or improperly stored tank is a hazard due
to possible gas release from the safety relief valve.
This could cause an intense fire with risk of property
damage, serious injury or death.
• If you see, smell or hear escaping gas, immediately get
away from the LP tank/grill and call your fire
department.
• 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 1 outlet compatible with
regulator or grill.
• Safety relief valve.
• UL listed Overfill Protection
Device (OPD). This OPD safety
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.
OPD Hand Wheel
LP (Liquefied Petroleum Gas)
• LP gas is nontoxic, odorless and colorless when produced. For
Your Safety, LP gas has been given an odor (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 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 LP tank collar, then
lift LP tank up and off of support bracket. Install safety 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 Tank Valve
Safety Cap
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 leave an LP tank inside a vehicle
which may become overheated by the sun.
LP Tank Filling
• Use only licensed and experienced dealers.
• LP dealer must purge tank before filling.
• Dealer should NEVER fill 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.
• Do not store an LP tank in an area where children play.
4 • 464321907 • 464322107
LP Tank Exchange
Connecting Regulator To The LP Tank
• Many retailers that sell grills offer you the option of replacing
your empty LP tank 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. During leak test, keep grill away from open flames
or sparks.
• Use a 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 by growing bubbles.
WARNING
1. LP tank must be properly secured onto grill. (Refer to
assembly section.)
2. Turn all 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.
c
k
w
o
i
l
s
e
Strap and Cap
OPD Hand Wheel
Type 1 outlet with
thread on outside
Safety Relief Valve
C
f
f
O
Do not use a POL transport plug
(plastic part with external threads)!
It will defeat the safety feature of
the valve.
If “growing” bubbles appear do not use or move the LP tank.
Contact an LP gas supplier or your fire department!
s Do not use household cleaning agents. Damage to gas train
components can result.
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 so as not to crossthread the connection.
Nipple has to be centered
into the LP tank valve.
464322107 • 464321907 • 5
tS raight
Hold coupling nut and regulator
as shown for proper connection
to LP tank valve.
6. Turn the coupling nut clockwise and tighten to a full stop. The
regulator will seal on the 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 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 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:
®
s 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 unable to complete the
connection, do not use this regulator!
DANGER
• Do not insert any tool or foreign objects into the valve outlet
or safety relief valve. You may 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, STOP and call the fire
department.
• If you cannot stop a gas leak, immediately close LP tank
valve and call LP gas supplier or your fire department!
WARNING
• Never attempt to attach this grill to the self-contained LP gas
system of a camper trailer 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 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 • 464321907 • 464322107
WARNING
For Safe Use Of Your Grill And To Avoid Serious
Injury:
• Do not let children operate or play near grill.
• Keep grill area clear and free from materials that burn.
• Do not block holes in bottom or back of grill.
• Check burner flames 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.
• Do not use charcoal or ceramic briquets in a gas grill.
(Unless briquets are supplied with your grill.)
• Use grill at least 3 ft. from any wall or surface. Maintain
10 ft. clearance to objects that can catch fire or sources of
ignition such as pilot lights on water heaters, live electrical
appliances, etc.
Safety Tips
s Before opening LP tank valve, check the coupling nut for
tightness.
s When grill is not in use, turn off all control knobs and LP tank
valve.
s Never move grill while in operation or still hot.
s Use long-handled barbecue utensils and oven mitts to avoid
burns and splatters.
s Maximum load for shelves is 10 lbs.
s Do not use a cooking pot larger than 9” on grid.
s The grease cup must be attached to grease cup clip and
emptied after each use. Do not remove grease cup until grill
has completely cooled.
s 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,
hose and regulator before continuing. Perform a leak test.
s The regulator may make a humming or whistling noise during
operation. This will not affect safety or use of grill.
• Apartment Dwellers:
Check with 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.
• NEVER attempt to light burner with lid closed. A buildup
of non-ignited gas inside a closed grill is hazardous.
• 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.
s If you have a grill problem see the "Troubleshooting Section".
WARNING
If 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!
464322107 • 464321907 • 7
CAUTION
• 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.
Sideburner Ignitor Lighting
1. Top cover must be open when burner is operational.
2. To ignite SIDEBURNER, open sideburner cover.
3. Turn sideburner knob to , push and hold ELECTRONIC
IGNITOR button.
4. If sideburner does NOT light in 5 seconds, turn knob to OFF,
wait 5 minutes, then repeat lighting procedure.
Sideburner Match Lighting
1. Open top cover.
2. Hold lit match to any port on the burner. Push in and turn
sideburner knob to HIGH. Be sure burner lights and
stays lit.
Turn on gas at LP tank.
Main Burner Ignitor Lighting
s Do not lean over grill while lighting.
1. Open lid during lighting.
2. To ignite, turn IGNITION BURNER knob to .
3. Push and hold ELECTRONIC IGNITION button.
4. If ignition does NOT occur in 5 seconds, turn the burner
controls off, wait 5 minutes, and repeat the lighting procedure.
5. Ignite other burners by turning 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 ignite with risk of injury.
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 HIGH to LOW. You should see
a smaller flame in LOW position than seen on HIGH. Always
check flame prior to each use. If only low flame is seen refer to
"Sudden drop or low flame" in the Troubleshooting Section.
HI
LO
Hose Check
• Before each use, check to see if hoses are cut, worn or kinked.
Replace damaged hoses before using grill. Use only
valve/hose/regulator specified in the Parts List.
Match-Lighting
s Do not lean over grill while lighting.
1. Open lid during lighting. Turn on gas at LP tank.
2. Place match into match holder (hanging from side of cart).
Light match, place into lighting hole on right side of firebox.
3. Push in and turn right knob to HIGH position. Be sure burner
lights and stays lit.
4. Light other burners by pushing knob in and turning to HIGH
position.
8 • 464321907 • 464322107
Normal
Hose
Kinked
Hose
Turning Grill Off
• Turn all knobs to OFF position. Turn LP tank off by turning
OPD hand wheel clockwise to a full stop.
CAUTION
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. 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 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 it once 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.
• Coating the cooking grids with spray-on cooking oil will keep the
food from sticking and make clean up easier. After cooking,
scrape the grates with a long handled, brass wire bristle brush.
• Check inside the grill bottom for grease build up and clean
often, especially after cooking fatty meat.
SPIDER ALERT!
SPIDER AND WEBS
INSIDE BURNER TUBE
If you notice that your grill is getting hard to light or that the
flame isn’t as strong as it should be, take the time to check and
clean the burner’s.
CONTROL PANEL
VALVE
SPIDER WEBS
INSIDE TUBE
BURNER
• Do not mistake brown or black accumulation of grease and
smoke for paint. Apply a strong solution of detergent and water
or use a grill cleaner with scrub brush on insides of grill lid and
bottom. Rinse and allow to completely air dry. Do not apply a
caustic grill/oven 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.
• Plastic parts: Wash with warm soapy water and wipe dry.
s 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 be wiped away with baking soda/water solution or
specially formulated cleaner. Use non-abrasive scouring
powder for stubborn stains.
In some areas of the country, spiders or small insects have been
known to create “flashback” problems. The spiders spin webs, build
nests and lay eggs in the grill’s burner tube(s) obstructing the flow of
gas to the burner. The backed-up gas can ignite in the tube behind
the control panel. This is known as a flashback and it can damage
your grill and even cause injury.
To prevent flashbacks and ensure good performance the burner
assembly should be removed from the grill and cleaned before use
whenever the grill has been idle for an extended period.
464322107 • 646321907 • 9
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