Kenmore 415.162040 Assembly Instructions/use And Care Manual

Assembly Instructions/Use and Care Manual

Liquid Propane Gas Grill

with VapoRISER Smoking Tray
Model No. 415.162040

This Grill Is For
Outdoor Use Only

NO TOOLS

ASSEMBLY

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

• Use and Care

• Troubleshooting

• Safety Rules

Assembly Questions?
Call 1-800-4-MY-HOME

Parts Ordering:
Call 1-800-366-PART (7278)

To Installer/Assembler: Leave
these instructions with
consumer.

To Consumer: Keep this
manual for future reference.

®

463834703 / 0-4165219 (11-18-02)

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

WARNING

FOR YOUR SAFETY

1. Do not store or use gasoline or other
flammable vapors and liquids 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.

FOR YOUR SAFETY
If you smell gas:

1. Shut off gas to the appliance.

2. Extinguish any open flame.

3. Open lid.

4. If odor continues, immediately call your

gas supplier or your fire department.

Call Grill Service Center For Help And Parts

If you have questions or need assistance during assembly,
please call . You will be speaking to a
representative of the grill manufacturer and not a Sears
employee. To order new parts call Sears at .

Product Record

IMPORTANT: Fill out the product record information below.

1-800-241-7548

1-800-4-MY-HOME

Installation Safety Precautions

•

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

•

Grill installation must conform with local codes, or in their
absence with

Z223.1

LP Gas Code 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.

electrical cords and/or fuel supply hoses away from any hot
surfaces.

• 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.

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: Indicates an imminently hazardous situation

which, if not avoided, will result in death or serious injury.

National Fuel Gas Code, NFPA 54 / ANSI

. Handling and storage of LP cylinders must conform to

NFPA/ANSI 58.

Keep any

DANGER

Model Number

UPC (on carton) Label Lot # GG

Serial Number

Date Purchased

CAUTION

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

WARNING

CARBON MONOXIDE HAZARD

Burning charcoal releases carbon monoxide which has no
odor and can cause serious injury or death. Never burn
charcoal inside homes, vehicles or tents.

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.

2 • 463834703

TABLE OF CONTENTS WARRANTY

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

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

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

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

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

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

Parts List...........................................4

Parts Diagram.......................................5

Assembly ........................................6-16

Use and Care ...................................17-27`

VapoRISER Smoking Tray .....................23

Cooking Chart...............................25

Troubleshooting...........................26-27

KENMORE GRILL WARRANTY

Full 1-Year Warranty on Grill

For one year from the date of purchase Sears will repair or
replace, at our option, any grill part (except for paint finish)
that is defective in material or workmanship.

Limited Warranty on Selected Grill Parts

From one year after the date of purchase for the designated
time periods listed below, Sears will replace the following grill
parts if they are defective in material or workmanship. You
will be charged for labor.

• Lifetime of Grill: Aluminum Top and Bottom Castings

(except for paint finish)

• 2 years: Burner Assembly

WARRANTY SERVICE

Warranty service is available by contacting Sears at

®

1-800-4-MY-HOME

.

WARRANTY RESTRICTIONS

This warranty is void if grill is used for commercial or rental
purposes.

This warranty applies only when the grill is used in the United
States.

This warranty gives you specific legal rights, and you may
also have other rights which vary from state to state.

Sears, Roebuck and Co., Dept. 817WA,

Hoffman Estates, IL 60179

463834703 • 3

PARTS LIST – Model No. 415.162040

Key Qty Description Part #

1 2 Leg Assembly.......................4502443

2 1 Base ..............................4503192

3 1 Midshelf ...........................4151035

4 11 #10-24x2” Carriage Bolt ...............4080064

5 12 #10-24 Plastic Tee Knob...............4080091

6 2 Wheel Assembly.....................4310003

7 4 1” Hitch Pin.........................4080062 STD624001

8 2 Leg Extender .......................4154556

9 1 Upper Front Panel ...................4154426

10 1 Lower Front Panel ...................4154557

11 1 Upper Panel Wire ....................4156095

12 1 Condiment Wire .....................4151039

13 1 Grill Bottom.........................4580488

14 1 Burner Assembly ....................4505078

15 1 Collector Box .......................4500278

16 1 #10-16x1/2” Self-Tap Screw ............4080059 STD611005

17 1 Electrode ..........................5156119

18 1 Control Panel .......................4526145

19 4 #10x1/2”, T-20, Self-Tap Screw .........4080043

20 1 Valve/Hose/Regulator Assembly ........4524171

21 1 Electronic Ignition Module .............4153189

22 1 Ignition Module Locking Ring ...........4157145

23 1 Ignitor Wire .........................4153720

24 1 Sideburner Ignitor Wire................5156109

25 2 Control Knob........................4154559

26 2 Valve Clip ..........................4156172

27 2 1/4-20x1-1/4” Carriage Bolt ............4080615 STD532512

28 2 1/4-20 Wing Nut .....................4080221 STD541625

Key Qty Description Part #

29 2 #10-24x1-1/4” Carriage Bolt ............4080074

30 1 Tank Wire ..........................4151019

31 1 VapoRISER Bar Wire .................4151041

32 2 VapoRISER Bar .....................4500306

33 4 EndCap...........................4080065

34 1 Side Shelf ..........................4154373

35 4 #10-12x1-7/8” Wing Screw.............4080096

36 1 Tool Holder .........................4154377

37 1 Sideburner Body.....................4526146

38 1 #10-12x2-1/4” Wing Screw.............4080093

39 1 Sideburner Frame....................4501705

40 4 #10-24 Wing Nut.....................4080063 STD541610

41 1 Sideburner .........................5068018

42 1 Sideburner Knob.....................4154471

43 1 Sideburner Grate ....................4156376

44 1 Grill Lid ............................4580117

45 1 Heat Indicator with Bracket.............4156800

46 1 #10-24 Hex Nut (keps) ................4080208 STD541410

47 1 Logo Plate .........................4157122

48 2 3/16” Pal Nut........................4153096

49 2 1/4x1-1/8” Hinge Pin..................4156513

50 1 Handle ............................4154473

51 2 #10-24x1” Machine Screw .............4080302 STD511010

52 1 SwingAway.........................4152125

53 1 Cooking Grate ......................4152741

54 1 Grease Clip.........................5156607

55 1 AAA Battery ........................4153177

56 1 Ignition Button Assembly ..............4157156

4 • 463834703

PARTS DIAGRAM – Model No. 415.162040

44

53

32

32

43

31

41

4

40

39

37

24

42

4

36

49

6

15

14

7

27

13

1

40

33

4

16

17

49

7

54

3

28

5

5

5

38

40

50

27

28

4

5

46

51

33

35

35

5

4

5

48

47

45

52

34

19

18

35

19

19

29

21

55

1

23

11

4

25

22

29

19

25

26

20

26

56

9

7

4

30

5

5

5

2

5

4

4

6

7

8

4

12

10

463834703 • 5

ASSEMBLY – Model No. 415.162040

Cart Assembly Step 1

Position base on edge with tank hole to left side.

1

Leg Assembly

Insert legs into base and attach with carriage bolts
and plastic wing nuts. DO NOT FULLY TIGHTEN.
Insert midshelf into holes on insides of legs, long
wires toward left side. Fully tighten carriage bolts
and plastic wing nuts.

5

Qty. 8

4

Qty. 8

Long midshelf wire
to left side.

IMPORTANT!

USE TOP HOLE

4

5

Base

6 • 463834703

Cart Assembly Step 2

Insert wheel/hubcap assemblies into

2

Wheel/Hubcap Assembly

bottom holes on left legs.
Secure beneath base with hitch pins.
See inset below.
Push leg extenders into right legs.

7

Qty. 2

7

Leg Extender

Completed assembly with
hitch pin in axle bolt.

463834703 • 7

3

Upper And Lower Front Panel Assembly

Snap the upper and lower front panels together.
Insert the two pins on lower panel into holes in
front of cart base.
Snap the upper panel over the midshelf wire.

Upper Front Panel

Lower Front Panel

Upper panel
snaps onto
midshelf wire.

8 • 463834703

NOTE: Rear view of cart.
Wheels are to right side.

4

Upper Panel Wire And Condiment Wire Assembly

Insert panel wire through upper panel and into leg,
then bend wire slightly to insert opposite end.
Hook the outer condiment wires into the top holes
on front of upper panel, then slide remaining wires
into panel holes below the condiment shelf.

Upper Panel Wire
(Bend slightly to insert)

NOTE: Rear view of cart.
Wheels are to right side.

NOTE: front view of cart.
Wheels are to left side.

Condiment Wire

463834703 • 9