Kenmore 640-104261-110 Owner’s Manual
Assembly instructions/Use and Care Manual
LiquidPropaneGasGrill
KenmoreModelNo. 415.16117
Kmart Item No. 640-104261-110
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 464322107. 464321907•80009283,11-04-06
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 symbols and 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 not avoided, will result in death or serious injury.
WARNING: Bealertto the possibility of serious bodily injury
if the instructions are not followed. Be sureto read and
carefully follow all of the messages.
1. Donotstoreor usegasolineorother
flammableliquidsorvaporsin the vicinityof
thisor any otherappliance.
2. AnLPcylindernotconnectedfor use shaftnot
bestoredin the vicinityof thisor any other
appliance.
Carl Grifl Service Center For Help And Parts
Ifyou have questions or need assistance during assembly,
please call 1.800.241.7548. Youwill be speaking to a
representative ofthe grill manufacturer and not a 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 situationwhich,
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 d 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/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 United States 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.
2,464321907 * 464322107
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
One-YearFullWarranty on KenmoreGrill
If thisgrillfailsduetoadefect inmaterialorworkmanshipwithin
oneyearfromthedateof purchase,call 1-800-4-MY-HOME®to
arrangeforfreerepair(orreplacementifrepairprovesimpossible).
Five-YearLimitedWarrantyon StainlessSteelBurners
Forfiveyearsfromthe dateof purchase,anystainlesssteel
bumerthatruststhroughwillbereplacedfreeofcharge.Afterthe
firstyearfromthedateof purchase,youpayforlaborifyouwishto
haveit installed.
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 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 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- 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. 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.
Sears installation Service
All warrantycoverageexcludesignitorbatteriesandgrillpartpaint
loss,discolorationor rusting,whichareeitherexpendableparts
thatcanwearoutfromnormalusewithinthewarrantyperiod,or
areconditionsthatcan betheresultof normaluse,accidentor
impropermaintenance.
All warrantycoverageis voidif thisgrilliseverusedfor
commercialor rentalpurposes.
All warrantycoverageappliesonlyif thisgrillisusedin theUnited
States.
Thiswarrantygivesyouspecificlegalrights,andyou mayhave
otherrightswhichvaryfromstatetostate.
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®
464322107. 464321907.3
• NEVER store a spare LPtank 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.
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 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)
• 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.
• if you see, smell or hear escaping gas, immediately get
away from the LP tank/grill and call your fire
department.
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, 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 TankVamve
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 leavean LP tank inside a vehicle
which may become overheated bythe sun.
• LP gas is highlyflammable and may ignite unexpectedly when
mixed with air.
LP Tank Filling
Use only licensed and experienced dealers.
• LP dealer 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. 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 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 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-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.
464322107•464321907• 5
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-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 istightly connected to LP tank.
3. Completely open 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 unable to 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 result in explosion, fire, severe
personal injury,or death..
. If a leak is detectedat 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!
. 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 LPtank valve after performing leak test by
turning hand wheel clockwise.
. Donot use grill until leak-tested.
6,464321907. 464322107
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 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 use charcoal 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 beattached to grease cup clip and
emptied after each use. Do not remove grease cup until grill
hascompletely cooled.
A If you notice greaseor 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 a humming or whistling noise during
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 is hazardous.
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.
464322107,464321907,7
CAUTION
Putting outgrease 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
preventgrease fires.
Main Burner ignitor Lighting
A Do not lean over grill while lighting.
1. Open lidduring lighting.
2. Toignite, 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. igniteother burners byturning knob to 5.
6. if ignitor does not work, wait 5 minutes, then follow match
lighting instructions.
Sideburner ignitor Lighting
1. Top cover must be open when burner is operational.
2. To ignite SIDEBURNER, open sidebumer cover.
3. Turn sidebumer knob to _ _, push and hold ELECTRONIC
iGNiTOR button.
4. if sidebumer does NOT light in 5 seconds, turn knob to OFF,
wait 5 minutes, then repeat lighting procedure.
Sideburner Match Lighting
1. Open top cover. Turn on gas at LP tank.
2. Hold lit match to any port on the burner. Push in and turn
sidebumer knob to_ _ HIGH. Be sure burner lights and
stays lit.
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. Youshould see
a smaller flame in LOW position than seen on HIGH.Always
check flame prior to each use. If only lowflame is seen referto
"Sudden drop or low flame" in the Troubleshooting Section.
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 ignitewith
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. Turn on gas at LP tank.
2. Place match into match holder (hanging from side of cart).
Light match, placeinto lighting hole on rightside of firebox.
3. Push in and turn right knob to HiGH position. Besure burner
lights and stays lit.
4. Light other burners by pushing knob in and turning to _ HiGH
position.
Hose Check
• Beforeeach 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• 464321907•464322107
Turning Grill Off
. Turn all knobs to OFF position. Turn LP tank off byturning
OPD handwheel clockwise to a full stop.
Ignitor Check
• Turn gas off at LP tank. Pressand 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
f
SPIDER ALERT!
SPIDER AND WEBS ....ii_
• 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 inside the 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.
INSIDE BURNER_::,I_TUBE
If younotice that your grill is getting hard to light or that the
flame isn't as strong as it should be, take the timeto checkand
clean the burner's.
CONTROLPANEL. INSIDE TUBE
SPIDER WEBS
BURNER
!
Insomeareasofthecountry,spidersorsmallinsectshavebeen
knowntocreate"flashback"problems.Thespidersspinwebs,build
nestsandlayeggsin thegrill'sburnertube(s)obstructingtheflowof
gasto theburner.Thebacked-upgascanigniteinthetubebehind
thecontrolpanel.Thisis knownasa flashbackanditcandamage
yourgrillandevencauseinjury.
. 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.
Topreventflashbacksandensuregoodperformancetheburner
assemblyshouldberemovedfromthegrillandcleanedbeforeuse
wheneverthegrillhasbeenidleforanextendedperiod.
\ Y
464322107 • 646321907 • 9
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