Kenmore 640-119560-118, 41516107 Owner’s Manual

Assembly instructions/Use and Care Manual

LiquidPropaneGasGrill

Kenmore Model No. 415.16107
Kmart Item No. 640-119560-118

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 inChina 464820707. 80004867•11-29-06

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 boxesshown below explain what each heading

means. Read andfollow all of the messagesfound 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 seriousbodily injury
if the instructionsare not followed. Be sure to read and

carefully follow all of the messages.

1. Donotstoreor use gasolineorother

flammableliquidsorvaporsinthe vicinityof
thisor any otherappliance.

2. AnLPcylindernotconnectedfor useshaftnot

bestoredin the vicinityof thisoranyother

appliance.

Carl Grifl Service Center For Help And Parts
Ifyou have questions or needassistance duringassembly,

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

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

ProductRecord
iMPORTANT:Fillouttheproductrecordinformationbelow.

Model Number

cAo.

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

installation Safety Precautions

• Use grill, aspurchased, only with LP (propane) gas andthe
regulator/valve assemblysupplied.

• Grill installation mustconformwith localcodes, or in their
absence d local codes, with eitherthe 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 accordancewith local codes, or
National Electrical Code,ANSI/NFPA 70. Keep any electrical

cords and/orfuel supply hosesaway 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 asafety hazard.

Serial Number

Seeratinglabelongrillforserialnumber.

Date Purchased

m m

cAuT,o.

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

2,464820707

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

Grill ServiceCenter................................... 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.................................. 25-27

Repair Protection Agreements
Congratulations onmaking a smart purchase. Yournew

Kenmore®product isdesigned and manufactured for years of
dependable operation.But like all products,it may require repair

from timeto time. That's when having a Repair Protection
Agreement can save you money and aggravation.

Purchase aRepair ProtectionAgreement now andprotect
yourself from unexpectedhassle and expense.

Here's what's included inthe Agreement:

[] Expert service by our 12,000 professionalrepair 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 ofservice and service-

related parts not coveredby the agreement; also, 10%off
regular price of preventivemaintenance check

[] Fast help by phone- phone support from a Sears

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

Once you purchasethe Agreement, a simple phonecall is all that
it takes for you toschedule 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 andaccessories. That's
the kind of professionalism youcan count onto help prolong the
life of your new purchasefor years to come. Purchaseyour

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 grillfails due toa defect in material or workmanship

within one yearfrom thedate 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 willbe replacedfree ofcharge. After
thefirst year from the date of purchase,you payfor labor if

youwish to have it installed.

All warranty coverage excludes ignitor batteries and grillpart

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

thewarranty period, orare conditions that can bethe 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 onlyif this grillis used inthe
United States.

This warranty gives you specific legal rights, and you may
have other rightswhich vary from 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®

464820707.3

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 onlywiththese required measurements: 12"
(30.5cm) (diameter) x 18" (45.7 cm)(tall) with 20 lb. (9 kg.)

capacity maximum.

, LP tanks must beconstructed 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 vaporwithdrawal 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, a fire causing

death or serious injury may occur.

LP Tank Removal, Transport And Storage
, Turn OFFall control knobsand LP tank valve. Turncoupling

nut counterclockwise by hand only - do not use tools to
disconnect. Lift LP tank wire upward offof LPtank collar, then

lift LPtank up and offof support bracket. Install safety cap onto
LP tank valve.Always use cap andstrap supplied withvalve.

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 hasbeen given an odor (similarto rotten

cabbage) so that it can be smelled.

• LP gas is highlyflammable and may ignite unexpectedlywhen
mixed with air.

LP Tank Filling

Use only licensed and experienceddealers.

• LP dealer must purge tank beforefilling.

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

• A frosty regulator indicatesgas overfill, immediately close LP
tank valve and calllocal LPgas dealerfor assistance.

, Do not release liquid propane (LP) gas into the atmosphere.

This is a hazardous practice.

, Toremovegas from LP tank, contact an LPdealer orcall 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 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 maybecome overheated bythe sun.

, Do not store anLP tank in an area where children play.

4 • 464820707

LP Tank Exchange

Connecting Regulator To The LP Tank

, Many retailers that sell grills offeryou theoption of replacing

your empty LPtank throughan exchange service. Useonly
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 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 berepeated 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 testedoutdoors ina well-ventilated area,
away from ignition sources such as gas fired or electrical

appliances. Duringleak test, keep grillaway from open flames
or sparks.

1. LP tank must be properly secured onto grill. (Refer to

assembly section.)

2. Turnall control knobsto the OFF position.

3. Turn LPtank OFFby turning OPD handwheel clockwise to a

full stop.

4. Remove theprotective cap from LPtank 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. Leaks are indicated bygrowing bubbles.

If "growing" bubbles appear do not use or movethe LPtank.

Contact anLP gas supplier oryour 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 regulatorand insert nipple into LP

tank valve. Hand-tightenthe coupling
nut, holding regulator in a straight line

with LPtank valve soas not to cross-

thread the connection.

Nipplehasto becentered
intothe LPtank valve.

464820707 • 5

Holdcoupling nut andregulator
asshownfor proper connection

to LP tank valve.

6. Turnthe coupling nut clockwise andtighten to a full stop. The
regulatorwill seal onthe 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 LPtank.

3. Completely open LPtank valve byturning OPD handwheel
counterclockwise. Ifyou heara rushing sound, turn gas off

immediately.There is a major leak atthe connection. Correct
before proceeding by calling Sears for replacement parts at

1-800-4-MY-HONIE®.

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

A Never remove threaded

orifice at end of valve.

If you cannot complete theconnection, disconnect regulator and
repeat steps 5 and6. If you arestill unable to complete the

connection, do not use this regulator!

. Donot insertany tool or foreign objects into the valveoutlet

or safety reliefvalve. Youmay damage the valve and cause
a leak. Leakingpropane may result in explosion, fire, severe

personal injury,or death..

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

department.

. If you cannotstop a gas leak, immediately close LPtank

valve andcall LP gas supplier or yourfire department!

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

system of a campertrailer or motor home.

5. If "growing" bubbles appear, there is a leak.Close LP tank
valve immediately andretighten 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 afterperforming leak test by
turning hand wheel clockwise.

. Donot usegrill until leak-tested.

6°464820707

For Safe Use Of Your Grill And To Avoid Serious

injury:

* Donot letchildren operate orplay neargrill.

Keep grill area clear and free from materials that burn.
Donot block holes in bottomor back of grill.
Check burnerflames regularly.

Use grill only in well-ventilated space. NEVER use in

enclosed spacesuch as carport, garage, porch, covered

patio, or under anoverhead structure of any kind.
Donot use charcoal or ceramicbriquets 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 lightson water heaters, live electrical

appliances, etc.

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

tightness.

A When grill is notin use,turn offall control knobsand LP tank

valve.

A Never move grillwhile in operation or still hot.
A Use long-handled barbecue utensils andoven mitts to avoid

burnsand splatters.

A Maximum load for shelves is 10 Ibs.
A Do notusea cooking pot larger than 9" on grid.

A The grease cup must be attached togrease cup clip and

emptied after eachuse. 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 supplyat once.

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

A The regulator may make a humming or whistling noiseduring

operation. Thiswill not affect safetyor 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 fromwalls or rails. Donot use on or under

balconies.

A If you havea grillproblem 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.

464820707.7

ignitor Lighting

A Do not lean over grill while lighting.

1. Open lid during lighting.

2. Toignite, turn left knob to_ _ HIGH.

3. Push and hold ELECTRONIC IGNITION button.

Sideburner Ignitor Lighting

1. Topcover must be open when burneris operational.

2. To ignite SIDEBURNER, open sideburner cover.

3. Turn sideburner knob to4 6 HIGH, push and hold
ELECTRONIC IGNITION button.

4. If sideburner does NOT light in 5 seconds, turn knob to OFF,

wait 5 minutes, then repeat lighting procedure.

4. If ignition does NOT occur in 5 seconds, turn the burner
controls off, wait 5minutes,and repeat the lighting procedure.

5. Ignite right burner,turn 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 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.

Sideburner Match Lighting

1. Turnon 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.

-- 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 preheatingor

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 (hanging from 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 upgrillon 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 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.

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.

8•464820707

Normal Kinked
Hose Hose

Turning Grill Off

. Turn all knobs to 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. 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

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. Ifknobs
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 upeasier.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.

SPIDER ALERT!

GAS COLLECTOR

BOX &IGNITOR

CONTROL PANEl

VALVE AIR VENTURI

SHUTTER

/

If you notice that yourgrill is getting hard to light or that the
flame isn't as strong as it should be, take the timeto check and

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
gastothe burner,The backed-upgascan igniteintheventuribehind
thecontrolpanel.Thisis knownasa flashbackanditcandamage

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 partscan result.

• Porcelain grates: Becauseof 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.

Topreventflashbacksandensuregoodperformancetheburnerand
venturiassemblyshouldberemovedfromthegrillandcleaned

beforeusewheneverthegrillhasbeenidleforanextendedperiod.

464820707,9