Kenmore 640-175289115 Owner’s Manual
Use and Care Guide
LiquidPropaneGasGrill
KenmoreModelNo.415.16505900
Kmart itemNo.640-t 75289tt5
This Grill isfor OutdoorUseOnly
®
• Read and follow all Safety, Assembly,
and Use and Care instructions in this
Guide before assembling and cooking
with this grill.
• Failure to follow all instructions in this
Use and Care Guide may lead to fire or
explosion, which could result in property
damage, personal injuryor death.
SAVETHESEINSTRUCTIONS!
Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A.
©2008Sears,RoebuckandCo.,AllRightsReserved PrintedinChina
• Safety
• Parts
• Use and Care
• Assembly
AssemblyQuestions.'?
Callt-800-241-7548
Tools needed for assembly:
Adjustable wrench (not provided)
Screwdriver (not provided)
7/16" Combination wrench (not provided)
464722309•464722509• 80017881• 11-24-08
ifyou smell gas:
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.
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 Tank 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 havequestions orneed assistance during assembly,
please call 1-800-241-7548. You wilt 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®.
Product Record
IMPORTANT:Fillouttheproductrecordinformationbelow.
Model Number
CALIFORNIA PROPOSITION65
1. Combustion by-products produced when using
this product contain chemicals known to the State of
California to cause cancer, birth defects, and other
reproductive harm.
2. This product contains chemicals, including lead
and lead compounds, known to the State of
California to cause cancer, birth defects or other
reproductive harm.
Wash your hands after handling this product.
installation Safety Precautions
• Use grill, as purchased, only with LP(propane) gas and the
regulator/valve assembly supplied. A conversion kit must be
purchased for use with natural gas.
• 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, CSAB149.1, orPropane Storage and
Handling Code,B149.2, orthe Standardfor Recreational
Vehicles,ANSI A 119.2/NFPA1192,and CSAZ240 RV Series,
Recreational VehicleCode, as applicable.
• All electrical accessories (such as rotisserie) must be
electrically grounded in accordance with localcodes, or
National Electrical Code,ANSI/ NFPA 70or Canadian
Electrical Code,CSA C22.1. Keep any electrical cords and/or
fuel supply hosesaway fromany hot surfaces.
• This grill issafety certified for use in the United States and/or
Canada only. Donot modify for use inany other location.
Modification wilt result in a safety hazard.
Serial Number
Seeratinglabelongrillfor serialnumber.
Date Purchased
To InstalledAssembler: Leave these instructionswith
consumer.
To Consumer: Keep this manual for future reference.
CAUT,o. /K
, Some parts may contain sharp edges,
especially as noted in these instructions.
Wear protective gloves if necessary.
CAUTION
For residential use only. Do not use for commercial
cooking.
2,464722309,464722509
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 imminentlyhazardoussituation
which, if not avoided,will result in death orserious injury.
WARNING: Indicatesan potentiallyhazardous situation
which, if not avoided, could result in death or serious injury.
CAUTION
CAUTION: Indicatesa potentiallyhazardoussituationor
unsafepracticewhich, ifnotavoided, may result in minor
or moderate injury.
For Your Safety ...................................... 2
Grill Service Center................................... 2
KENMORE GRILL WARRANTY
Product Record Information ............................ 2
Safety Symbols ...................................... 2
Installation Safety Precautions .......................... 2
Kenmore Elite Grill Warranty ........................... 3
Use and Care .................................... 4-10
Parts List .......................................... 11
Parts Diagram...................................... 12
Assembly ....................................... 13-24
Troubleshooting.................................. 25-27
Repair Protection Agreements
Congratulations on making a smart purchase. Your new
Kenmore®productisdesigned 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 cansave you money andaggravation.
Purchase a Repair ProtectionAgreement now and protect
yourself from unexpected hassle and expense.
Here's what the Repair ProtectionAgreement* includes:
171 Expert service by our 10,000 professional repair specialists
[] Unlimited service and no charge for partsand laboron all
covered repairs
[] Product replacement up to $1500 if your coveredproduct
can't be fixed
[] Discount of 10% from regular price of service and related
installed parts not covered by the agreement; also, 10%off
regular priceof preventive maintenance check
[] Fast help by phone -we call it Rapid Resolution-
phone support from a Sears representative.Think of us
as a "talkingowner's manual."
Once you purchase the Repair ProtectionAgreement, a simple
phone call isall that it takes for you to schedule service. Youcan
call anytime day or night, or schedulea service appointment
online.
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% arrange for free repair (orreplacement if repair
proves impossible).
Three-Year Limited Warranty on Burners
Forthree years from the date of purchase, any burner that
ruststhrough wilt be replaced free of charge.After the first
yearfrom the date of purchase,you payfor labor ifyou 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
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 ever used for
commercial or rental purposes.
All warranty coverage applies only if this grill is used inthe
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., Hoffman Estates, IL 60179
The Repair ProtectionAgreement isa risk-free purchase. Ifyou
cancel for any reason during the product warranty period, we will
provide a full refund. Or, a prorated refund anytime after the
product warranty periodexpires. Purchase your Repair
ProtectionAgreement today!
Some limitations and exclusions apply.
For prices and additional information call 1-800-827-6655.
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®
464722309,464722509,3
• NEVERstore a spare LPcylinder under or near the
appliance or inan enclosed area.
• Never fill a cylinder beyond 80%full.
• If the informationin two points above is not
followed exactly, afire causing death or serious
injury may occur.
• An over filled or improperlystored cylinder isa
hazard due to possible gas release from the safety
relief valve. This could cause an intensefire with
risk of property damage, serious injury or death.
• If you see, smell or hear gas escaping, immediately
get away from the LP cylindedappliance and call
your fire department.
LP Tank Removal, Transport And Storage
• Turn OFF all control knobs and LPtank valve. Turn coupling
nut counterclockwise by handonly - do not use tools to
disconnect. LiftLP tank wire upward off of LP tank collar, then
lift LP tank up and offof 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
*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 20lb. (9 kg.)
capacity maximum.
•LPtanks 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.
*LPtank valve must have:
,Type 1outlet compatible with
regulatoror grill.
,Safety reliefvalve.
,UL listed Overfill Protection
Device (OPD). This OPD safety
feature is identified by a unique triangular handwheel. Use
only LP tanks equipped with this type of valve.
•LPtank must be arranged for vapor withdrawal and include
collar to protect LP tank valve.
LP cylinder in upright position for vapor withdrawal
LP (Liquefied Petroleum Gas)
*LPgas is nontoxic, odorless and colorless when produced.For
Your Safety, LPgas has been given an odor (similar to rotten
cabbage) so that it can be smelled.
*LPgas is highly flammableand mayignite unexpectedly when
mixedwith air.
LP Tank Filling
*Useonly licensed and experienced dealers.
OPDHand Wheel
LP Tank Valve
Salty Cap
RetainerStrap
• Adisconnected LP tank in storage orbeing transported must
have a safety cap installed (as shown). Do notstore an LPtank
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.
• Do not store an LPtank in an area where children play.
4,464722309,464722509
*LPdealer must purge tank before filling.
*Dealer should NEVERfill LP tank more than 80% of LPtank
volume. Volume of propane in tank will vary by temperature.
*Afrosty regulator indicates gas overfill. Immediatelyclose LP
tank valve and call local LP gas dealer for assistance.
,Do not releaseliquid propane (LP) gas into the atmosphere.
This is a hazardous practice.
,To remove gas from LP tank, contact an LP dealer orcall a
local fire department for assistance. Check the telephone
directory under "GasCompanies" for nearest certified LP
dealers.
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 exchangeservice. Useonly
those reputable exchange companiesthat inspect, precision fill,
test and certifytheir cylinders. Exchange your tank only for
an OPD safety feature-equipped tank as described inthe
"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 berepeated each time LP tank isexchanged or
refilled.
*Do notsmoke during leak test.
*Do notuse an open flame to check for gas leaks.
*Grill must be leak tested outdoors ina well-ventilatedarea,
away from ignition sources such as gas fired or electrical
appliances. Duringleak test, keep grill away from open flames
or sparks.
•Usea clean paintbrushand a 50/50 mild soap and water
solution. Brush soapy solution onto areas indicated byarrows
in figure below. Leaks are indicated bygrowing bubbles.
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 clockwiseto a
full stop.
4.Remove the protectivecap from LP tank valve.Always use
cap and strap supplied with valve.
OPDHandWheel
j Type1outletwith
threadon outside
Safety Relief Valve
!
Strapand Cap
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 movethe LP tank.
Contact an LP gas supplier or your fire department!
A Do not use household cleaning agents. Damage to gas
train components can result.
5.Hold regulatorand insert nipple into LP
tank valve. Hand-tightenthe coupling
nut, holding regulator in a straight line
with LP tank valve so as not to cross-
thread the connection.
Nipplehas to be centered
intothe LP tankvalve.
464722309.464722509.5
Holdcoupling nut and regulator
asshown for properconnection
to LP tank valve.
6.Turn the coupling nut clockwiseand tighten to a full stop. The
regulatorwill seal on the back-checkfeature inthe 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.Be sure regulator istightly connected to LP tank.
3.Completely open LPtank valveby turning OPD handwheel
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 areaswhere bubbles are shown in
picture below:
A Neverremovethreaded
orifice atendof valve.
If you cannot complete the connection, disconnect regulator and
repeat steps 5 and 6. If you are still unableto completethe
connection, do not use this regulator!
Do not insert anytool or foreignobject into the valve
outlet or safetyrelief valve. You may damage the valve
and cause a leak. Leaking propane may result in
explosion,fire, severe personal injury,ordeath.
Outdoorgas appliance is not intended to beinstalled
in or on a boat.
Outdoorgas appliance is not intended to beinstalled
in or on an RV.
5.If "growing" bubbles appear, there is a leak. Close LPtank
valve immediately and retightenconnections. 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 handwheel clockwise.
. Never attemptto attach this grill to the self-contained
LPgas system of a campertrailer or motorhome.
. Donot use grill until leak-tested.
. If a leak is detectedat any time,STOPand call the fire
department.
. If you cannot stop a gas leak, immediately close
LPcylindervalve and call LPgas supplier or yourfire
department!
6,464722309,464722509
zL zL
For Safe Use Of Your Grill And To Avoid Serious
Injury:
*Do notlet children operate or play near grill.
•Keepgrillarea clear and free from materials that burn.
•Do notblock holes in bottom or back of grill.
•Check burner flames regularly.
•Usegrillonly inwell-ventilated space. NEVER use in
enclosed space such as carport, garage, porch, covered
patio, or under an overhead structure of any kind.
•Do notuse charcoal or ceramic briquets in a gas grill.
(Unless briquets are supplied with your grill.)
•Use grill at least 3ft. from any wall or surface. Maintain
10 ft. clearance to objects thatcan catch fire or sources of
ignitionsuch as pilot lights on water heaters, live electrical
appliances, etc.
Safety Tips
A Before opening LP cylindervalve, check the coupling nutfor
tightness.
A When grill is not in use, turn off all control knobsand LP
cylinder valve.
A If the outdoor cooking gas appliance is not in use, the gas
must be turned off at the supply cylinder. Storage of an
outdoor cooking gas appliance indoorsis permissible only if
the cylinder is disconnected and removed from the appliance.
,& Never move grill while inoperation or still hot.
,& Use long-handled barbecue utensils and oven mittsto avoid
burnsand splatters.
,& Maximum load for side shelves is 10 Ibs.
,& The grease cup must be inserted into grease clip and
emptied after each use.Do not remove grease cup until grill
has completely cooled.
,& Clean grill often, preferablyaftereach cookout. Ifa bristle
brush is used to clean any of the grill cookingsurfaces,
ensure no loose bristles remain on cooking surfaces priorto
grilling. Itis not recommendedto clean cooking surfaces
while grill is hot.
,& If you notice grease or other hot materialdripping from grill
onto valve, hoseor regulator,turn off gas supply at once.
Determinethe cause, correct it, then clean and inspect valve,
hoseand regulator before continuing. Perform a leak test.
,& The regulator may make a humming or whistling noiseduring
operation. This will notaffect safety or use of grill.
,& Onlyuse the pressure regulator and hose assembly supplied
with this grill. Replacementpressure regulator and hose
assemblies must be specified orsupplied by Char-Broil, LLC.
,& If you have a grill problem see the "Troubleshooting Section".
,& If the regulator frosts, turn off grill and LPcylinder valve
immediately.This indicatesa problemwith the cylinderand it
should notbe used on any product. Return to supplier!
•Apartment Dwellers:
Check with management to learn the requirements and fire
codes for using an LPgas grill inyour apartment complex. If
allowed, use outside on the ground floor with a three (3) foot
clearance from walls or rails. Do not use on orunder
balconies.
•NEVERattempt 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.
CAUTION
Putting out grease fires by closing the lid is not
possible. Grills are well ventilated for safety
reasons.
Do not use water ona grease fire. Personal injury
may result. If a grease fire develops, turn knobs
and LP cylinder off.
Do not leave grill unattended while preheating or
burning off food residue on HI.If grill has not been
regularly cleaned, a grease fire can occur that may
damage the product.
464722309,464722509,7
Main burner ignitor Lighting
A Do notlean over grill while lighting.
1. Open lid during lighting.
2. TurnON valve fromsource or tank.
3. Push and turn IgnitionBurner controlknob to _ HI and
immediately press and hold Electronic Ignition button.
4. Ifignition does NOToccur in 5 seconds, turn Left Burner
control knob OFF, wait 5minutes, and repeatthe lighting
instructions.
5. To Light Main Burner,turn control knob to HI.
If ignitor does not work, follow match lighting instructions.
After Lighting: Turn knobs to HI position for 15 minutesto pre-
heat grill. Then turn knob to desired setting for cooking.
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.
Sideburner Match Lighting
1. Turn OFF all burner controlvalves.
2. Open sideburner lid (if equipped).
Turn on gas at LPcylinder.
3.Place lit match near burner.
4.Turn sideburner knobto
,,¢ HI. Be sure burner
lights and stays lit.
Before Your First Cookout
•Light burners, check to make sure they are lit,close thelidand
warm up grill on HIGHfor 15minutes. This curing of paint and
partswilt produce an odor only on first lighting.
Burner Flame Check
•Light burner, rotate knobs from HIGHto LOW.You should see
a smaller flame in LOW position than seen on HIGH.Always
check flame priorto each use.Ifonly low flame is seen refer to
"Sudden drop or low flame" in the Troubleshooting Section,
Match-Lighting
A Do not lean over grill while lighting.
1. Open lidduring lighting.
2. Place match into match holder (hanging from side of cart).
3. Push in and turn left knob to ,,¢ HIposition. Be sure burner
lights and stays lit.
4. Light right burner by pushing knob in and turning to_ HI
position.
Sideburner Ignitor Lighting
,A,Donot leanovergrill whilelighting,
1.Open lid or coverfor Side Burnerduring lighting.
2. TurnON valvefrom source or tank.
3. Push and turn Side Burnercontrol knob to,C. HI and
immediatelypress and hold Electronic Ignition button.
4. Ifignition does NOToccur in5 seconds, turn Side Burner
controlknob OFF, wait 5 minutes, and repeatthe lighting
instructions.
Ifignitordoesnotwork,followmatchlightinginstructions.
AfterLighting:TurnknobstoHI positionforwarm-up.
Hose Check
•Beforeeach 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.
Normal Kinked
Hose Hose
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 greasefire. Personal injurymay
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 instructionson General
Grill Cleaning and Cleaning The Burner Assembly to
prevent grease fires.
8,464722309 o464722509
Turning Grill Off
•Turn all knobsto OFF position.Turn LPtank off byturning
OPD handwheel clockwise to a full stop.
cAuT,o.
Ignitor Check
•Turn gas off at LP tank. Press and hold ignitor button. "Click"
should be heardand sparkseen each time between collector
box or burnerand 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 inknobs 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
•Keepthe outside of your grill looking new by cleaning it once a
month with warm soap and water ora non-abrasive cleaner. If
you don't havea grill cover, wipe off dust andgrime before
starting your grill.
• Coating the cooking gridswith spray-on cooking oil will keep the
food from stickingand makeclean up easier.After cooking,
scrape the grateswith along handled, brass wire bristlebrush.
•Check inside the grill bottom for grease build upand clean
often, especially after cooking fatty meat.
•Do not mistake brown or black accumulation of grease and
smoke for paint. Apply astrong solution of detergentand water
or use a grill cleaner with scrub brush on insidesof grill lid and
bottom. Rinse and allow to completely air dry. Do not apply a
caustic grill/oven cleanerto 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 soapywater andwipe dry.
,A. 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 awaywith baking soda/water solutionor
specially formulated cleaner. Use non-abrasive scouring
powder for stubborn stains.
•Painted surfaces: Wash with mild detergent or nonabrasive
cleaner and warm soapy water. Wipe dry with asoft
nonabrasive cloth.
•Stainless steel surfaces: To maintain your grill's high quality
appearance, wash with mild detergent and warm soapy water
and wipe drywith a soft cloth after each use. Baked-ongrease
deposits may requirethe use of an abrasive plastic cleaning
pad. Useonly in direction of brushed finish to avoid damage.
Do not use abrasive pad on areas with graphics.
• Cooking surfaces: If a bristlebrush isused to cleanany of
the grill cooking surfaces, ensure no loose bristles remain on
cooking surfaces prior to grilling. It is not recommendedto
clean cooking surfaces while grill is hot.
SPIDER ALERT!
GAS COLLECTOR
VALVE AIR VENTURI
Ifyou notice that your gri// is getting hard to light orthat the
flame isn't as strong as itshou/d be,take the time to checkand
dean theventuri's.
Insomeareasofthecountry,spidersor smallinsectshavebeen
knowntocreate"flashback"problems.Thespidersspinwebs,build
nestsandlay eggsin thegrill'sventuritube(s)obstructingtheflowof
gasto theburner.Thebacked-upgas canignitein theventuribehind
thecontrolpanel.Thisis knownasa flashbackanditcan damage
yourgrilland evencauseinjury.
Topreventflashbacksandensuregoodperformancetheburnerand
venturiassemblyshouldberemovedfromthe grilland cleaned
beforeusewheneverthegrillhas beenidleforanextendedperiod.
,,. j
Storing Your Grill
• Clean cooking grates.
• Store indry location.
• When LP tank isconnected to grill, store outdoors in well-
ventilated space andout of reachof children.
• Covergrill ifstored outdoors.
• Store grill indoorsONLYif LP tank is turned off and
disconnected, removedfrom grill andstored outdoors.
• When removing grillfrom storagefollow "CleaningBurner
Assembly" instructions before starting grill.
SHUTTER
LIFTOUT
BURNERASSEMBLY
CLEANOUT SPIDER WEBS
VENTUR] INSIBE VENTURI
REMOVE
BURNER
CLIPS
464722309,464722509.9
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