Kenmore 640-641215405 Owner’s Manual

Use and Care Guide

LiquidPropaneGasGrill

KenmoreModelNo.415.1612380t
KmartItem No.640-641215405

This Grill isfor OutdoorUseOnly

®

• Read and follow all Safety, Assembly,
and Use and Care instructionsin this

Guide before assembling and cooking
with this grill.

• Failure to follow all irstructions in this
Use and Care Guide may lead to fire or

explosion, which could result in property
damage, personal injury or death.

SAVETHESEINSTRUCTIONS!

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

©2008Sears,RoebuckandCo.,AllRightsReserved PrintedinChina

• Safety

• Parts

• Use and Care

• Assembly

AssemblyQuestions.'?

Call 1-800-241-7548

Tools needed for assembly:
Adjustable wrench (not provided)

Screwdriver (not provided)
7/16" Combinationwrench (not provided)

464310209•464311009•80018056• 10_07_08

if you smell gas:

1. Shut off gas to the appliance.

2. Extinguish any open flame.

3. Open lid.

4. ifodor 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 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 havequestions or needassistance during assembly,

please call 1-800-241-7548. You will 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

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

• Usegrill, as purchased, only with LP (propane) gas and the

regulator/valve assembly supplied. A conversion kit must be
purchased for use with naturalgas.

• 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 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 local codes, or

National Electrical Code,ANSI / NFPA 70or Canadian
Electrical Code, CSA C22.1. Keep any electrical cords and/or

fuel supply hoses away from any hot surfaces.

• This grill is safety certified for use in the United States and/or
Canada only. Donot modify for use in any other location.

Modification wilt result inasafety 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.

IMPORTANT:Fillouttheproductrecordinformationbelow.

Model Number

Serial Number

Seeratinglabelongrillfor serialnumber.

Date Purchased

CAUTION

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

2 °464310209° 464311009

DANGER: Indicates an imminentlyhazardous situation

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, if not avoided, mayresult 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 Grill Warranty ............................... 3

Use and Care .................................... 4-10

Parts List .......................................... 11

Parts Diagram...................................... 12

Assembly ....................................... 13-22

Troubleshooting.................................. 23-25

Repair Protection Agreements
Congratulations on making a smart purchase. Your new

Kenmore®productisdesigned and manufacturedfor years of
dependable operation. But like all products, it may require repair

from time to time. That'swhen having a Repair Protection
Agreement cansave you money and aggravation.

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 parts and labor on all

covered repairs

[] Product replacement up to $1500 ifyour covered product

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. You can

call anytime day or night, or schedule a service appointment
online.

One Year Full Warranty on Kenmore Grill
If this grill fails dueto a defect in material or workmanship

within one year from the date of purchase, call 1-800-4-MY-

HOME% arrange for free repair (or replacement if repair
proves impossible).

Five-Year Limited Warranty on Burners
Forfive 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 pay for 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 usewithin

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 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., 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 period expires. 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®

464310209' 464311009'3

• NEVERstore a spare LP cylinder under or near the
appliance or in an enclosed area.

• Never fill a cylinder beyond 80%full.

• If the information in two points above is not
followed exactly, afire causingdeath or serious
injury may occur.

• An over filled or improperlystored cylinder isa
hazard due to possible gas releasefrom 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 gas escaping, immediately
get away from the LP cylinderlapplianceand call

your fire department.

LP Cylinder

• The LP cylinder used with your grill must meet the
following requirements:

• Use LP cylinders only with these required measurements: 12"
(30.5cm) (diameter) x 18" (45.7 cm) (tall) with 20 lb. (9 kg.)
capacity maximum.

• LP cylinders must be constructed and marked in accordance
with specifications for LP cylinders of the U.S. Department of

Transportation (DOT) or for Canada, CAN/CSA-B339,
cylinders, spheres and tubes for transportation of dangerous

goods. Transport Canada (TC). See LP cylinder collar for

marking.

• LP cylinder valve must have:

• Type 1 outlet compatiblewith

regulatoror grill.

• Safety relief valve.

• UL listed Overfill Protection OPDHandWheel

Device (OPD). This OPD safety

feature is identified by a unique triangular hand wheel. Use

only LP cylinders equipped with this type of valve.

• LP cylinder must be arranged for vapor withdrawal and include
collar to protect LP cylinder valve.Always keep LP cylinders in

upright position during use, transit or storage.

i i_;i__:>_ilji¸

LP cylinder in upright position for vapor withdrawal

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 upand 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.

LPTankValve

SafetyCap

RetainerStrap

• A disconnected LP tank in storage or being transported must
have a safety cap installed (as shown). Do notstorean LPtank

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 bythe sun.

• Do not store an LPtank in an area where children play.

4 °464310209° 464311009

LP (Liquefied Petroleum Gas)

• LPgas is nontoxic, odorless andcolorless when produced. For

Your Safety, LPgas has been given an odor (similar to rotten
cabbage) so that it can be smelled.

• LPgas is highly flammable and may ignite unexpectedly when
mixedwith air.

LP Cylinder Filling

• Use only licensed and experienced dealers.

• LPdealer must purge new cylinder before filling.

• Dealer should NEVER fill LP cylinder more than 80% of LP

cylinder volume. Volumeof propane in cylinderwilt vary by
temperature.

• A frosty regulator indicates gas overfill. Immediately close LP

cylinder valve and call local LP gas dealer for assistance.

• Do not releaseliquid propane (LP) gas into the atmosphere.

This is a hazardous practice.

• Toremovegas from LP cylinder,contact an LP dealer or call a

local fire department for assistance. Check the telephone
directory under "Gas Companies" 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 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 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 be repeated each time LP tank isexchanged or
refilled.

*Do notsmoke during leak test.
*Do notuse an openflame to check for gas leaks.

*Grill must be leak tested outdoors in a well-ventilatedarea,

away from ignition sources such as gas fired or electrical
appliances. Duringleak test, keep grill away fromopen flames
or sparks.

•Usea clean paintbrush and 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 byturning OPD hand wheel clockwiseto a
full stop.

4.Remove the protective cap from LP tank valve.Always use
cap and strap supplied with valve.

OPDHandWheel

j Type 1outlet with

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 LPtank.

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.

464310209. 464311009.5

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 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 by 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 regulatorand
repeat steps 5 and 6. If you are still unable to completethe

connection, do not use this regulator!

Do not insertany tool or foreignobject 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,ordeath.

Outdoorgas appliance is not intended to be installed
in or on a boat.

Outdoorgas appliance is not intended to be installed
in or on an RV.

5.If "growing" bubbles appear, there is a leak. Close LPtank

valve immediately and retighten connections. If leaks cannot

be stopped do not try to repair. Call Searsfor replacement
parts at 1-800-4-MY-HOME.°

6.Always close LP tank valveafter performing leak test by

turning hand wheel clockwise.

. Never attempt to attach this grill to the self-contained

LPgas system of a campertrailer or motorhome.

. Do not usegrill until leak-tested.
. If a leak is detected at any time, STOPand call the fire

department.

. If you cannot stop a gas leak, immediately close

LPcylindervalve and call LPgas supplieror your fire
department!

6,464310209. 464311009

For Safe Use of Your Grill and to Avoid Serious
Injury:

• Do not letchildrenoperateor play near grill.

• Keep grill area clear and freefrom materials that burn.

• Do not block holes in sidesor back of grill.

• Check burnerflames regularly.

• Use grill only inwell-ventilated space. NEVERuse in
enclosedspace such as carport,garage, porch,

covered patio,or under anoverhead structure of any
kind.

Do not usecharcoalorceramic briquetsin a gasgrill.
(Unlessbriquets are supplied with your grill.)

Usegrill at least 3 ft. from any wall or surface.
Maintain 10ft. clearanceto objects that cancatchfire

or sources of ignition such as pilot lightsonwater

heaters,liveelectrical appliances,etc.

Safety Tips
,A, Before opening LP cylinder valve, check the coupling nutfor

tightness.

,A, When grill is not in use, turn off all control knobs and LP

cylinder 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 sideburner and side shelf is 10 Ibs.
,A, The grease tray must be insertedinto grill andemptied after

each use. Do not remove grease tray until grill has

completely cooled.

,A, Clean grill often, preferably after each cookout. If a bristle

brush is used to clean any 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.

,A, If you notice grease or other hot material dripping from grill

onto valve, hose or regulator, turn off gas supply at once.

Determinethe cause, correct it, then clean and inspect valve,
hoseand regulator before continuing. Perform a leak test.

,A, Keep ventilation openings in cylinder enclosure (grill cart) free

and clear of debris.

,A, Do not store objects or materials inside the grill cart

enclosure that would block the flow of combustion air to the

undersideof either the control panel or the firebox bowl.

,A, The regulatormay make a humming or whistling noiseduring

operation. This will notaffect safety or use of grill.

,A, If you have a grill problem see the "Troubleshooting Section".
,A, If the regulator frosts, turn off grill and LP cylinder valve

immediately.This indicates a problem with the cylinder and it

should notbe used on any product. Return to supplier!

• Apartment Dwellers:
Checkwith managementto learnthe requirements

and fire codes for usingan LPgasgrill inyour
apartmentcomplex.If allowed, useoutside onthe

ground floorwith a three (3) foot clearance fromwalls
or rails. Do not use on or under 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 cylinderout of correct
position specified in assembly instructions.

• Always close LP cylinder valve and remove
coupling nut before moving LP cylinder from

specified operation position.

CAuT,o.

• Putting out grease fires by closingthe 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

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.

Main Burner Ignitor Lighting
A Do not lean over grill while lighting.

1. Open lid during lighting.

2. Turn ON valve from source or tank.
3, Push and turn Ignition Burner control knobto_ HI and

immediately press and hold Electronic Ignition button.

4. If ignition does NOT occur in 5 seconds, turn Ignition
Burner control knob OFF, wait 5minutes, and repeat the
lighting instructions.

5.To Light Other Burners 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.

Lighting instructionscontinued onnextpage.

464310209,464311009,7

Turn controls and gas source or tank OFF when not
in use.

CAUT,o.

If ignitiondoes NOT occur in 5seconds, turn the
burner controls OFF,wait 5minutes and repeat the
lighting procedure. If the burner does not ignitewith
the valve open, gas will continue to flow out of the

burner and could accidently ignite with risk of injury.

Match-Lighting

,L. Do not lean over grill while lighting.

1. Open lid during lighting.

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_ HI
position.

Sideburner Ignitor Lighting
,A.Do not lean over grill while lighting.

1. Open lid or cover for Side Burner during lighting.

2. Turnon valve from source or tank.

3. Push and turn Side Burner control knob to _;: HI and
immediately press and hold Electronic Ignition button.

4. If ignition does NOT occur in 5 seconds, turn Side Burner
control knob OFF, wait 5 minutes,and repeatthe lighting

instructions.

Sideburner Match Lighting

1.Open sideburner lid. Turn on gas at LP cylinder.

2.Place lit match near burner.

3.Turnsideburner knob to HI.
Be sure burner lights and

stays lit.

8,464310209,464311009

Burner Flame Check

•Remove cooking gratesand flame tamers. Light burners, rotate
knobs from HIGH to LOW.You should see a smaller flame in

LOW position than seen on HIGH. Perform burner flame check
on sideburner, also.Always check flame prior to each use. If

only low flame is seen refer to "Sudden drop or low flame" in
the TroubleshootingSection.

Turning Grill Off

•Turn all knobs to OFF position. Turn LP cylinder off by turning
hand-wheel clockwise to a full stop.

ignitor Check

•Turn gas off at LP cylinder. Press and hold electronic ignitor
button. "Click" should be heard and spark seen each time

between collector box or burner and electrode. See

"Troubleshooting" if no click or spark.

Valve Check

•important: Makesure gas is off at LP cylinder 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 LOW position then turn back to
OFF position.Valves should turn smoothly.

Hose Check

•Before each use, check to see if hoses are cut or worn.
Replace damaged hoses before usinggrill. Use only
valve/hose/regulator specified by manufacturer.

General Grill Cleaning

•Do not mistake brown or black accumulation of grease and
smoke for paint. Interiors of gas grills are not painted at the

factory (and should never be painted). Apply a strong solution
of detergent and water or use a grill cleanerwith 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.

• Plastic parts: Wash with warm soapy water andwipe dry.

A Donot use citrisot,abrasive cleaners, degreasers or a
concentrated grill cleaner on plastic parts. Damage to and
failure of parts can result.

•Porcelain surfaces: Because of glass-like composition, most
residuecan be wiped away with baking soda/water solutionor

specially formulated cleaner. Use nonabrasive scouring powder
for stubborn stains.

•Painted surfaces: Wash with milddetergent or nonabrasive

cleaner and warm soapy water. Wipe dry with a soft
nonabrasive cloth.

•Stainless steel surfaces: Tomaintain your grill's high quality

appearance, wash with mild detergent and warm soapy water
and wipe dry with a soft cloth after each use. Baked-on grease

deposits may require the use of an abrasive plastic cleaning
pad. Use only in direction of brushed finish to avoid damage.

Do not use abrasive pad on areas with graphics.

• Cooking surfaces: Ifa bristle brush is usedto clean any 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.

cAuTioN

f

SP|DNR ALNRT!

If you notice that your grill is getting hard to light or thatthe
flame isn't as strong as it should be, takethe time to checkand

clean the venturi's.

CONTROLPANEL

Insomeareasofthe country,spidersor smallinsectshavebeen
knowntocreate"flashback"problems.The spidersspinwebs,build

nestsandlayeggsinthe grill'sventuritube(s)obstructingtheflowof
gasto theburner.Thebacked-upgascanigniteintheventuribehind
thecontrolpanel.Thisisknownasa flashbackandit candamage

yourgrillandevencauseinjury.
Topreventflashbacksandensuregoodperformancetheburnerand

venturiassemblyshouldberemovedfromthegrillandcleaned
beforeusewheneverthegrill hasbeenidleforanextendedperiod.

\ J

SPIDERWEBS

INSIDE VENTURI

BURNER

Cleaning the Burner Assembly
Follow these instructions to clean and/or replace parts of burner

assembly or if you have trouble igniting grill,

1. Turn gas off at control knobs and LP cylinder.

2. Remove cooking grates and flame tamers.

3. Remove screws and carryover tubes from rear of burners.

4. Remove screw and washers to disengage burner from

bracket on firebox.

5. Remove screws to detach electrode from burner.Electrode

should remain in firebox.

6. Carefully lift each burner up and away from valve openings.

We suggest three ways to clean the burner tubes. Use the one
easiest for you.

(A) Bend a stiff wire (a light weight coat hangerworks well)

into a small hook. Run the hook through each burner
tube several times.

,.D

(B) Use a narrow bottle brushwith a flexible handle (do not

use a brass wire brush), run the brush through each
burner tube several times.

(C) Wear eye protection: Use an airhose to force air into

the burner tube and out the burner ports. Check each
port to make sure air comes out each hole.

7. Wire brush entire outer surface of burner to remove food

residue and dirt.

8. Clean any blocked ports with a stiff wire such as an open

paper clip.

9. Check burner for damage, due to normal wear and corrosion

some holes may become enlarged. If any large cracks or
holes are found replace burner.

VERY IMPORTANT: Burner tubes must reengage valve

openings. See illustrations at right.

10. Attach electrode to burner. Correct

11. Carefully replace burners, engagement

12. Attach burners to brackets onfirebox.

13. Reposition carryover tubes and attach
to burners. Replace flame tamers and

cooking grates.

burner-to-valve

Storing Your Grill

•Clean cooking grates.

•Store in dry location.

•When LPcylinderis connected to grill, store outdoors in a well-
ventilated space and out of reach of children.

•Cover grill if stored outdoors. Choose from a variety of grill
covers offered by manufacturer.

•Store grill indoors ONLYif LP cylinder is turned off and
disconnected, removed from grill and stored outdoors.

•When removinggrillfrom storage, follow "Cleaning the Burner
Assembly" instructions before starting grill.

Firebox
burner

bracket

Electrode

464310209°464311009'9