Versa Flame BY12-084-029-97 Assembly & Operating Instructions

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BY12-084-029-97 Eng 1 of 44 20111105–V0

Versa*FlameTM Gas & Charcoal Grill

Models Number: BY12-084-029-97

ASSEMBLY & OPERATING INSTRUCTIONS

For Outdoor Use Only

z This instruction manual contains important information necessary for the

proper assembly and safe use of the appliance.

z Read and follow all warnings and instructions before assembling/using

the appliance.

z Follow all warnings and instructions when using the appliance. z Keep this manual for further reference

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DANGER

If you 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 fire department

WARNING

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

DANGER

(a) Do not store a spare LP-gas cylinder under or near this appliance; (b) Never fill the cylinder beyond 80 percent full; and (c) If the information in (a) and (b) is not followed exactly, a fire causing death or serious injury may occur.

SAFETY LABELS

DANGER: Indicates an imminently hazardous situation which, if not avoided, will

result in death or serious injury

WARNING: Be alert to the possibility of serious bodily injury if the instructions are not

followed. Be sure to read and carefully follow all of the messages.

CAUTION: Indicates a potentially hazardous situation, which, if not avoided, may

result in minor or moderate injury.

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GAS GRILL GENERAL WARNINGS

WARNING

z This outdoor cooking gas appliance shall be used only outdoors and shall not be

used in a building, garage or any other enclosed area.

z This outdoor cooking gas appliance is not intended to be installed in or on boats.

For other than RV grills, this appliance is not intended to be installed in or on recreational vehicles.

z Use your grill OUTDOORS in a well ventilated space away from dwellings or other

buildings to prevent dangers associated with gas accumulation and toxic vapors. The grill should be situated at least 60 inches (153 cm) from buildings. Not adhering to these clearances will prevent proper ventilation and may increase the risk of a fire and/or property damage, which could also result in personal injury.

z Maintain a minimum clearance of 60

inches (153 cm) between all sides of grill, deck railings, walls or other combustible material. DO NOT use grill under overhead unprotected combustible construction.

z DO NOT obstruct the flow of

combustion/ventilation air.

z DO NOT leave the grill unattended

while in use.

z DO NOT use while under the influence

of drugs or alcohol.

z Keep the fuel supply hose away from heated surfaces. z DO NOT put grill in storage or move it immediately after use. Allow grill to cool to

touch before moving/storing. Failure to do so could result in fire resulting in property damage, personal injury or death.

z The appliance is for household use only. DO NOT use this grill for other than its

intended purpose.

z Never use natural gas in a unit designed for liquid propane gas. z Never use charcoal or wood briquettes in a gas grill. Flavoring chips must be

contained in a metal smoking box to contain ash and prevent fires.

z Leak test must be conducted prior to each use. z Keep a fire extinguisher on hand acceptable for use with gas products. Refer to your

local authority to determine proper size and type.

z Grill is hot when in use. To avoid burns:

z DO NOT attempt to move the grill. z Wear protective gloves or oven mitts. z DO NOT touch any hot grill surfaces. z DO NOT wear loose clothing or allow hair to come in contact with grill.

z Never close the SIDE BURNER LID during operation.

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USE OF LP GAS CYLINDER AND INSTALLATION BEFORE INSTALLING:

The installation must conform with local codes or, in the 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 Standard for Recreational Vehicles, ANSI A 119.2/NFPA 1192, and CSA Z240 RV Series, Recreational Vehicle Code, as applicable.

BEFORE EVERY USAGE:

Be sure to inspect the hose for leaks, cuts, wear, abrasion, or damage of any sort before using this appliance. If any damage is apparent the hose must be replaced with a replacement hose specified by the manufacturer before it is put in use.

LP GAS CYLINDER

The LP (liquid propane) cylinder specifically designed to be used with this unit MUST have a 20 lb. (9.1kg) capacity with a Type 1 cylinder value and an overfilling protection device (OPD). Only use LP cylinders with this type of valve. The nominal cylinder: Height = 18 inches (45.7 cm), Diameter = 12 inches (30.5cm) and bottom ring diameter = 8 inches (20.3 cm)

LP tank valve must have:

z Type 1 outlet compatible with regulator or appliance. z Safety relief valve. z UL listed Overfill Protection Device(OPD). This OPD safety

feature is identified by a unique triangular hand wheel. Use only tanks equipped with this type of valve.

z LP tank must be arranged for vapor withdrawal.

The LP cylinder must be constructed and marked in

accordance with the Specifications for LP-Gas Cylinders of the U.S. Department of Transportation (D.O.T.) or the National Standard of Canada CAN/CSA – B339, Cylinder, Spheres and Tubes for Transportation of Dangerous Goods; and Commission of Dangerous Goods; and Commission, as applicable.

z The LP cylinder must include a collar to protect the cylinder

valve.

z The LP cylinder must be stored outdoors out of the reach of children and pets. It

SHALL NOT be stored in a building, garage, shed, breezeway, or any other enclosed space. Cylinders can be stored indoors ONLY if cylinders are disconnected and removed from the appliance.

z The cylinder should ALWAYS be put in an upright position.

WARNING

Place dust cap on cylinder valve outlet whenever the cylinder is not in use. Only install

the type of dust cap on the cylinder valve outlet that is provided with the cylinder valve.

Other types of caps or plugs may result in leakage of propane.

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DANGER

z DO NOT connect this grill to an existing #510 POL cylinder valve with Left hand

threads. The Type 1 valve can be indentified with the large external threads on the valve outlet.

z DO NOT connect to a propane cylinder exceeding this capacity. z DO NOT connect to a cylinder that uses any other type of valve connection device. z Never store a spare LP gas cylinder under or near your grill. This could cause

pressure to be expelled through the vapor relief valve resulting in fire, explosion, or severe personal injury including death.

z Keep the ventilation opening(s) of the LP gas cylinder enclosure free and clear from

obstructions and debris.

z DO NOT insert any foreign objects into the valve outlet. Damage to the back-check

could result. A damaged back-check can cause a leak, possibly resulting in explosions, fire, severe bodily harm, or death.

z Place dust cap on cylinder valve outlet whenever cylinder is not in use. Only install

the type of dust cap on the cylinder valve outlet that is provided with the cylinder valve. Other types of caps or plugs may result in leakage of propane.

WARNING

FOR FILLING THE LP GAS CYLINDER

z Allow only qualified LP gas dealers to properly fill or repair your LP cylinder. z DO NOT allow the cylinder to be filled beyond 80% capacity. Over-filled tanks can

create a dangerous condition. Over-filled tanks can build-up pressure and cause the relief valve to expel propane gas vapors. The vapor is combustible and if it comes in contact with a spark source or flame an explosion causing severe burns, bodily harm, or death could occur.

z Always use a safety cap when grill is not connected to cylinder. z If you exchange a cylinder with a qualified exchange program, be sure the cylinder

has a Type 1 valve and an over-filling prevention device (OPD).

INSTALLING GAS CYLINDER

1. Check that cylinder valve is closed by turning knob

clockwise.

2. Place the gas cylinder onto the base hole of

bottom shelf and position it where the valve opening faces side burners and make sure the hose is not kinked/damage or touch any hot surface.

3. Lock the gas tank with the locking bolt on the right

edge of bottom shelf.

4. Attach the regulator to the gas cylinder valve.

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WARNING

Keep the fuel supply hose away from any heated surfaces.

WARNING

z The pressure regulator and hose assembly supplied with your gas grill must be

used. Replacement pressure regulators and hose assemblies must be those specified by the grill manufacturer.

z Do not attempt to connect it to any other fuel supply source. z Do not attempt to adjust or repair the regulator. The regulator is designed to operate

at the maximum output pressure of 11 inches of water column (2.74 kPa).

CONNECTION PROCEDURES

Connecting Regulator to the LP Tank

1. Place LP tank on a secure, level, and stable surface.

2. Turn control knob 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 the LP tank valve. Always use dust cap and strap supplied with valve.

5. Hold regulator, insert nipple (B) into LP tank valve. Hand tighten coupling nut, holding regulator in a straight line (C) with LP tank valve so as not to cross thread the connection.

6. Turn the coupling nut clockwise to tighten to a full solid stop. The regulator will 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 connection. Tighten by hand only – do not use tools.

NOTE: If you cannot complete connection, disconnect regulator and repeat step 5 and 6. If you are still unable to complete the connection, do not use this regulator!

To disconnect LP gas cylinder:

WARNING

z If the grill is not in use, the gas must be turned off at the supply cylinder(s). Storage of

the grill is permissible only if the cylinder is disconnected and removed from the grill.

z Cylinders must be stored outdoors out of the reach of children and pets and must not

be stored in a building, garage or any other enclosed area.

Do not use a POL transport plug (A) (plastic part with external threads)! It will defeat the safety feature of the valve.

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1. Turn the burner valves off.

2. Turn the tank valve off fully (turn clockwise to stop).

3. Detach the regulator assembly from the tank valve by turning the quick coupling nut

counterclockwise.

LEAK TEST

WARNING

z DO NOT SMOKE WHILE CONDUCTING LEAK TEST. z NEVER PERFORM LEAK TEST WITH AN OPEN FLAME. z Perform test OUTDOORS only in a well ventilated area. z If it is evident there is excessive abrasion or wear, or the hose is cut, it must be

replaced prior to the appliance being operational. The replacement hose shall be

specified the by manufacturer. When to perform a leak test: z After assembling the grill and before lighting for the first time, even if purchased

fully assembled. z Every time the LP gas cylinder is refilled or if any of the gas components are

replaced.

Checking for leaks:

1. Create a mixture of 50% water and 50% liquid dishwashing soap.

2. Open the lid.

3. Ensure all control knobs are set to the “OFF” position.

4. Turn on the fuel supply at the cylinder valve. Turn the cylinder valve knob one turn counter-clockwise.

5. Apply the soap water mixture to the following:

a. Supply tank weld. b. Connection nut to tank valve. c. Back side of connection nut to brass nipple. d. Brass nipple connection into regulator. e. Regulator connections to gas supply hoses. f. Gas supply hose connection. g. Side burner valve stem cap h. Side burner connection to hose. i. Hose connection to gas manifold. j. The full length of gas supply hose. k. Tank valve to cylinder.

6. Check each place (a-k) for growing bubbles which indicates a leak.

7. Turn off gas supply at cylinder valve.

8. Turn on control knobs to release gas pressure in hose.

9. Turn control knobs to “OFF” position.

10. Tighten any leaking connections.

11. Repeat soapy water test until no leaks are detected.

12. Turn off gas supply at cylinder valve until you are ready to use your grill.

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LIGHTING INSTRUCTIONS

BEFORE LIGHTING

WARNING

z Inspect the gas supply hose prior to turning the gas “ON”. z If there is evidence of cuts, wear, or abrasion, it must be replaced prior to use. z Do not use the grill if the odor of gas is present. z Only the pressure regulator and hose assembly supplied with the unit should be

used.

z Perform the “LEAK TEST” according to instruction before operating the grill. z ALWAYS keep your face and body as far away from the burner as possible while

lighting.

LIGHTING THE MAIN BURNER OF GRILL

1.Read all instructions before lighting.

2.Open lid during lighting.

3.Light the IGNITION BURNER first. Push and turn main burner knob slowly to HI. Burner

should light immediately.

4. Once the IGNITION BURNER is lit, you may light the rest of burners.

5. If ignition does not occur in 5 seconds, turn the knob(s) off, wait 5 minutes, then repeat

the lighting procedure.

6. To turn burners off, turn the control knobs clockwise until they lock in the OFF

position.Turn gas supply to OFF.

Light this burner first! Turn

counterclockwise to open

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LIGHTING THE SIDE BURNER (Side burner):

DANGER

Never close the SIDE BURNER LID during operation

1. Read all instructions before lighting.

2. Open lid during lighting.

3. Push and turn main burner knob slowly to HI. The side burner should light immediately.

4. Once burner is lit, continue to push and hold control knob for 45 seconds.

5. If ignition does not occur in 5 seconds, turn the knob off, wait 5 minutes, then repeat the lighting procedure or light by match.

6. To turn burners off, turn the control knob clockwise until it locks in the OFF position. Turn gas supply to OFF.

MATCH LIGHTING THE MAIN BURNERS:

1. Turn OFF all burner valves.

2. Make sure the lid is open.

3. Place a lighted match between the coils on

the extension rod and hold next to the burner.

4. Turn the control knob(s) to the “HI/Light”

osition. Burner should light immediately.

5. For infra-red side burner, once the burner is

lit continue to push and hold control knob for 45 seconds.

6. If the burner does not light in 4 seconds turn

the knob off, wait 5 minutes and repeat above procedures.

MATCH LIGHTING THE SIDE BURNER:

1. Turn OFF all burner valves.

2. Make sure the lid is open.

3. Strike and carefully palce a long match 1/2” (1 to 2 cm) from

the side burner

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4. Turn the control knob to the “HI/Light” position. Burner should light immediately.

5. Once the burner is lit continue to push and hold control knob for 45 seconds.

6. If the burner does not light in 4 seconds turn the knob off, wait 5 minutes and repeat above

procedures.

DANGER

z Keep your face and hands as far away from the grill as possible when lighting it.

FLAME CHARACTERISTICS

This procedure outlines how to check for proper burner flame characteristics. Burner flames should be blue and stable with little yellow tips, with no excessive noise, or lifting. If the flame is yellow, it indicates insufficient air. If the flame is noisy and tends to lift away from the burner, it indicates too much air. If any of these conditions exist call our customer service line. Visually check the burner flames prior to each use. The flame should look like this picture. If they do not, refer to the burner maintenance part of this manual.

MAINTENANCE GUIDE

Before cleaning the grill, place it in an area clear and free from combustible materials, gasoline and other flammable vapors and liquids. Do Not obstruct the flow of combustion and ventilation air.

GRILL RACK

The easiest way to clean the grill is immediately after cooking is completed and after turning off the flame. Wear a barbeque mitt to protect your hand from the heat and steam. Dip a brass bristle barbeque brush in tap water and scrub the hot grill. Dip the brush frequently in the bowl of water. Steam, created as water hits the hot grill, assists the cleaning process by softening any food particles. The food particles will “fall off” and burn. If the grill is allowed to cool before cleaning, cleaning will be more difficult.

GREASE TRAY

The grease tray should be emptied and wiped down periodically and washed with a mild detergent and warm water solution. A small amount of sand or cat litter may be placed in the bottom of grease tray to absorb the grease. Check the grease tray frequently. Don’t allow excess grease to accumulate and overflow out of the grease tray.

GRILL BURNERS

Extreme care should be taken when removing a burner as it must be correctly centered on the orifice before any attempt is made to re-light the grill. Frequency of cleaning will depend on how often you use the grill.

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Spiders and small insects occasionally spin webs or make nests in the grill burner tubes during transit and warehousing. These webs can lead to gas flow obstruction which could result in a fire in and around burner tubes. This type of fire is known as flashback and can cause serious damage to your grill and create an unsafe operating condition for the user. Although an obstructed burner tube is not the only cause of flashback, it is the most common cause. To reduce the chance of flashback, you must clean the burner tubes before assembling your grill, and at least once a month in late summer or early fall when spiders are most active. Also, perform this burner tube cleaning procedure if your grill has not been used for an extended period of time.

You should inspect the burners at least once a year or immediately after any of the following conditions occur:

1. The smell of gas in conjunction with the burner flames appearing yellow.

2. The grill does not reach temperature.

3. The grill heats unevenly.

4. The burners make popping noises.

WARNING

z ENSURE that the gas supply and the knobs are in the “OFF” position.

Cleaning The Burner Tubes and Burner Ports (For main burners)

To reduce the chance of FLASHBACK FIRE you must clean the Burner Tubes as follows at least once a month in summer and fall or whenever spiders are active in your area, and if your grill has not been used for an extended period of time.

Removing the main burner(s):

1. Turn all Burner Valves to the full OFF position.

2. Turn the LP Gas tank valve to the full OFF position.

3. Detach the LP Gas regulator assembly from your gas cylinder.

4. Remove the Cooking Grates and Heat Distribution Plates from your grill.

5. Remove the screw from the front of each Burner using a Phillips Head Screwdriver.

6. Carefully lift each Burner up and away from the Gas Valve Orifice.

7. Check and clean burner/ venturi tubes for insects and insect nests. A clogged tube can lead to a fire beneath the grill.

8. Bend a stiff wire or wire coat hanger into a small hook as shown and run the hook through the Burner Tube and inside the Burner several times to remove debris.

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WARNING

For safe operation ensure the Gas Valve Assembly Orifice is inside the Burner Tube before using your grill. See figure. If the Orifice is not inside the Burner Tube, lighting the Burner may cause explosion and/ or fire resulting in serious bodily injury and/or property damage.

When an appliance is supplied on casters and is connected to the supply piping by means of a connector for movable appliances, the operator shall be aware there is a restraint on the appliance and, if disconnection of the restraint is necessary, to reconnect this restraint after the appliance has been returned to its originally installed position.

Cleaning The Infrared side burner

1. Turn all Burner Valves to the full OFF position.

2. Turn the LP Gas tank valve to the full OFF position.

3. Detach the LP Gas regulator assembly from your gas cylinder.

4. Remove the Cooking Grates from the side burner.

5. Remove the mounting screws at the back of side burner.

6. Slide the infrared burner out of the enclosure.

7. Check and clean burner/ venturi tubes for insects and insect nests. A clogged tube can

lead to a fire beneath the grill.

8. Bend a stiff wire or wire coat hanger into a small hook as shown and run the hook

through the Burner Tube and inside the Burner several times to remove debris.

WARNING

CAUTION

z Keep outdoor cooking gas appliance area clear and free from combustible materials,

gasoline and other flammable vapors and liquids.

z Do not obstruct the flow of combustible and ventilation air. z Keep the ventilation openings of the cylinder enclosure free and clear of debris.

z Check and clean burner/venturi tubes for insects and insect nests. A clogged tube

can lead to a fire beneath the grill.

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CHARCOAL GRILL GENERAL WARNINGS

WARNING

z The maximum weight of charcoal to be used is 2.4lb (1.1kg). Too much

charcoal may cause the gas component to overheat and malfunction.

z The charcoal chamber is for charcoal cooking only. Gas grill and side burner

cannot be used for charcoal cooking.

z Only use this grill on a hard, level, non-combustible, stable surface (concrete,

ground etc.) capable of supporting the weight of the grill. Never use on wooden or other surface that could burn.

z DO NOT use grill without charcoal ash tray in place. DO NOT attempt to

remove charcoal ash tray while tray contains hot coals.

z Use your grill OUTDOORS in a well ventilated space away from dwellings or

other buildings to prevent dangers associated with gas accumulation and toxic vapors. The grill should be situated at least 60 inches (153cm) from buildings. Not adhering to these clearances will prevent proper ventilation and may increase the risk of a fire and/or property damage, which could also result in personal injury.

z Maintain a minimum clearance of 60 inches (153 cm) between all sides of grill,

deck railings, walls or other combustible material. DO NOT use grill under overhead unprotected combustible construction.

z For outdoor use only. Do not use this grill for other than its intended purpose. z For household use only. Do not use this grill for other than its intended purpose. z We recommend the use of a Charcoal Chimney Starter to avoid the dangers

associated with charcoal lighting fluid.

z Use charcoal chimney starter or charcoal that has been pre-treated with lighter

fluid when starting fire in charcoal section of your grill.

z Do not store lighter fluid or other flammable liquids, material or charcoal that

has been pre-treated with lighter fluid under the grill or inside stroage shelves.

z Do not use gasonline or alcohol for lighting charcoal. Use of any of these or

similar products could cause an explosion possibly leading to severe bodily injury.

z Never add charcoal lighting fluid to hot or even warm coals as flashback may

occur causing severe burns.

z Place grill in an area where children and pets cannot come into contact with

unit. Close supervision is necessary when grill is in use.

z Do not leave grill unattended when in use. z When adding charcoal and/or wood, use extreme caution and follow instruction

in Adding Charcoal / Wood During Cooking section of this manual.

z Do not store or use grill near gasoline charcoal or other flammable liquids or

where flammable vapors may be present.

z Use caution when adjusting charcoal grate height. Handle may be hot when in

use.

z Use caution since flames can flare-up when fresh air suddenly comes in

contact with fire. When opening the lid, keep hands, face and body a safe distance from hot steam and flame flare-ups.

z Extinguished coals and ashes should be placed a safe distance from all

structures and combustible materials.

z Never raise or lower charcoal grate when water is smoking as hot water may

splash onto coals.

z Use caution since flames can flare-up when fresh air suddenly comes in

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contact with fire. When opening the lid, keep hands, face and body a safe distance from hot steam and flame flare-ups.

z After each use, clean the grill thoroughly and apply a light coat of vegetable oil

to the interior to prevent rusting. Cover the grill to protect it from excessive rusting.

z Grill is hot when in use. To avoid burns:

z DO NOT attempt to move the grill z Wear protective gloves or oven mitts. z DO NOT touch any hot grill surfaces. z DO NOT wear loose clothing or allow hair to come in contact with grill.

PREPARATION FOR USE & LIGHTING INSTRUCTIONS

WARNING

OUTDOOR USE ONLY. DO NOT OPERATE GRILL INDOORS OR IN AN ENCLOSED SPACE

Never use grill indoors. Carbon Monoxide poisoning can lead to death.

Curing your grill

Prior to your first use of the Grill, follow the instructions below carefully to cure your grill. Curing your grill will minimize damage to the exterior finish as well as rid the grill of paint odor that can impart unnatural flavors to the first meal prepared on the grill.

IMPORTANT: To protect your grill from excessive rust, the unit must be properly cured and

covered at all times when not in use.

Step 1

Lightly coat all interior surfaces of the grill with vegetable oil or vegetable oil spray.

Step 2

Follow the instructions below carefully to build a fire. You may use charcoal and/or wood as fuel for the grill (see “Adding Charcoal/Wood During Cooking” section of this manual).

WARNING

Use only a high grade plain charcoal or charcoal /wood mixture.

NOTE: To extend the life of your grill, make sure that hot coals and wood do not touch the walls of grill.

IF USING CHARCOAL CHIMNEY STARTER, PROCEED TO STEP 5.

If you choose to use charcoal lighting fluid, ONLY use charcoal lighting fluid approved for lighting charcoal. Do not use gasoline, kerosene, alcohol or other flammable material for lighting charcoal. Follow all manufacturer’s warnings and instructions regarding the use of their product. Start with

3.3 lb(1.5 kg ) of charcoal. This should be enough charcoal to cook with, once the curing process

has been completed. Place the charcoal in the center of each charcoal grate.

Step 3

Saturate charcoal with lighting fluid. With lid open, wait 2 to 3 minutes to allow lighting fluid to soak into charcoal. Store lighting fluid a safe distance from the grill.

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Step 4

With grill lid and doors open, stand back and carefully light charcoal through the doors. Allow to burn until covered with a light ash (approximately 20 minutes).

WARNING

Charcoal lighting fluid must be allowed to completely burn off prior to closing grill lid (approximately 20

minutes). Failure to do this could trap fumes from charcoal lighting fluid in grill and may result in a flash-fire or

explosion when lid is opened.

Step 5

Place lump or briquette charcoal on top of grate in chimney starter until full. Underneath grate place balled up paper and light with match or lighter thru holes in bottom of chimney sides. Once paper lights, fire will spread up thru charcoal until entire column is glowing red in the bottom with ash formation on top. Pick up by handle and pour lit charcoal into grill.

With coals burning strong, close the lid and doors. Allow the temperature to reach 225°F (107°C) on both heat indicators. Maintain this temperature for 2 hours.

Step 6

Increase the temperature to 400°F (205°C) on charcoal chamber indicator. This can be achieved by adding more charcoal and/or wood (see “Adding Charcoal/Wood During Cooking“ section of this manual). Maintain this temperature for 1 hour then allow unit to cool completely.

IMPORTANT: to protect your grill from excessive rust, the unit must be cured periodically

and covered at all times when not in use.

OPERATING INSTRUCTIONS

WARNING

DO NOT use grill without charcoal ash tray in place. DO NOT attempt to remove charcoal ash tray while tray

contains hot coals.

CAUTION

Always wear oven mitts/gloves when adjusting cooking levels to protect your hands from burns.

Grilling/Searing

Step 1

Follow the instructions below carefully to build a fire. You may use charcoal and/or wood as fuel in the charcoal side of the Hybrid Grill (see “Adding Charcoal/Wood During Cooking” section of this manual).

WARNING

Use only a high grade plain charcoal or charcoal/wood mixture.

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If using a Charcoal Chimney Starter, follow “Operating Instruction Step 4” or follow all manufacturer’s warnings and instructions regarding the use of their product.

Start with 2.4 pounds (1.1 kg ) of charcoal. When charcoal is burning strong, carefully place hot coals in center of the charcoal tray.

WARNING

DO NOT use grill without charcoal ash tray in place. DO NOT attempt to remove charcoal ash tray while tray contains hot coals.

NOTE: To extend the life of your grill, make sure that hot coals and wood do not touch the walls of grill.

IF USING CHARCOAL CHIMNEY STARTER, PROCEED TO STEP 4.

If you choose to use charcoal lighting fluid, ONLY use charcoal lighting fluid approved for lighting charcoal. Do not use gasoline, kerosene, alcohol or other flammable materials for lighting charcoal. Follow all manufacturer’s warnings and instructions regarding the use of their product. Start with 2.4 pounds (1.1 kg ) of charcoal. Place the charcoal in center of the charcoal tray.

Step 2

Saturate charcoal with lighting fluid. With lid and doors open wait 2 to 3 minutes to allow lighting fluid to soak into charcoal. Store charcoal lighting fluid a safe distance from the grill.

Step 3

With grill lid and doors open, stand back and carefully light charcoal and allow to burn until covered with a light ash (approximately 20 minutes).

WARNING

Charcoal lighting fluid must be allowed to completely burn off prior to closing grill lid and doors (approximately 20 minutes).Failure to do this could trap fumes from charcoal lighting fluid in grill and may result in a flash-fire or explosion when lid is opened.

Step 4

Place cooking grates on grill support lips. Use charcoal tray handle adjuster to position charcoal grates to desired cooking level.

WARNING

Always wear oven mitts/gloves when adjusting cooking levels to protect your hands from burns.

Step 5

Place food on cooking grates and close grill lid. Always use a meat thermometer to ensure food is fully cooked before removing from grill.

Step 6

Allow grill to cool completely, and then follow instructions in the “After-Use Safety” and “Proper Care & Maintenance” sections of this manual.

Flavoring Wood

To obtain your favorite smoke flavor, experiment by using chunks, sticks or chips of flavor producing wood such as hickory, pecan, apple, cherry, or mesquite. Most fruit or nut tree wood may be used

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for smoke flavoring. Do not use resinous wood such as pine as it will produce an unpleasant taste.

Wood chunks or sticks 3” to 4” (7 to 10 cm) long and 1” to 2” (2 to 4 cm) thick work best. Unless the wood is still green, soak the wood in water for 30 minutes or wrap each piece in foil and tear several small holes in the foil to produce more smoke and prevent the wood from burning too quickly. Only a few pieces of wood are required to obtain a good smoke flavor. A recommended amount for the grill is 5 to 6 wood chunks or sticks. Experiment by using more wood for stronger smoke flavor or less wood for milder smoke flavor.

Additional flavoring wood should not have to be added during the cooking process. However, it may be necessary when cooking very large pieces of food. Follow instructions and cautions in the “Adding Charcoal/Wood During Cooking” section of this manual to avoid injury while adding wood.

Regulating Heat

By adjusting the position of the charcoal tray, the temperature of grill can be regulated. To increase the heat, move the charcoal towards the cooking grates. Lowering it will decrease the temperature.

To increase heat, more wood and/or charcoal may be needed. Follow instructions in “Adding Charcoal/Wood

During Cooking” section of this manual.To maintain the temperature, more wood and/or charcoal may need to be added during the cooking cycle.

NOTE: Dry wood burns hotter than charcoal, so you may want to increase the ratio of wood to charcoal to increase the cooking temperature. Hardwood such as oak, hickory, mesquite, fruit and nut wood are an excellent fuel because of their burning rate. When using wood as fuel, make sure the wood is seasoned and dry. DO NOT use resinous wood such as pine as it will produce an unpleasant taste.

Adding Charcoal/Wood During Cooking

Additional charcoal and/or wood may be required to maintain or increase cooking temperature.

Step 1

Stand back and carefully open grill lid. Use caution since flames can flare-up when fresh air suddenly comes in contact with fire.

Step 2

Wearing oven mitts/gloves, use charcoal tray adjuster to place charcoal tray at the lowest level of cooking chamber. Open doors to allow access to charcoal tray.

Step 3

Stand back at a safe distance and use long cooking tongs to lightly brush aside ashes on hot coals. Use cooking tongs to add charcoal and/or wood to charcoal tray, being careful not to stir-up ashes and sparks. If necessary, use your Charcoal Chimney Starter to light additional charcoal and/or wood and add to existing fire.

WARNING

Never add charcoal lighting fluid to hot or even warm coals as flashback may occur causing severe burns.

Step 4

When charcoal is burning strong again, wear oven mitts/gloves and carefully return charcoal tray to desired cooking level. Extinguish any hot ashes, coals or embers which may have fallen from doors or beneath and around grill.

Step 5

Close the grill lid and doors. Allow food to continue cooking.

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AFTER-USE SAFETY

CAUTION

z Always allow grill and all components to cool completely before handling. z Never leave coals and ashes in grill unattended. Make sure coals and ashes are completely

extinguished before removing.

z Before grill can be left unattended, remaining coals and ashes must be removed from grill.

Use caution to protect yourself and property. Place remaining coals and ashes in a non-combustible metal container and completely saturate with water. Allow coals and water to remain in metal container 24 hours prior to disposing.

z Extinguished coals and ashes should be placed a safe distance from all structures and

combustible materials.

z With a garden hose, completely wet surface beneath and around the grill to extinguish any

ashes, coals or embers which may have fallen during the cooking or cleaning process.

z Cover and store grill in a protected area away from children and pets.

Proper Care & Maintenance

z Cure your grill periodically throughout the year to protect against excessive rust. z To protect your grill from excessive rust, the unit must be properly cured and covered at all

times when not in use.

z Wash cooking grates with hot, soapy water, rinse well and dry. Lightly coat grates with

vegetable oil or vegetable oil spray.

z Clean inside and outside of grill by wiping off with a damp cloth. Apply a light coat of

vegetable oil or vegetable oil spray to the interior surface to prevent rusting.

z If rust appears on the exterior surface of your grill, clean and buff the affected area with steel

wool or fine grit emery cloth. Touch-up with a good quality high-temperature resistant paint.

z Never apply paint to the interior surface. Rust spots on the interior surface can be buffed,

cleaned, and then lightly coated with vegetable oil or vegetable oil spray to minimize rusting.

How do I season my Cast Iron Grates?

1. Wash grates in hot, soapy water. Rinse grates and dry completely using a towel. Towel may

become discolored. This is normal.

2. Apply a thin, even coating of melted shortening (Crisco, as an example) to the grates with a

soft cloth or paper towel. Apply to both sides of the grates.

3. Heat grill with a small fire to around 350 degrees. Place grates in grill not directly over the

coals and close lid. Leave closed for at least one hour. Let grates remain in grill until cool.

4. Place grates in proper position in the grill.

Your cast iron grates should be properly seasoned and ready to use!

Tips & Suggestions:

1. Seasoning is an ongoing process. Periodically reapply the oil to grates with a soft cloth,

especially if you see any rust developing or before long periods of storage.

2. Never put your Cast Iron Grates in the dishwasher or allow to air dry.

3. IF rust does appear, remove with a grill brush and repeat the seasoning process.

4. Cleaning of the grates should be done before the cooking begins, not after the cooking is over.

A little residue left on the Cast Iron crates helps protect them between uses.

5. The more Cast Iron Grates are used the better the non-stick qualities become. This is a great

excuse to grill more often!

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Product Diagram

38 39

36 10

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Component List

1. Front Panel 2. Left Panel 3. Right Panel 4. Grill Body Back

1 Pc 1 Pc 1 Pc 1 Pc

5. Back Panel 6.Bottom Shelf 7.Grease collector 8.Reinforcement

1 Pc 1 Pc 1 Pc 1 Pc

9.Left Front Leg 10.Left Rear Leg 11.Right Front Leg 12.Right Rear Leg

1 Pc 1 Pc 1 Pc 1 Pc

13.Charcoal Chamber Lid 14.Gas Chamber Lid 15. Left Side Shelf 16.Right Stove Housing

1 Pc 1 Pc 1 Pc 1 Pc

17.Middle Separator 18.Storage Rack 19. Side Burner 20.Gas valve assembly

1 Pc 1 Pc 1 Pc 1 Pc

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21. Outer Heat Shield 22. Inner Heat Shield 23. Carry Over 24. Burner Tube

1 Pc 1 Pc 1 Pc 3 Pcs

25. Flame Tamer 26.Left Warming Rack 27.Right Warming Rack 28. Charcoal Grill

(Shorter) (Longer) Cooking Grid

3 Pcs 1 Pc 1 Pc 2 Pcs

29. Lifting Action Bar 30.Left Lifting Bar 31.Right Lifting Bar 32.Charcoal Tray

1 Pc 1 Pc 1 Pc 1 Pc

33. Stove Rack 34.Lid Handle 35. Air Vent 36.Latch

1 Pc 2 Pcs 2 Pcs 1 Pc

37.Locking Plate 38.Crank Holder 39. Crank 40.Electrode

1 Pc 1 Pc 1 Pc 1 Pc

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41.Temperature Gauge 42. Grease Cup 43. Drawer Handle 44. Caster

2 Pcs 1 Pc 1 Pc 4 Pcs

45. Control Knob 46.Lower Hinge 47.Upper Hinge 48. Locking Bolt

4 Pcs 4 Pcs 4 Pcs 1 Pc

49.Lifter 50. Gas Grill Cooking

Grid

1 Pc 2 pcs

Hardware List

Item No. Item name Diagram Qty

A BOLT M6x55

B BOLT M6x35

C BOLT M6x15

D BOLT M6x12

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E BOLT M5x10

F BOLT M4x10

G BOLT M4x8

8 pcs attached to the valves (20),

1 pc attached to the crank(39).

H FLANGE Nut M6

J FLANGE Nut M4

K LOCK NUT M10

L LOCK NUT M6

M AXIAL SCREW M4

N PLANE WASHER

HEAT RESISTANT

WASHER

Q HINGE PIN

R COTTER PIN

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Assembly Procedures Symbol: The following symbols will be shown in each procedure for indication of tightening the bolt and nut if necessary.

Some steps may require the assistance of a friend.

Step 1.

Step 2.

Hand Tighten only at this

time

Tighten with tools at this time

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Step 3.

Step 4.

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Step 5.

Step 6.

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Step 7.

Step 8.

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Step 9.

Step 10.

Tighten all the bolts and nut in step 3, 4, 5 and 9.

Step 11.

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Step 12.

Step 13.

VALVE

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Step 14.

Step 15.

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Step 16.

Step 17.

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Step 18.

Step 19.

Loosen the bolts at the four corners to halfway as per below pictures.

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Step 20.

Step 21.

Left Back

Left Front

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Step 22.

Step 23.

Right Back

Right Front

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Step 24.

Step 25.

SIDE BURNER VALVE

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Step 26.

Step 27.

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Step 28.

Step 29.

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Step 30. Tighten all the bolts and nut in step 27.

Step 31.

Step 32.

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Step 33.

Step 34.

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Step 35.

Step 36.

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LIMITED WARRANTY

1. Manufacturer warrants this Product to be free from defects in workmanship and

materials for a period of Ninety (90) days from the date of purchase, PROVIDED claims

are submitted, in writing, with proof of purchase.

2. If any part of this item fails because of a manufacturing defect within the Limited

Warranty Period, Manufacturer offers to replace such part(s) provide that such parts

have not been improperly repaired, altered, or tampered with or subject to misuse,

abuse or exposed to corrosive conditions. This Limited Warranty is, however, subject to

certain limitations, exclusions, time limits and exceptions (Hereinafter “Conditions”) as

listed below. Read these Conditions carefully.

3. This Limited Warranty shall be limited to the replacement or repair of any part(s) which

Manufacturer determines, after reasonable examination, to have been defective at the

time of manufacturing and manufacturer’s obligation(s) shall be limited to replacement,

if any, of defective part(s) which shall be shipped at Original Purchaser’s expense to

Original Purchaser’s designated shipping address.

4. This Limited Warranty is given to and covers the ORIGINAL PURCHASER ONLY and

such coverage terminates Ninety (90) days from the date of purchase.

5. DAMAGE LIMITATION WARNING: IN NO EVENT SHALL MANUFACTURER BE

LIABLE FOR ANY INCIDENTIAL OR CONSEQUENTIAL DAMAGES, INCLUDING

(BUT NOT LIMITED TO) LOSS OF USE OF THE PRODUCT, LOSS OF TIME, LOSS

OF FOOD, INCONVENIENCE, EXPENSES FOR TRAVEL, TRANSPORTATION

LODGING EXPENSES, LOSS BY DAMAGE TO PERSONAL PROPERTY OR LOSS

OF INCOME, PROFITS OR REVENUE.

6. MANUFACTURER’S OBLIGATION: Manufacturer’s liability shall be limited to the

delivery of a good, merchantable Product and, if necessary, the repair or replacement,

at manufacturer’s option, of any defective part or unit.

7. TRANSFER LIMITATIONS: This Limited Warranty is not assignable or transferable.

It covers only the original purchaser.

8. RESERVED RIGHT TO CHANGE: Manufacturer reserves the right to make changes

or improvements to products it produces in the future without imposing on itself any

obligations to install the same improvements in the products it has previously

manufactured.

9. This Limited Warranty gives the Original Purchaser specific legal rights but there may

be other rights which vary by jurisdiction.

10. This warranty does not cover the following items:

z Chips or scratches on porcelain or painted surfaces

z Rust or corrosion is not deemed a manufacturing or materials defect

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z Discoloration or loss of paint due to handling during assembly, heat or cleaning

products. Paint may require touch up.

z Stainless steel discoloration or corrosion

z Consumables such as batteries

IF CUSTOMER SERVICE BECOME NECESSARY:

1. The Original Purchaser is responsible for shipping and handling charges of the

returned item(s) and replacement parts, if any.

2. All parts to be replaced will need to be shipped before replacement items will be

sent.

3. Follow the Customer Service Representative’s instructions exactly. If a return is

necessary, it must be packed carefully and shipped prepaid.

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Should you encounter any problems,

DO NOT return product to the store!

Rankam Metal Products Manufactory Ltd.

1618 W.Rosecrans Ave.,

Gardena, CA90249.

Email: CustomerService@rankam.com

Toll Free

(888) 837 – 1380

Hours of Operation 8a.m.-5p.m. Pacific Standard Time

Versa Flame BY12-084-029-97 Assembly & Operating Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual