Kokomo Grills KO-BAK3BG User manual

Kokomo Grills Outdoor Products Instructional Book
PG 1
Version 2.8
USER MANUAL & CARE GUIDE
Gas Grill Model:
KO-BAK3BG (LP/NG)
KO-BAK4BG (LP/NG)
KO-BAK5BG (LP/NG)
Side Burner Model:
KO-BAK1BG (LP/NG)
KO-BAK2BG (LP/NG)
DANGER:
IF YOU SMELL GAS:
1) Shut off the gas supply to the appliance at
its source.
2) Extinguish any open flames.
3) Open grill hood to release any
accumulation of gas vapor.
4) If a gas odor persists, Keep away from
your appliance and contact your gas supplier
or fire department immediately.
WARNING:
-Do not store or use gasoline or other
flammable liquids or vapor in the vicinity of
this or any other appliance
-A LP cylinder not connected for use shall
not be stored in the vicinity of this or any
other appliances.
ATTENTION CONSUMER:
PLEASE READ & RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE AND
BEFORE INSTALLING OR OPERATING.
Kokomo Grills Outdoor Products: USA Nationwide
Help Desk: www.kokomogrills.com
THIS MANUAL APPLIES TO THE FOLLOWING KOKOMO GRILLS & SIDE BURNERS:

PG 2
MODEL: KO-BAK3BG (LP/NG)
3 BURNER KOKOMO GRILL
MODEL: KO-BAK4BG-LP/NG
4 BURNER GRILL
CUTOUT
DIMENSIONS
W:23 1/2” H:7 5/8” D:20 1/4”
CUTOUT
DIMENSIONS
W:30 7/8” H:7 5/8”D:20 1/4”
BTU OUTPUT
12,000 BTU PER BURNER X
3
BTU OUTPUT
12,000 BTU PER BURNER X4
INFERRED BACK
BURNER
NONE
INFERRED BACK
BURNER
12,000 BTU PER BURNER X1
TOTAL BTU
36,000
TOTAL BTU
60,000 BTU
PRIMARY
IGNITION
SURE LIGHT IGNITION
PRIMARY
IGNITION
SURE LIGHT IGNITION
SECONDARY
IGNITION
FLASH TUBE
SECONDARY
IGNITION
FLASH TUBE
COOKING GRIDE
DIMENSIONS
22 1/2” X 18 1/4”
COOKING GRIDE
DIMENSIONS
30 1/4” X 18 1/4”
TOTAL COOKING
AREA
560 SQ.IN
(INCLUDES WARMING
RACK)
TOTAL COOKING
AREA
740 SQ. IN
(INCLUDES WARMING RACK)
FLAME TAMER
SEARING BRIQUETTE
SYSTEM
FLAME TAMER
SEARING BRIQUETTE
SYSTEM
ROTISSERIE KIT
(MOTOR & FORKS)
OPTIONAL/UPGRADE
ROTISSERIE KIT
(MOTOR &
FORKS)
OPTIONAL/UPGRADE
BURNER
3 STAINLESS PIPE
BURNERS
BURNER
4 STAINLESS PIPE BURNERS
GAS TYPE
ALL GRILLS ARE SHIPPED
LP EACH SHIPMENT
CONTAINS NG
CONVERSION KIT
GAS TYPE
ALL GRILLS ARE SHIPPED LP
EACH SHIPMENT CONTAINS
NG CONVERSION KIT
WARRANTY
LIFETIME LIMITED
WARRANTY
KOKOMO GRILLS HAVE A
LIFETIME LIMITED
WARRANTY ON GRILL
HOUSING AND HOOD
AGAINST MANUFACTURE
DEFECTS AND
WORKMANSHIP.
10 YEAR LIMITED
WARRANTY ON BURNERS
AND GRATES
2 YEARS ON ALL OTHER
PARTS
30 DAYS ON ALL GRILL
ACCESSORIES
WARRANTY
LIFETIME LIMITED
WARRANTY
KOKOMO GRILLS HAVE A
LIFETIME LIMITED
WARRANTY ON GRILL
HOUSING AND HOOD
AGAINST MANUFACTURE
DEFECTS AND
WORKMANSHIP.
10 YEAR LIMITED
WARRANTY ON BURNERS
AND GRATES
2 YEARS ON ALL OTHER
PARTS
30 DAYS ON ALL GRILL
ACCESSORIES

PG 3
MODEL: KO-BAK5BG-LP/NG
5 BURNER GRILL
CUTOUT
DIMENSIONS
W:37 3/4” H:7 5/8”D:20 1/4”
BTU OUTPUT
12,000 BTU PER BURNER X4
INFERRED BACK
BURNER
12,000 BTU PER BURNER X1
TOTAL BTU
60,000 BTU
PRIMARY
IGNITION
SURE LIGHT IGNITION
SECONDARY
IGNITION
FLASH TUBE
COOKING GRIDE
DIMENSIONS
30 1/4” X 18 1/4”
TOTAL COOKING
AREA
920 SQ. IN
(INCLUDES WORMING
RACK)
FLAME TAMER
SEARING BRIQUETTE
SYSTEM
ROTISSERIE KIT
(MOTOR & FORKS)
OPTIONAL
BURNER
5 STAINLESS PIPE
BURNERS
GAS TYPE
ALL GRILLS ARE SHIPPED
LP EACH SHIPMENT
CONTAINS NG
CONVERSION KIT
WARRANTY
LIFETIME LIMITED
WARRANTY
KOKOMO GRILLS HAVE A
LIFETIME LIMITED
WARRANTY ON GRILL
HOUSING AND HOOD
AGAINST MANUFACTURE
DEFECTS AND
WORKMANSHIP.
10 YEAR LIMITED
WARRANTY ON BURNERS
AND GRATES
2 YEARS ON ALL OTHER
PARTS
30 DAYS ON ALL GRILL
ACCESSORIES

PG 4

PG 5
NOTE:
CHECK WITH CITY AND FIRE DEPARTMENT FOR LOCAL BUILDING
CODES. A PERMIT MAY BE REQUIRED FOR OUTDOOR KITCHEN
CONSTRUCTION.

PG 6

PG 7

PG 8
KO-BAK1BG-LP/NG
SIGLE SIDE BURNER
KO-BAK2BG-LP/NG
DOUBLE SIDE BURNER
Cutout
Dimensions
W: 11 1/2” H:0” D:15
1/2”
Cutout
Dimensions
W: 11” H: 6 3/4” D: 20
1/4”
Total BTU
Output
12,000BTU(1Bnr)
Total BTU
Output
24,000BTU(2Bnr)
Number of
Burners
1
Number of
Burners
2
Burner
Aluminum & Brass
Burner
Aluminum & Brass
Ignition
SURE LIGHT
Ignition
SURE LIGHT
Gas Type
Burners are shipped LP.
Each shipment contains
an NG
Conversion Kit.
Gas Type
Burners are shipped NG.
Each shipment contains an
LP
Conversion Kit
Warranty
1 year
Warranty
1 year

PG 9

PG 10
BUILDING BBQ SPECIFICATIONS
ALL BBQ ISLANDS MUST BE MANUFACTURED FROM “NON-
COMBUSTIBLE” MATERIAL.
Minimum clearance to adjacent combustible construction at 14” from sides &
16” from back

PG 11
Safety and Installation Instructions
WARNING
To reduce the risk of fire, electric shock, or injury, read and follow these
basic precautions before operating your gas grill or side burners.
WARNING
Improper installation, adjustment, alteration, service or maintenance can cause
injury or property damage. Read the installation, operating and maintenance
instructions thoroughly before installing or servicing this equipment.
WARNING
EXPLOSION HAZARD
Do not use the grill as storage area for flammable materials. Keep area clear and
free from combustible materials, gasoline, and other flammable vapors and liquids.
Failure to do so can result in death, explosion, or fire.
GRILL INSTALLATION
This gas grill must be installed in accordance with all local codes.If installation is
planned in an area with no local codes, the gas grill must be installed in accord with the
National Fuel Gas Code ANSI Z223.1 and storage and handling of liquefied petroleum
gases, ANSI/NFPA 58 or CSA B149.1 natural gas and propane installation code.
CALIFORNIA PROPOSITION 65 WARNING
The burning of gas cooking fuel generates some by-products which are on the list of
substances which are known by the State of California to cause cancer or reproductive
harm. California law requires businesses to warn customers of potential exposure to such
substances. To minimize exposure to these substances, always operate the unit according
to the use and care manual, ensuring you provide good ventilation when cooking.

PG 12
Instructions Overview
Location of your Barbecue:
Most importantly, this is an outdoor appliance. Ensure your barbecue is positioned safely
away from anything that can catch fire. Under no circumstance is this barbecue to be used
indoors. This includes garages or any other enclosed area.
Clearance from Combustibles: Ensure your barbecue remains at a distance of at least
18” from any combustible material such as wood, rock, paper and plants. Do not store
combustible materials, gasoline or flammable liquids or vapors around the barbecue.
Adequate Ventilation: Ensure there is adequate ventilation for both the barbecue and
cylinder. This is required not only for proper combustion, but also to prevent gas build
up.
Firm Level Surface: Use your barbecue only on a firm level surface. This barbecue is
not designed for recreational vehicles, and should not be installed on a boat or marine
craft.
Protection from Weather: Keep the barbecue protected from adverse weather, including
rain and high winds. Polyvinyl covers are available that have been specially designed for
this range of barbecues. Allow clear access to the entire gas supply hose and regulator.
Maintenance Access: When your barbecue is installed, you should be able to access the
gas supply line including the gas piping or hose, gas regulator, gas cylinder and any shut
off valves.
Partial Enclosures: Many backyards have areas that are partially closed off, such as
balconies and pergolas. In some cases, it is hard to decide whether these partially
enclosed areas should be classified as indoor areas, particularly in terms of permanent
(non-closable) ventilation. The gas safety authorities have agreed on the definition of
partial enclosures below.
IMPORTANT: Consult the AHJ (Authority Having Jurisdiction) or local contractor of any uncertainty.

PG 13
Safety and Installation Warnings
Please read all instructions before installing or operating your gas grill to prevent injury and
appliance damage.
Before installation or service, disconnect the power supply to the work area by removing the fuse,
"tripping" the circuit breaker, or unplugging the unit.
All gas grills will get hot during use. Use extreme caution when operating the grill.
Do not touch hot surfaces. Always use the handle to open or close the grill.
Close supervision is necessary when this or any appliance is used near children. Keep children
away from the grill during operation and until the grill has cooled off.
Do not store any LP cylinder or tank not connected for use with the grill, in the area of this grill
or any other appliance. Never store an LP cylinder or tank indoors, or within the reach of
children.
Keep any electrical supply cord and fuel supply hose away from any heated surfaces, sharp edges
and dripping grease.
Be certain your appliance is properly installed and grounded by a qualified technician in
accordance with applicable codes. To guarantee the electrical safety of this appliance, continuity
must exist between the appliance and an effective grounding system. It is imperative that this
basic safety requirement be met. The manufacturer cannot be held responsible for damages
caused by the lack or inadequacy of an effective grounding system.
Do not twist the gas supply hose.
Before each use, visually inspect the gas supply hose for cracks, cuts or excessive wear. Replace
the hose if necessary.
Never test the grill for gas leaks using a lighted match or any other open flame; see leak test
procedures using soap/water solutions - included in following pages of this manual.
The use of accessories, regulators, or components not recommended by the appliance
manufacturer may cause injuries and will void warranty.
Never light the grill with the hood closed and be certain that the burners are positioned and seated
over the gas valves and on the burner support.
Never lean over the cooking surface when lighting or operating the grill.
Use barbecue tools with wood handles and insulated oven mitts when operating the grill.
Gas Specifications: Be sure that the gas supplied to the grill conforms to the model you
purchased. A
Natural Gas grill requires natural gas to operate; an LP grill requires liquid propane gas to
operate.
Check the rating label on the left hand side of the unit.
RATING PLATE LOCATION

PG 14
Never connect the appliance to an unregulated gas supply line. Grills operated without a regulator
are unsafe and will not be serviced until installed properly and safely. Unsafe operation without a
gas regulator will void warranty of the grill.
Grills operated with NG (natural gas) gas must be installed with the NG regulator supplied with
the unit and set to 4.0" water column pressure.
Grills operated with LP (liquid propane) gas must be installed with an LP regulator not supplied
with the unit and set to 11" water column pressure.
The gas valves used in the grills are preset at the factory for LP operation. Please contact your
dealer and use a licensed contractor or installer to convert your grill to the different gas type.
The self-contained LP system barbecue grill is design certified to be used with a standard 20 lb.,
12 1/4" diameter; 18" high cylinder with right handed connection threads and this is the
maximum size LP tank to be used. The cylinder must be marked in accordance with the latest
U.S. Department of Transportation specifications for LP gas cylinders. (DOT. CFR49 or National
Standards of Canada CAN/CSA-B359 Cylinders, Spheres and Tubes for the Transportation of
Dangerous Goods) a Propane Tank with an ODP) Overfill Prevention Device) must be used at all
times. Natural Gas Requirements
Always check the Rating Plate to make sure the gas supply you are hooking up to is the
gas type the grill is manufactured for. IMPORTANT: Never connect the grill to an
unregulated gas supply.
The installation of this appliance must conform with local codes or in the absence of local
codes, to the national fuel gas code, ANSI Z223.1a-1998. Installation in Canada must be
in accordance with the standard CAN/CGA- B149.2, Propane Installation Code.
A licensed contractor or local gas company representative must perform all natural gas
connections.
Ensure that the service supplying the grill is fitted with a shut off valve conveniently
positioned near the grill and giving ease of access.
The grill must be isolated from the gas supply piping system by closing its individual
manual shutoff valve during any pressure testing of the gas supply piping system at test
pressures equal to or less than 0.5 psi (3.5 kPa).
The grill and its individual shutoff valve must be disconnected from the gas supply piping
system during any pressure testing of that system at test pressure in excess of 0.5 psi (3.5
kPa).

PG 15
Connection
1) Slide the grill forward to gain access to the regulator and gas connection point in
the rear.
2) Connect a suitable natural gas flex connector to the grill regulator.
3) Check the grill controls to ensure all control valves are in the full OFF position.
4) Turn on the main gas supply and check all connections for leaks using soapy water
as described in the leak testing procedure section.
Warning: If you see bubbles in the soapy solution at any of the connections, turn off the
gas supply and tighten the connection. If tightening the connection does not seal the leak,
it may be necessary to replace the flex hose.
SAFETY! BEWARE OF SPIDERS
CAUTION: BURNER TUBES MUST BE INSPECTED AND CLEANED BEFORE USE.
SPIDERS AND SMALL INSECTS OCCASIONALLY SPIN WEBS OR MAKE NESTS IN
THE BURNER DURING WAREHOUSING AND TRANSIT. THESE WEBS CAN LEAD TO
GAS FLOW OBSTRUCTION, WHICH COULD RESULT IN A FIRE IN AND AROUND THE
BURNER TUBES. THIS TYPE OF FIRE IS KNOWN AS “FLASH-BACK” IT IS THE MOST
COMMON CAUSE,AND FREQUENT INSPECTION AND CLEANING OF THE BURNER
TUBES IS NECESSARY
Checking for Gas Leaks
Perform a leak test at least once a year whether the gas supply cylinder has been
disconnected or not. In addition, whenever the gas cylinder is connected to the regulator
or whenever any part of the gas system is disconnected or replaced, perform a leak test.
As a safety precaution, remember to always leak test your grill outdoors in a well-
ventilated area. Never smoke or permit sources of ignition in the area while doing a leak
test. Do not use a flame, such as a lighted match to test for leaks. Use a solution of soapy
water.
1) Prepare a leak testing solution of soapy water by mixing in a spray bottle one part
liquid soap to one part water.
2) Make sure all the control knobs are in the OFF position.
3) Turn on the gas
4) On Natural Gas systems, turn the main feed valve to the grill.
5) On LP systems, turn the cylinder valve knob counter clockwise one turn to open.
6) Apply the leak-testing solution by spraying it on joints of the gas delivery system.
a. Bubbles in the soap solution indicate that a leak is present. Stop a leak by
tightening the loose joint or by replacing the faulty part with a replacement
part recommended by the manufacturer. Do not attempt to repair the
cylinder valve if it is damaged. The cylinder must be discarded to a proper
LP tank location and then replaced.

PG 16
7) Turn all control knobs back to the full OFF position.
a. If you are unable to stop a leak turn all control knobs back to the full OFF
position, shut off the gas supply to the grill and release pressure in the hose
and manifold by pushing in and turning any of the control valves one
quarter turn counter-clockwise.
8) On LP systems, remove the cylinder from the grill.
9) Call an authorized gas appliance service technician or an LP gas dealer.
10)Do not use the appliance until the leak is corrected.

PG 17
Liquid Propane (LP) Gas Requirements
LP TANK REQUIREMENTS:
A collar to protect the cylinder threads on the customer supplied tank.
An arrangement for gas vapor withdrawal.
A safety relief device having direct communication with the vapor space of the
cylinder.
A method of mounting.
When not in use, the tank shut off valve should be turned off.
WARNING
All purging and refilling of LP gas cylinders must be performed by qualified
personnel in the LP gas industry. Never store a spare LP gas cylinder under or near
this appliance. Never fill the LP gas cylinder beyond 80 percent full. Failure to
follow these instructions may result in explosion, personal injury or death.
Filling and Refilling LP Gas Cylinders:
Turn control knobs and cylinder valve to the OFF position.
Unscrew valve.
Remove cylinder and have it filled at your local qualified propane dealer.
Once filled, carefully connect the valve and make sure it is secure and not
leaking.
With the control knobs in the OFF position, turn on the cylinder valve.
oIf you smell gas or hear the hiss of gas escaping from the tank, get away from the
tank and do not attempt to correct the problem yourself. Call the Fire Department
immediately.
oIf your grill has no leak at the cylinder, then re-check for loose connections and
retest for leaks using the method detailed in the following pages with soapy
solution.
oDo not subject your LP gas cylinder to excessive heat, and always store the
cylinder in an upright position. Never store your LP cylinders indoors.
oMake sure that when attaching components, all connections are secured and fully
tightened to prevent leakage. If one is not already available, it is recommended
that an ON-OFF shutoff valve be installed at the gas supply source, and that the
gas supply be turned off when either Natural Gas or LP Gas grills are not in use.

PG 18
Transporting and Storing LP Gas
Transport only one cylinder at a time. Ensure the cylinder is secured in an upright
position with the control valve turned off and the dust cap in place. Be sure to store
cylinders outdoors and out of the reach of children. Do not store cylinders in a building,
garage, or any other enclosed area.
Leak Testing
All gas piping and connections must be tested for leaks after installation or service. All
leaks must be corrected immediately. Remember, before exchanging an empty bottle for
a new one; make sure all control valves are in the “off” position.
Open the valve (shut-off or ‘ON’ LP tank).
Apply liquid soap solution to all joints.
Bubbles forming indicate gas leak.
NEVER USE AN OPEN FLAME TO CHECK FOR LEAKS.

PG 19
FOR YOUR SAFETY
1. Do not store or use gasoline or other flammable vapors and liquids
in the vicinity of this or any other appliance.
2. Do not store any propane/butane (G31-G30) cylinder (that is not
connected for use) in the vicinity of this or any other appliance.
Installing the Grill in a BBQ Island
You will need a second person to help you avoid damaging the grill or your
barbecue island.
Before installing a grill in any island or cut out, make sure that the opening is not
bigger than the outside frame of the grill unit. The grill should rest on the lip of the
frame.
oPay careful attention to the location of the gas line. It should be routed
away from sources of heat, sharp edges and should make as few bends as
possible.
Check to see if the gas line connection will be accessible when grill is installed. If
the gas line connection is not easily accessible when the grill is installed, support
the grill above counter level and attach the gas line to the grill. When the gas
connection is made, slide the grill into the cut out. If the gas line connection is
accessible when the grill is installed, slide the grill into the cut out and then attach
the gas line.
oBe very careful not to kink the gas line when lowering the grill into the cut
out.
Keep your fingers away from where the grill will be supported on counter. Your fingers
could become trapped and a serious injury could occur.
Check to make sure the grill is level and is supported around the entire outside edge. If the
grill is not level or is unstable, use non-combustible shims under the outside lip to stabilize.
Perform the leak test procedure as described earlier in this manual.

PG 20
Electrical Precautions
Extension cords are available and may be used if care is exercised in their use.
If an extension cord is used:
The marked electrical rating of the cord set or extension cord should be at least as great
as the electrical rating of the appliance
The cord should be arranged so that it will not touch hot surfaces, sharp edges or drape
over the countertop or tabletop (where it can be pulled or tripped over unintentionally).
Outdoor extension cords should be used with products suited for outdoor use. They are surface
marked with suffix letters "W" or "W-A" and with a tag stating "Suitable for Use with Outdoor
Appliances".
To protect against electrical shock, the power cord and plug should be kept dry and off of the
ground.
Do not clean this product with water spray; do not spray cleaners into the lamp socket area.
Do not operate any appliance with a damaged power cord or power plug, and do not operate any
appliance after the appliance malfunctions or has been damaged in any manner. If this should
occur, return the appliance to the nearest authorized service facility for examination, repair or
adjustment.
Be certain your appliance is properly installed and grounded by a qualified technician in
accordance with applicable codes. To guarantee the electrical safety of this appliance, continuity
must exist between the appliance and an effective grounding system. It is imperative that this
basic safety requirement be met. The manufacturer cannot be held responsible for damages
caused by the lack of or inadequacy of an effective grounding system.
This appliance conforms to all uniform electrical safety codes and electrical grounding
regulations. Install unit according to I.A.W. local codes or with National Electrical Code
ANSI/NFPA 70 or CSA C22.1 in their absence.
General Safety and Care
NOTE: The manufacturer cannot be held responsible for damage or injury caused by improper
use of this appliance.
Gasoline, lighter fluid or other flammable liquids and vapors should never be stored in
the area of this grill or any other appliance.
Do not store anything in the grill. Make sure food is not forgotten in the grill; forgotten
items could melt or catch fire when the appliance is turned on.
To prevent injuries, do not use accessories that are not recommended by the
manufacturer.
Before cleaning the appliance, disconnect the rotisserie and "trip" the circuit breaker.
Never use the grill in windy conditions. If located in a consistently windy area
(oceanfront, mountaintop, etc.) a wind break will be required. Winds blowing into or
across the back hood gap, can cause poor performance and/or cause the control panel to
get dangerously hot.