Vermont Castings PIONEER User manual

VERMONT CASTINGS PIONEERTM/MC
KAMADO CHARCOAL BARBECUE
ASSEMBLY MANUAL
PLEASE TAKE THE OPPORTUNITY TO REVIEW US AT
WWW.VERMONTCASTINGSBBQ.COM
ENHANCE YOUR ASSEMBLY EXPERIENCE WITH BILT

WELCOME TO VERMONT CASTINGS
Founded in 1975, Vermont Castings has always stood for
uncompromising commitment to quality craftsmanship and
meaningful design. Our wood stoves and hearth products deliver
more than heat — they create a warmth that unites.
Lit with purpose, our line of Vermont Castings barbecues
are designed to deliver your best barbecuing experience.
With a durable, robust construction built to last through the
years, thoughtfully constructed components that stand up
to barbecuing in any season and a simplied system to make
maintaining your investment easier, Vermont Castings continues
the promise of unwavering quality and purposeful design.
Vermont Castings barbecues do more than just barbecue. They
let you create enduring connections around food and ame.
CONTACT US: 18445864660
WWW.VERMONTCASTINGS.COM
PLEASE KEEP THIS MANUAL WITH YOUR
BARBECUE FOR FUTURE REFERENCE

4
Table of Contents
START IT
SAFETY 5
Ensure you have read and understand the safety instructions
TOOLS 7
Ensure you have these tools handy for assembly
PARTS 8
Ensure you have all the parts
BUILD IT
ASSEMBLY INSTRUCTIONS 921
Step-by-step assembly instructions
CHECK IT
INSTRUCTIONAL CHECKLIST 22
LIGHT IT
LIGHTING INSTRUCTIONS 23–25
FIX IT
WARRANTY 26
TROUBLESHOOTING 2728
TABLE OF CONTENTS

5
CONTACT US: 1-844-586-4660
www.vermontcastings.com
SAFETY
FOR YOUR FAMILY’S SAFETY, PLEASE CHECK THE FOLLOWING:
READ and UNDERSTAND the owner's manual safety instructions.
DO NOT position or operate the barbecue under an overhang or on an unprotected
construction site, against a wall or near aluminum sidings, windows or fencing.
ALWAYS put charcoal on top of the re grate and not directly into the bottom
of the barbecue. When adding charcoal or wood while cooking, use extreme caution.
DO NOT USE gasoline, kerosene or alcohol for lighting charcoal. Use of these or
similar products could cause an explosion resulting in bodily harm. DO NOT use
lighter uid on coals that are already lit.
When cooking, OPEN barbecue slowly to let a gradual amount of air in. This prevents
coals from being suocated or over ring.
Beware of HOT SURFACES including the lid, lid handle, side tables and control panel.
Wear protective gloves while barbecuing. Remove and clean the re bowl and ash
pan frequently to help prevent are-ups and improve performance of the barbecue.
START IT

6
Table of Contents SAFETY
SAFETY
CAUTION: READ AND FOLLOW ALL SAFETY STATEMENTS, ASSEMBLY INSTRUCTIONS, USE AND CARE INSTRUCTIONS BEFORE
ATTEMPTING TO ASSEMBLE AND COOK. THE STAINLESS STEEL AND PAINTED STEEL PARTS OF YOUR BARBECUE CAN BECOME
VERY HOT BOTH IN DIRECT SUN AND WHILE IN OPERATION.
WARNING: FAILURE TO FOLLOW ALL OF THE MANUFACTURER’S INSTRUCTIONS COULD RESULT IN HAZARDOUS FIRES,
EXPLOSIONS, PROPERTY DAMAGE, SERIOUS PERSONAL INJURY OR EVEN DEATH. FOLLOW ALL LEAK CHECK PROCEDURES
CAREFULLY PRIOR TO OPERATION OF THE BARBECUE, EVEN IF THE BARBECUE WAS ASSEMBLED BY A DEALER. DO NOT TRY TO
LIGHT THIS BARBECUE WITHOUT READING THE LIGHTING INSTRUCTIONS SECTION OF THIS MANUAL.
• USE CAUTION WHEN ASSEMBLING AND OPERATING YOUR BARBECUE TO AVOID SCRAPES OR CUTS FROM SHARP EDGES.
• DO NOT USE GASOLINE, KEROSENE OR ALCOHOL FOR LIGHTING CHARCOAL. USE OF ANY OF THESE OR SIMILAR
PRODUCTS COULD CAUSE AN EXPLOSION, POSSIBLY LEADING TO SEVERE BODILY INJURY.
• DO NOT USED LIGHTER FLUID ON ALREADY LIT COALS.
• KEEP CHILDREN AND PETS AWAY FROM THE BARBECUE. SUPERVISION IS REQUIRED. DO NOT LEAVE THE BARBECUE
UNATTENDED WHILE IN USE.
• USE CAUTION WHEN MOVING THE BARBECUE TO PREVENT STRAINS.
• KEEP THE BARBECUE AT LEAST 4.5 METRES 15 FEET FROM ANY COMBUSTIBLE MATERIAL DECKS, BUILDINGS, FENCES,
TREES, BUSHES ETC.
• WHEN ADDING CHARCOAL AND/OR WOOD, EXERCISE EXTREME CAUTION.
• NEVER MOVE THE BARBECUE WHEN IT IS IN USE OR WHEN IT CONTAINS HOT COALS OR ASHES, KEEP THE BARBECUE IN A
LEVEL POSITION AT ALL TIMES WHILE IN USE.
• DO NOT PLACE THE BARBECUE NEAR FLAMMABLE LIQUIDS, GASES OR WHERE FLAMMABLE VAPOURS MAY BE PRESENT.
• WHEN OPENING THE BARBECUE, FIRST OPEN IT SLIGHTLY TO LET A SMALL AMOUNT OF AIR IN FOR A FEW SECONDS. THIS
PREVENTS LARGE AMOUNTS OF OXYGEN FROM GETTING TO SUFFOCATED COALS WHICH MAY CAUSE DANGEROUS
FLASH BACK.
• EXERCISE CAUTION AS FLAMES CAN FLARE UP WHEN FRESH AIR SUDDENLY COMES INTO CONTACT WITH FIRE. WHEN
OPENING THE LID, KEEP HANDS, FACE AND BODY AWAY FROM HOT STEAM AND FLAME FLAREUPS.
• REMOVING EXCESS FAT BEFORE COOKING WILL HELP PREVENT FLAREUPS.
• KEEP YOUR BARBECUE CLEAN TO HELP PREVENT FLAREUPS.
• ALWAYS PLACE CHARCOAL ON TOP OF THE FIRE GRATE AND NOT DIRECTLY INTO THE BOTTOM OF THE BARBECUE.
• DO NOT EXCEED A TEMPERATURE OF 371˚C 700˚F.
• DO NOT ALLOW CHARCOAL AND/OR WOOD TO REST ON THE WALLS OF THE BARBECUE. DOING SO WILL GREATLY REDUCE
THE LIFE OF THE BARBECUE.
• ALWAYS WEAR OVEN MITTS TO PROTECT HANDS FROM BURNS, ESPECIALLY WHEN ADJUSTING DAMPERS. AVOID
TOUCHING HOT SURFACES.
• EXERCISE EXTREME CAUTION AND ALWAYS WEAR HEATRESISTANT GLOVES WHEN REMOVING HEAT DEFLECTORS OR
COOKING GRIDS WHILE BARBECUE IS IN USE.
• WHEN OPENING THE LID, MAKE SURE IT IS PUSHED ALL THE WAY BACK SO IT RESTS AGAINST THE LID SUPPORT BRACKET.
USE EXTREME CAUTION AS THE HOOD COULD FALL BACK TO A CLOSED POSITION AND CAUSE BODILY INJURY.
• CLOSE THE LID AND ALL DAMPERS TO HELP SUFFOCATE THE FLAME.
• ALWAYS HOLD AN OPEN LID BY THE HANDLE TO PREVENT IT FROM CLOSING UNEXPECTEDLY.
• NEVER LEAVE COALS AND ASHES UNATTENDED. BEFORE THE BARBECUE CAN BE LEFT UNATTENDED, COALS AND ASHES
MUST BE REMOVED. USE CAUTION TO PROTECT YOURSELF AND PROPERTY.
• CAREFULLY PLACE REMAINING COALS AND ASHES IN A NONCOMBUSTIBLE METAL CONTAINER AND SATURATE
COMPLETELY WITH WATER. ALLOW COALS AND WATER TO REMAIN IN THE METAL CONTAINER FOR 24 HOURS
PRIOR TO DISPOSING.
• TO PROTECT AGAINST BACTERIA THAT COULD CAUSE ILLNESS, KEEP ALL MEATS REFRIGERATED AND THAW IN A
REFRIGERATOR OR MICROWAVE. KEEP RAW MEATS SEPARATE FROM OTHER FOODS AND WASH EVERYTHING THAT COMES
INTO CONTACT WITH RAW MEAT.
• COOK MEAT THOROUGHLY AND REFRIGERATE LEFTOVERS IMMEDIATELY.
• USE A CALIBRATED FOOD THERMOMETER AND THE USDA GUIDELINES TO ENSURE THAT MEAT, POULTRY, SEAFOOD AND
OTHER COOKED FOODS REACH A SAFE MINIMUM INTERNAL TEMPERATURE.
• THIS BARBECUE IS FOR USE IN OUTDOOR AND WELLVENTILATED AREAS ONLY.
• HAVE A FIRE EXTINGUISHER NEARBY AT ALL TIMES. MAINTAIN AND CHECK YOUR FIRE EXTINGUISHER REGULARLY.
THIS BARBECUE IS FOR OUTDOOR USE ONLY
INSTALLER OR ASSEMBLER/CONSUMER: THIS MANUAL SHOULD BE KEPT WITH THE BBQ AT ALL TIMES.
START IT

7
CONTACT US: 1-844-586-4660
www.vermontcastings.com
1 ¼-20 x ½” Hex bolt 35
1
7 Hub cap 2
30
8 ¼" Fiber washer 2
6
9 ¼" Flat washer 2
7
2 ¼-20 x 3/4” Hex bolt 8
2
3 ¼-20 x 3/4” Hex bolt (with blue locking compound) 8
3
4 ¼" Lock washer 34
4
5 2/5" Flat washer 2
5
6 Hair cotter pin 2
8
TOOLS REQUIRED
Mallet
TOOLS
START IT
START IT
2 people
PART NO. DESCRIPTION PHOTO QTY
Nut Driver
7/16
Screwdriver
#2

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Table of Contents
EXPLODED PARTS
START IT
4
5
1
2
7
8
9
11
10
12
13
14
26
17
15
19
20
15
24
27
28
29
30
31
32
11
33
34
3
66
11
32
12
16
19
21
22
29
10
35
23
25
18
START IT

9
CONTACT US: 1-844-586-4660
www.vermontcastings.com
STEP 1
BUILD IT
BUILD IT
BUILD IT
x3
1
21
22

10
Table of Contents
STEP 2 x10 x10
BUILD IT
BUILD IT
1 4
INSTALL BOLTS LEAVING A SPACE TO SLIDE THE CART SUPPORT
BRACE IN PLACE BEFORE TIGHTENING COMPLETELY.
ENSURE THE LOCK WASHER IS NEXT TO
THE BOLT HEAD BEFORE TIGHTENING.
BUILD IT
Nut Driver
7/16
A 7/16 NUT DRIVER IS RECOMENDED TO USE IN THIS
STEP TO SECURE THE CART TO THE BBQ BODY.
21
15
17
LOCK WASHER
BOLT

11
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www.vermontcastings.com
STEP 3
BUILD IT
BUILD IT
BUILD IT
NOW TIGHTEN BOLTS COMPLETELY TO
INSURE EVERYTHING IS FIRMLY IN PLACE.
Nut Driver
7/16
A 7/16 NUT DRIVER IS RECOMENDED TO USE IN THIS
STEP TO SECURE THE CART TO THE BBQ BODY.
28
1413
27
x8 x8
14

12
Table of Contents
STEP 4 x4
BUILD IT
BUILD IT
1
BUILD IT
26
27
28
14
13

13
CONTACT US: 1-844-586-4660
www.vermontcastings.com
STEP 5
BUILD IT
BUILD IT
BUILD IT
x2 x2x25 8 30
26
29
31
30

14
Table of Contents
STEP 6
BUILD IT
TURN THE BARBECUE
RIGHT SIDE UP.
BUILD IT
BUILD IT

15
CONTACT US: 1-844-586-4660
www.vermontcastings.com
BUILD IT
BUILD IT
STEP 7A
STEP 7B
SLIDE THE ASH PAN IN AND THEN UP TO SECURE
THE ASH PAN SUPPORT CLIP TO THE ASH PAN
SUPPORT BRACKET INSIDE THE BARBECUE BODY.
SECURE THE ASH PAN BY CLOSING THE LATCHES ON BOTH SIDES.
24
24
23

16
Table of Contents
CONTACT US: 1-844-586-4660
www.vermontcastings.com
STEP 9
Hardware is included
with the handle.
BUILD IT
BUILD IT
BUILD IT
STEP 8 x8
3
1
19
6
5
4
6
7

17
CONTACT US: 1-844-586-4660
www.vermontcastings.com
BUILD IT
STEP 10
STEP 11
Hardware is included with
the thermometer.
BUILD IT
BUILD IT
x2 x2 x26 7
1
3
4
6
7
1

18
Table of Contents
STEP 12 x8 x8
11
32
BUILD IT
BUILD IT
BUILD IT
14
32
INSTALL BRACKETS WITH THE SMOOTH SIDE FACING OUTWARDS.
11
9
33

19
CONTACT US: 1-844-586-4660
www.vermontcastings.com
BUILD IT
BUILD IT
BUILD IT
INSTALL BOLTS LEAVING A SPACE TO SLIDE THE SIDE SHELF IN
PLACE BEFORE TIGHTENING COMPLETELY.
STEP 13 x8x8 42
10
33
9

20
Table of Contents
STEP 14
BUILD IT
BUILD IT
BUILD IT
35
7
8
20 34