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Great Outdoors 4000 Series Assembly And Owner's Manual

Portable gas grill
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A s s e m b l y and
O w n e r ' s M a n u a l
Model 4000
Series
Portable
Gas Grill
ASSEMBLER / INSTALLER:
Leave these instructions with the consumer
CONSUMER / USER:
Read all of these instructions and keep them in a safe place for future reference.
FOR YOUR SAFETY
If you smell gas:
1
Shut off gas to the appliance.
2
Extinguish any open flame.
3
Open lid.
4
If odor continues, immediately call
your gas supplier or fire department.
.
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
An unconnected liquid propane
cylinder should not be stored in the
vicinity of this or any other appliance.
AO000110-0102
®

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  • Page 1 ® A s s e m b l y and O w n e r ’ s M a n u a l Model 4000 Series Portable Gas Grill ASSEMBLER / INSTALLER: Leave these instructions with the consumer CONSUMER / USER: Read all of these instructions and keep them in a safe place for future reference.
  • Page 2 Statement of Commitment Congratulations and thank you for your purchase of the Great Outdoors gas grill. We are pleased that you have recognized the value of the design, function, and quality of components used in this product. We believe it is the finest grill on the market.

  • Page 3: Table Of Contents

    1st printing Sept. 2001 © 2nd printing Jan. 2002 © The Great Outdoors Grill Company® logo is a Registered Trademark of the Great Outdoors Grill Company® and not to be used without express permission by the owners and managers of the Great Outdoors Grill Company®.

  • Page 4: Chapter One - Installation

    Model 4000 Series Installation Chapter • Operating this or any gas-fired appli- Necessary Information to ance in an enclosed area can produce a Safely Use a Gas Grill. build-up of carbon-monoxide, which could result in injury or death. 2. Installation must conform with local...

  • Page 5: Portable L.p. Gas Grills

    • Do not place combustible material, such as cloth or plastic, on grill surface during use. • Do not lean on side tables or place more than 15 pounds of weight on a side table. 9. Make sure that the heat shield and drip pan are in place under the grill bot- tom.
  • Page 6 2. The system has a thermal element that The L.P. FUEL SUPPLY SYSTEM will shut off the flow of gas between 240° F An L.P. gas grill requires a fuel delivery sys- and 300° F. tem made up of an L.P gas supply cylinder, a 3.
  • Page 7 L.P. GAS CYLINDER SPECIFICATIONS Allow only a qualified L.P. gas dealer to fill or repair an L.P. gas-supply cylinder. Any L.P. gas-supply cylinder used with this grill must be approximately 12 inches Inform the gas dealer if it is a new or used diameter and 18 inches high.

  • Page 8: Important Features Of The Series 4000 Lp Gas Grill

    Rear view of Series 4000 grill with the heat shield, gaskets, collar assembly. X-BRACE RETAINER WIRE It is important to properly fit the X-Brace retainer wire inside the pillar to provide addi- tional stability.

  • Page 9: Gas Dealer Instructions

    Take These Instructions to the L.P. Gas Dealer. When using a cylinder exchange, be sure the The L.P. gas cylinder has a Type 1 cylinder exchanged cylinder is a Type 1 cylinder; a 510 valve with a back-check module in its outlet that POL cylinder will not fit a Type 1 regulator.

  • Page 10: Chapter Two - Assembly Instructions

    Model 4000 Series Assembly Instructions Chapter Getting Started 1. Please follow the steps in the order that they are presented. 2. Assemble the grill where you plan to use it. 3. You may want to place an old towel or cloth at the assembly site to prevent nuts and bolts from becoming lost.

  • Page 11: Identifying Parts

    Assembly Instructions • Identify the Grill Parts handle (1) Locate these parts: handle standoff (2) warming rack (1) grill lid (1) cooking grid (1) ceramic briquettes ( 1 package ) grill bottom assembly (1) rock grate (1) (burner assembly, heat shield, collar gasket and collar installed) left side table (1)

  • Page 12: Attach Pillar To Grill Bottom

    Assembly Instructions • Attach the Pillar to Grill Bottom. tools needed: Use hardware bag “B”: ⁄ " open-end wrench flat-blade screwdriver 1/4-20 x 3/4” ( 4 ) Locate these parts: back hinge strut HINT: For the first portion of the assembly you will be assembling the grill bottom, pillar and base up- side-down.
  • Page 13 pillar bottom fuel supply hose w/ regulator gas control valve ends burner venturi tubes collar grill bottom back back hinge strut...

  • Page 14: Assemble Base To Pillar

    Assembly Instructions • Assemble Base to Pillar tools needed: ⁄ " open-end wrench Use hardware bag “A”: ⁄ " open-end wrench 1/4-20 x 3/4” ( 6 ) Locate this part: 1/4-20 ( 6 ) back base ( 1 ) shown right- 1.
  • Page 15 base back pillar black lead wires heat shield bottom casting back ignitor unit...

  • Page 16: Install X-Brace

    Assembly Instructions • Install X-Brace. No tools needed. Locate this part: 1 Now with the help of an top bent assistant carefully turn the ends grill assembly right-side-up. IMPORTANT: Inspect beneath the grill bottom to check that the control-valve ends are still inside the burner venturi tubes.
  • Page 17 ATTENTION PRODUCT ASSEMBLER: Install the X-brace retainer wire across the back of the pillar for warranty validation. UPPER DETAIL back LOWER DETAIL 3. Position the wire ends “A” and “B” firmly into the pillar corners behind the bolt heads and against the base. (See Lower Detail.) 4.

  • Page 18: Install The Side Tables

    Assembly Instructions • Install the Side Tables. tools needed: Use hardware bag “C”: 3/8" open-end wrench 7/16" open-end wrench 1/4-20 1/4-20 x 3/4” bolt hex nut ( 8 ) ( 8 ) Locate these parts: left side table assembly ( 1 ) right side table assembly ( 1 ) 1.
  • Page 19 3. Insert four 3/4" bolts through holes in the HINT: Preformed hooks included on the right support brackets of the left side table side table assembly may be used to keep assembly. cooking utensils (not included) at hand. 4. Attach the left side table to the four holes CAUTION: Do not apply more than 15 located in the left side of the grill bottom pounds to either side table that could...

  • Page 20: Assemble Grill Lid

    Assembly Instructions • Assemble the Grill Lid tools needed: hairpin ( 2 ) 7/16" open-end wrench hardware bag “D”: flat-blade screwdriver hinge pin 1/4 x 1 1/8” ( 2 ) standoff gasket ( 2 ) 1/4-20 1/4-20 x 3/4” hex nut ( 2 ) bolt ( 4 ) Locate these parts: handle...
  • Page 21 3. Hold the lid to align the hinge holes. 4. Insert a hinge pin through the hinge hole in the lid and into the hole in the bottom hinge strut. 5. After the hinge pin is in place, insert a hair pin through the hole of the hinge pin to secure it.

  • Page 22: Installing The Internal Parts

    Assembly Instructions • Installing the Internal Grill Parts. No tools are needed. Locate these parts: rock grate ( 1 ) ceramic briquettes ( 1 box ) 1. Place the single rock grate into the grill bottom. cooking grid ( 1 ) warming rack 2.
  • Page 23 3. It is important to properly arrange all the ceramic briquettes onto the rock grate to allow for good air flow during use. NOTICE THE SPACING: The proper amount of briquettes are supplied and there is no need to add more. Some space between the briquettes is necessary.

  • Page 24: Installing An L.p. Gas Cylinder

    1 . Obatin a filled L.P. gas cylinder. items needed: REMINDER: An L.P. gas cylinder is not includ- ed in the 4000 series grill. Please refer to L.P. gas cylinder pages 6 and 7 of the manual for the correct ( 1 FILLED ) cylinder specifications.
  • Page 25 Connecting an L.P. Gas Cylinder. sure the nipple is centered in the valve 7. Make sure the hose has no kinks or sharp outlet. The coupling nut connects to the bends and clears any areas that will be- large outside threads on the valve outlet. come hot during use.

  • Page 26: Chapter Three - Use And Care Directions

    Model 4000 Series Use and Care Directions Chapter Leak Testing the Fuel Supply System Lighting Instructions Replacement Parts...

  • Page 27: Leak Testing

    Leak Testing DANGER To prevent fire or explosion hazard: · Do not smoke while performing a leak test. · Do not permit any sources of ignition in the area when testing for leaks. · Perform leak tests outdoors only. · Never perform a leak test near a fire or flame.

  • Page 28: Lighting Instructions

    Lighting Instructions IGNITER LIGHTING SYSTEM CAUTION: Do not stand with head or arms over the grill. The Igniter System consists of an igniter unit, a gas-collector box, one ceramic elec- STEP 5. To light using the igniter: trode, and lead wires. Gas is collected in Push in and turn the right burner con- the metal collector box located at the burn- trol knob counter-clockwise to a high setting.
  • Page 29 Lighting Instructions MATCH LIGHTING CAUTION: Do not touch any hot grill IMPORTANT! The match-lighting hole is parts. The outside of the grill bottom be- found under the front right corner of the grill comes very hot during use. It may be neces- bottom.

  • Page 30: Using Your Grill

    Using Your Gas Grill TO BREAK IN A NEW GRILL Try cleaning the burner to remove built-up residue. Check for clogged burner holes or Before using it for the first time; operate blocked venturi tubes. the grill with lid closed on a low setting for about 15 minutes.

  • Page 31: Cleaning And Maintenance

    Cleaning and Maintenance COOKING TIPS WHAT TO DO IN CASE OF A MAJOR GREASE FIRE, Coat cooking grids with cooking oil to pre- follow these steps: vent food from sticking. Preheat the grill with 1. Turn the burner-control knob(s) to off. the lid closed about five minutes before 2.
  • Page 32 Cleaning and Maintenance The small vent hole in the regulator must Because the burner is made of cast iron, be kept clean of dirt and debris. Keep the rusting is to be expected. Use a wire bristle gas-supply hose at least 3" away from any brush to clean the burner surface.
  • Page 33 Replace the orifices into the valve ends Grounding Instructions. Use an appliance when they are dry. equipped with a three-prong grounding plug for your protection against shock hazard. It WARNING! Never attempt to operate your should be plugged directly into a properly grill without orifices in the valve.

  • Page 34: Replacement Parts

    Model 4000 Series Replacement Parts Replacement parts are available direct You may also write to: from our warehouse. Some components are not available preassembled and may be the Great Outdoors Grill Company® ordered separately. For convenience, the 7980 East American Drive following parts list is provided along with a Joplin, Missouri U.S.A.
  • Page 35 Breakdown of Preassembled Components Bottom/Burner Assembly quantity description part number Bottom/Burner Assembly consisting of: Cast Iron Burner AZ001505 Venturi Tube w/gasket AZ000507 #8-32 x 7/16" Screw AM000603 Bottom Grill Casting BTM350-BLK Collar COLLAR C/P BLK Heat Shield AI000204 Forward Gasket AM000911 Side Gasket AM000910...

  • Page 36: Chapter Four - Outdoor Cooking / Recipes

    Outdoor Cooking Recipes Chapter BEEF FLAVORFUL FLANK STEAK DISAPPEARING SHISH KEBOBS 1/2 cup ketchup 1 beef flank steak (about 2 pounds) 3 tablespoons ketchup 1/2 cup sugar 1/2 cup soy sauce 1 tablespoon vegetable oil 1 tablespoon chopped onion 1 teaspoon garlic powder 1 teaspoon brown sugar 1 teaspoon ground ginger 1 teaspoon Worcestershire sauce...
  • Page 37 POULTRY PORK GRILLED CHICKEN BEST PORK RIBS 1 broiler/fryer chicken 3 pounds country-style pork ribs (3-1/2 to 4 pounds), quartered 1/2 teaspoon garlic salt 1/4 cup vinegar 1/2 teaspoon pepper 1/4 cup butter or margarine 1 cup ketchup 1/4 cup water 1/2 cup packed brown sugar 1/4 teaspoon dried thyme 1/2 cup honey...
  • Page 38 FISH / SEAFOOD SIDE DISHES SHIRMP COMBO PACKETS RICE ON THE SIDE cups peeled potatoes (about 1-1/4 lbs.), 1-1/3 cups uncooked instant rice sliced 1/8-inch thick 1/3 cup sliced fresh mushrooms cup sliced leeks or mild onions 1/4 cup chopped green pepper cup chopped plum tomatoes 1/4 cup chopped onion 20 jumbo shrimp (about 1 lb.)
  • Page 39 VEGETABLES DESSERTS ONION BLOOM CINNAMON APPLES 4 medium tart apples, cored 1 Bermuda onion 4 teaspoons brown sugar 1 tablespoon butter 1/4 cup red-hot candies 2 teaspoons honey Vanilla ice cream, optional 1/2 teaspoon Worcestershire sauce Place each apple in the center of a piece of Peel onion;...

  • Page 40: Warranty

    Manufacturers Limited Warranty The Great Outdoors grill is guaranteed against broken or damaged parts at the time of pur- chase. Components are guaranteed against defect as follows: All cast-aluminum parts are warranted against burn through, rust, and structural failure excluding paint, neglect, or abuse, for 50 years from the date of purchase.

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