Great Outdoors 4000 Series, Assembly And Owner'S Manual

Page 1: ...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 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 sa...

Page 2: ...uality grills that your family will enjoy for years to come If you are not satisfied with your new grill for any reason you can call this toll free number at any time 888 869 5454 We want you to be completely satisfied with your purchase so you will agree with our motto there s nothing like the great outdoors the Great Outdoors Grill Company 7980 East American Drive Joplin Missouri U S A 64804 For...

Page 3: ...1 Installing the Internal Parts 22 23 Installing an L P Gas Cylinder 24 Connecting an L P Gas Cylinder 24 25 Chapter Three USE and CARE DIRECTIONS 26 Leak Testing 27 Lighting Instructions 28 29 Using Your Grill 30 Cleaning and Maintenance 31 33 Replacement Parts 34 35 Chapter Four OUTDOOR COOKING RECIPES 36 Recipes 36 39 Warranty 40 3 1st printing Sept 2001 2nd printing Jan 2002 The Great Outdoors...

Page 4: ... conform with local codes or in the absence of local codes with either the National Fuel Gas Code ANSI Z223 1 NFPA 54 USA or CAN CGA B 149 2 Propane Installation Code Canada and CAN CGA B 149 1 Natural Gas Installation Code To check local codes contact your local gas dealer or gas company listed in the Yellow Pages for recommended installation procedures and regulations 3 This appliance is not int...

Page 5: ...valve or lid handle 5 Do not store spare cylinders near grill 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 Heat and hot drippings from cooking food could damage the fuel supply sys tem WARNING ...

Page 6: ...uires a fuel delivery sys tem made up of an L P gas supply cylinder a fuel regulator with hose and a gas control valve FUEL REGULATOR AND HOSE The fuel regulator supplied is equipped with a Type 1 coupling nut Do not attempt to con nect to any other L P cylinder not equipped with a mating Type 1 cylinder valve This grill is not to be used with any other cylin der connection device The fuel regulat...

Page 7: ...inder DANGER Do not insert any foreign ob jects into the valve outlet You may damage the back check A damaged back check can cause a leak which could result in explosion fire severe personal injury or death Allow only a qualified L P gas dealer to fill or repair an L P gas supply cylinder Inform the gas dealer if it is a new or used cylinder to be filled Caution the gas dealer not to overfill the ...

Page 8: ...ttached to the grill bottom would result in a hazardous situation which could cause serious damage to prop erty and possible physical injury X BRACE RETAINER WIRE It is important to properly fit the X Brace retainer wire inside the pillar to provide addi tional stability Remove the X Brace only when installing an L P gas supply cylinder Rear view of Series 4000 grill with the X Brace retainer wire...

Page 9: ... with a bleed port Purging can be accomplished using a hose end valve containing a bleed port which also allows for evacuation without the use of an adapter B Hose end valve without a bleed port When a hose end valve does not have a bleed port a separate device must be used for evacuation C Purging using a Type 1 connection L P gas cylinder evacuation can be accomplished during each purging by usi...

Page 10: ... 5 To be ready to barbecue immediately obtain a filled L P gas cylinder from an authorized L P dealer or cylinder exchange center Unpacking the Grill Parts 1 Remove and set aside all inner boxes and parts from the master carton 2 Remove and set aside all wrapping paper and additional packaging from the parts 3 Do not destroy carton or packing until your grill is completely assembled and oper ating...

Page 11: ...able 1 right side table 1 base 1 master hardware bag 1 consisting of 1 A bag 1 B bag 1 C bag 1 D bag 11 handle 1 handle standoff 2 grill lid 1 grill bottom assembly 1 burner assembly heat shield collar gasket and collar installed grease pan 1 pillar 1 knobs ignitor valve hose w regulator installed X brace wire 1 Locate these parts ...

Page 12: ...tom and align with holes in collar 4 IMPORTANT Make sure the gas control valve ends are inside the burner ven turi tubes extending through the grill bottom as shown See Adjacent Page 5 Thread screws into holes and tight en with a wrench screwdriver 12 Assembly Instructions Attach the Pillar to Grill Bottom pillar 1 shown right side up front control knobs 1 4 20 x 3 4 4 Use hardware bag B Locate th...

Page 13: ...back hinge strut pillar bottom grill bottom back gas control valve ends fuel supply hose w regulator burner venturi tubes collar 13 ...

Page 14: ...ighten with a wrench and a flat head screwdriver 4 Locate the two black lead wires inside the grill bottom Press the metal contacts of the loose ends of the lead wires onto the metal pins located on the base and side of the ignitor unit 14 base 1 shown right side up Assembly Instructions Assemble Base to Pillar 1 4 20 x 3 4 6 Use hardware bag A Locate this part 1 4 20 6 front locking casters tools...

Page 15: ...15 ignitor unit base back top pillar black lead wires heat shield bottom casting back ...

Page 16: ...e grill bottom to check that the control valve ends are still inside the burner venturi tubes The valve ends must always be inside the burner tubes for the grill to safely operate grill bottom as shown from below back No tools needed 16 Locate this part X brace 1 Assembly Instructions Install X Brace top bent ends ...

Page 17: ...e wire ends A and B firmly into the pillar corners behind the bolt heads and against the base See Lower Detail 4 Complete the installation by snapping bent ends C and D into the two holes in the pillar See Upper Detail 5 When complete the X brace should be positioned as shown in the lower right picture back UPPER DETAIL LOWER DETAIL ...

Page 18: ... x 3 4 bolt 8 Use hardware bag C 1 4 20 hex nut 8 right side table assembly 1 1 Insert four 3 4 bolts through holes in the support brackets of the right side table assembly 2 Attach the right side table to the four holes located in the right side of the grill bottom using the locking hex nuts provided left side table assembly 1 ...

Page 19: ...ble to the four holes located in the left side of the grill bottom using the locking hex nuts provided HINT Preformed hooks included on the right side table assembly may be used to keep cooking utensils not included at hand CAUTION Do not apply more than 15 pounds to either side table that could unbalance and tip the grill ...

Page 20: ...f 2 handle 1 1 Position the back of the lid so that the rear holes are in line with the hinge struts on the back of the grill bottom 2 Gently set the grill lid onto the grill bottom hairpin 2 use hardware bag D 1 4 20 x 3 4 bolt 4 standoff gasket 2 1 4 20 hex nut 2 hinge pin 1 4 x 1 1 8 2 grill lid 1 Locate these parts ...

Page 21: ...assem ble the opposite standoff to the lid in the same manner 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 HINT There is an air space between the back of the lid and the grill bottom where you can install th...

Page 22: ...ons Installing the Internal Grill Parts 22 ceramic briquettes 1 box warming rack 1 1 Place the single rock grate into the grill bottom cooking grid 1 2 Open the package containing the ceramic briquettes and place them on the rockgrate Locate these parts ...

Page 23: ...e proper amount of briquettes are supplied and there is no need to add more Some space between the briquettes is necessary 4 Set the porcelain coated cooking grid on the front and back ledges formed inside the grill bottom for a level cooking surface 5 Set the warming rack onto the back of the cooking grid The grill assembly is now complete 23 ...

Page 24: ...2 Read and follow all directions on the cylinder and fuel hose safety tags 3 Working behind the grill temporarily remove the X brace retainer wire from the pillar 4 Set the filled L P gas cylinder into the large round opening in the grill base Installing an L P Gas Cylinder 24 1 Obatin a filled L P gas cylinder REMINDER An L P gas cylinder is not includ ed in the 4000 series grill Please refer to ...

Page 25: ...er Install a Drip Pan in the Heat Shield The grease pan is a 3 1 2 x 6 aluminum loaf pan available at most grocery stores heat shield grease drip pan Locate this part grease drip pan 1 7 Make sure the hose has no kinks or sharp bends and clears any areas that will be come hot during use Never put strain on the hose where it joins a fitting The rub ber fuel supply hose must not touch the bottom gri...

Page 26: ...Use and Care Directions Chapter 3 26 Leak Testing the Fuel Supply System Lighting Instructions Replacement Parts Model 4000 Series ...

Page 27: ...ose then turn the control knobs back off 7 Wash off soapy solution with cold water and towel dry WARNING Do not attempt to repair the cylinder valve If it becomes dam aged the cylinder must be replaced If you are unable to stop a leak shut off the gas supply at the cylinder valve Remove the cylinder from the grill Call a gas appli ance serviceman or L P gas dealer Do not use appliance until the le...

Page 28: ...ck the burner venturi tubes for blockage from an insect nest see CLEANING THE BURNER VENTURI TUBES STEP 2 Ensure that both of the burner control knobs are in the OFF position STEP 3 OPEN GRILL LID WARNING Attempting to light the grill with the lid down could cause an explosion STEP 4 Go behind the grill and turn on the fuel supply valve One counter clock wise turn is generally enough to open the v...

Page 29: ...ame will track around the burner Allow grill to preheat with the grill lid closed for five minutes before cooking CAUTION Do not touch any hot grill parts The outside of the grill bottom be comes very hot during use It may be neces sary to use protective gloves HOW TO SHUT OFF THE GRILL STEP 1 Turn the burner control knob s off The burner flame will go out STEP 2 Turn off the top L P cylinder valv...

Page 30: ...gh flame setting is for quick searing of meat Sear foods then finish cooking on a lower setting A medium setting works best for cooking steaks pork chops and hamburgers The lowest setting works well for all roasts and rotisserie foods Even thick steaks when seared on a high setting first will have a better texture and be more juicy cooked on low DUAL BURNER COOKING SYSTEM The grill s burner may be...

Page 31: ... fat Frozen fish and vegetables will cook without thaw ing However placing frozen food onto very hot porcelain grids can crack the porcelain finish Add salt to food after cooking to prevent it from drying out Brush naturally lean meat poultry or fish with cooking oil or margarine Cook small pieces of tender foods in foil Apply barbecue tomato or sugar based sauces no sooner than the last ten minut...

Page 32: ...se a wire bristle brush to clean the burner surface A Burner Cleaning Kit has been provided and is attached inside the pillar wall just above the certification label Use the tool s serrated tip to clear the ports of any blockage CLEARING THE BURNER VENTURI TUBES Spiders and other insects are known to sometimes build homes inside a burner s venturi tubes This can become a serious problem A spider w...

Page 33: ...into the valve ends when they are dry WARNING Never attempt to operate your grill without orifices in the valve A serious and immediate fire hazard would result Replace the burner assembly into the grill bottom after it is clean IMPORTANT Make sure the valve orifices are inside venturi tubes Secure burner to the grill bottom and reconnect the igniter wires Replace all other parts inside grill Reco...

Page 34: ...105 8 1 4 x 20 Hex Keps Nut AM000904 1 Hardware Bag D 2 1 4 x 1 1 8 Hinge Pin AM000908 2 Hairpin AM000909 4 1 4 x 20 x 3 4 Bolt AM000105 4 1 4 x 20 Hex Keps Nut AM000904 2 Handle Gasket AM000704 Parts Enclosed quantity description part number 1 Grate AF000203 1 package Ceramic Briquettes AQ000103 1 Cooking Grid AF000104 1 Warming Rack AF000304 1 Grill Lid TOP350 BLK 1 Lid Handle AP000102 2 Handle ...

Page 35: ...C P BLK 1 Heat Shield AI000204 1 Forward Gasket AM000911 2 Side Gasket AM000910 4 1 4 x 20 x 1 1 4 bolt AM000107 8 Speed Nuts AM000906 1 Pillar Assembly consisting of 1 Pillar SF AH000401 2 10 x 24 x 1 2 Bolt AM000103 1 Valve Regulator Hose AL000104 1 Push Button Igniter AN000304 2 Control Knobs AZ000704 1 Right Side Table Assembly consisting of 1 R H Bracket SDTBL BRKT R BLK 1 L H Bracket SDTBL B...

Page 36: ...our patties Grill until desired doneness Serve on buns Yield 4 servings DISAPPEARING SHISHKEBOBS 1 2 cup ketchup 1 2 cup sugar 1 2 cup soy sauce 1 teaspoon garlic powder 1 teaspoon ground ginger 2 pounds boneless beef sirloin steak 1 1 2 inches thick cut into 1 1 2 inch cubes 1 2 fresh pineapple trimmed and cut into 1 inch chunks 2 to 3 small zucchini cut into 1 inch chunks 1 2 pound whole fresh m...

Page 37: ...blespoons poppy seed 6 ounces thinly sliced ham 6 ounces sliced Swiss cheese 6 sandwich buns Mix butter mustard onion and poppy seed Spread mixture on both halves of each bun layer a slice of Swiss cheese and several ham slices between halves Wrap each sandwich in foil and grill for 20 minutes Serve warm Yield 6 servings 37 POULTRY GRILLEDCHICKEN 1 broiler fryer chicken 3 1 2 to 4 pounds quartered...

Page 38: ...ads over Top cooked side of bread with a suggested topping Yields 4 servings FISH SEAFOOD SHIRMPCOMBOPACKETS 4 cups peeled potatoes about 1 1 4 lbs sliced 1 8 inch thick I cup sliced leeks or mild onions I cup chopped plum tomatoes 20 jumbo shrimp about 1 lb peeled and deveined 4 Tablespoon butter 2 teaspoon dill weed crushed I teaspoon garlic powder I teaspoon salt 1 2 teaspoon ground black peppe...

Page 39: ... expansion of steam Grill over medium hot until vegetables are cooked Allow about 20 minutes for peas and other small vegeta bles allow more time for larger vegetables Turn the package of vegetables frequently 39 DESSERTS CINNAMONAPPLES 4 medium tart apples cored 4 teaspoons brown sugar 1 4 cup red hot candies Vanilla ice cream optional Place each apple in the center of a piece of heavy duty foil ...

Page 40: ...is guaranteed to be free of defects for 90 days L P cylinders on propane models only are warranted by the cylinder manufacturer This warranty is void if the grill collar heat shield and heat gaskets are removed from the grill The X Brace retainer wire must always be kept in place for the warranty to be valid All parts that meet the warranty requirement will be shipped at no charge via the discreti...