Great Outdoors 4000 Series Assembly And Owner's Manual
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.
AO000110-0102
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.
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.
We are committed to producing quality 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 more information about our growing family
of barbecue grills visit our internet site at:
www.gogrills.com
Table of Contents
Page Number
Chapter One - INSTALLATION 4
Necessary Information 4
Choosing a Safe Location 4
Portable L.P. Gas Grills 5 - 7
Important Features of the Series 4000 LP Gas Grill 8
L.P. Gas Dealer Instructions 9
Chapter Two - ASSEMBLY INSTRUCTIONS 10
Identifying Parts 11
Attach Pillar to Grill Bottom 12 - 13
Assemble Base to Pillar 14 - 15
Install X-Brace 16 - 17
Install the Side Tables 18 - 19
Assemble Grill Lid 20 - 21
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
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®.
Patents Pending
USA1998 - 2002.
3
Model 4000 Series
Installation Chapter 1
Necessary Information to
Safely Use a Gas Grill.
The gas fuel used by this product is
highly flammable and must be used in
a responsible and cautious manner.
It is your responsibility to assemble,
operate, and maintain your gas
barbecue grill properly.
• Operating this or any gas-fired appli-
ance in an enclosed area can produce a
build-up of carbon-monoxide, which could
result in injury or death.
2. 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 (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.
!
If these instructions are ignored, there
is a possibility of a hazardous fire or
explosion which could result in proper-
ty damage, physical injury or death.
Choosing a Safe Location for a
Gas Barbecue Grill.
1. The gas barbecue grill may only be
used for cooking out-of-doors.
• Do not operate this barbecue in
garages, breezeways, sheds or any
enclosed area.
3. This appliance is not intended to be
installed in or on a recreational vehicle
and/or boat.
4. Keep the barbecue grill at least 24
inches (61 cm) away from any combustible
construction.
• Do not use a grill under a ceiling or
cover where the heat or flame could cause
damage.
• Choose a level surface where the grill
is not facing directly into the wind.
• Avoid moving the grill during use.
5. The grill area must be clear and free
from combustible materials, gasoline, and
any other flammable liquids or vapors.
• Do not use lighter fluid or charcoal briquettes in a gas grill. The flow of combustion and ventilation air is not to be obstructed.
4
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 bottom.
• Heat and hot drippings from cooking
food could damage the fuel supply system.
Portable L. P. Gas
Barbecue Grills
WARNING: Do not use natural gas in
an appliance designed for L.P. gas. Use
only liquid propane (L.P.) gas in an appliance designed for L.P. gas.
• The ventilation openings of the cylinder
enclosure must be kept free and clear from
other debris.
6. Do Not store a spare L.P. gas cylinder
under or near this appliance.
• Do not store an L.P. cylinder in a building, garage or any other enclosed area.
Instead, store the cylinder outdoors in a
well ventilated area, away from people and
out of the reach of children.
7. NOT FOR USE BY CHILDREN.
• Place your barbecue grill in a location
away from children and pets.
• Do not leave grill unattended when in
use.
8. The outside of the barbecue grill will
become hot during use.
• To avoid burns, do not touch any hot
grill surface. If necessary, use a protective
glove when operating control knobs, tank
shut-off valve, or lid handle.
L.P. Gas
Liquid Propane (abbreviated L.P.) gas
is stored under high pressure inside a
cylinder and will vaporize when released.
It is important that there are no leaky
connections on the grill fuel supply system. Refer to the Leak Testing section of
this manual.
L.P. gas
cylinder not
included with
grill
The L.P. Fuel Supply System
5
The L.P. FUEL SUPPLY SYSTEM
An L.P. gas grill requires a fuel delivery system made up of an L.P gas supply cylinder, a
fuel regulator with hose and a gas-control
valve.
Dual Burner Fuel-Control Valve
Type 1 Fuel Regulator
Valve Orifice
2. The system has a thermal element that
will shut off the flow of gas between 240° F
and 300° F.
3. The system has a flow-limiting device
which when activated, will limit the flow of
gas to 10 cubic feet per hour.
4. The pressure regulator and hose assembly provided is factory set at an outlet pressure of 11 inches water column (.4 lb. per
sq. inch).
WARNING: Any attempt to adjust the
regulator is dangerous and could create
a situation causing personal injury or
property damage. Consult your L.P. gas
dealer if you think the regulator is not
working properly.
Fuel Supply
Hose
The L.P. Fuel Supply System
(the fuel regulator and hose)
FUEL REGULATOR AND HOSE
The fuel regulator supplied is equipped with
a Type 1 coupling nut. Do not attempt to connect 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 cylinder connection device.
The fuel regulator and hose assembly with
the Type 1 fitting supplied must be used with
the appliance. Do not use a hose and regulator assembly other than the one supplied with
the grill or a manufacturer’s replacement fuel
pressure regulator assembly.
L.P. GAS SUPPLY CYLINDER
NOTE: AN L.P. CYLINDER IS NOT
INCLUDED WITH THIS GRILL MODEL.
An L.P. cylinder can be obtained at the
store where you purchased your grill or
from an authorized L.P. gas dealers.
Cylinder Control Valve
L.P. Gas
Cylinder
The Type 1 connection system has the following features:
1. The system will not allow gas to flow until a
positive connection has been made.
The L.P. Fuel Supply System
(L.P. gas cylinder)
6
L.P. GAS CYLINDER SPECIFICATIONS
Any L.P. gas-supply cylinder used with
this grill must be approximately 12 inches
diameter and 18 inches high. The maximum fuel capacity must be 20 pounds of
propane. Full-cylinder weight should be
approximately 38 pounds (43.7 lbs. nominal
water capacity).
The L.P. cylinder must have a shut-off
valve terminating in a Type 1 L.P gas-cylinder-valve outlet. A Type 1 compatible cylinder with a Type 1 cylinder valve has a positive seating connection that does not permit
gas flow until a positive seal has been obtained.
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 fuel cylinder.
After filling, have the gas dealer check for
leaks and that the relief valve remains free
to function.
Have the gas dealer weigh cylinder after
filling to ensure that the cylinder is not overfilled.
DANGER:
a.) Do not store a spare L.P. gas cylinder
under or near this appliance.
The cylinder must be arranged for vapor
withdrawal. It must also include a Collar to
protect the cylinder valve. A safety-reIief
device having direct communication with
the vapor space of cylinder must be provided. This will expel high-pressure gas if the
cylinder is overfilled or overheated.
All L.P. gas cylinders used with this appliance shall be constructed and marked in
accordance with the specifications for L.P.
gas cylinders of the U.S. Department of
Transportation (DOT) or the National Standard of Canada, CAN/CSA-B339,
Cylinders, Spheres and Tubes for
Transportation of Dangerous Goods; and
Commission, as applicable; and shall be
provided with a listed overfilling-prevention
device. Read labels on the L.P. gas-supply
cylinder.
DANGER: Do not insert any foreign objects 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.
b.) Never fill the gas cylinder beyond 80
percent full.
c.) If the information in “(a.)” and “(b.)”
is not followed exactly, a fire causing
death or serious injury may occur.
TRANSPORTING A FULL CYLINDER
WARNING! Handle a full cylinder with
care. Gas is under high pressure.
You should transport only one cylinder at a
time. Transport the cylinder in an upright
and secure manner with control valve turned
off and the POL plug in place.
Do not transport cylinder in the passenger
compartment of a vehicle.
Do not leave cylinder in direct sunlight or in
a high-heat area such as a closed car trunk.
High-heat areas could cause the relief valve
to vent gas.
Use a cylinder cap on cylinder-valve outlet
during transport and when the cylinder is not
connected to grill. Keep cylinder valve
closed when not in use.
7
Important Features of Series 4000 L.P. Gas Grills
HEAT SHIELD, GASKETS AND COLLAR
WARNING! Do not remove the heat
shield, gaskets, collar assembly from the
grill bottom.
Operating this grill without the heat shield,
gaskets, collar assembly attached to the grill
bottom would result in a hazardous situation
which could cause serious damage to property and possible physical injury.
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 additional 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 shown in place.
8
Take These Instructions to the L.P. Gas Dealer.
When using a cylinder exchange, be sure the
exchanged cylinder is a Type 1 cylinder; a 510
POL cylinder will not fit a Type 1 regulator.
FILLING AND PURGING TYPE 1 L.P. GAS CYLINDERS
DANGER! Purging and filling of L.P. Gas
cylinders must be performed by personnel
who have been thoroughly trained in accepted L.P. gas industry procedures. Failure to
follow this instruction may result in explosion, fire, severe personal injury, or death.
IMPORTANT: Purge new cylinders before filling. This tank is easily filled with a standard
CGA 510 POL filling connection.
The L.P. gas cylinder has a Type 1 cylinder
valve with a back-check module in its outlet that
will not permit gas to flow until an evacuation
device is installed. To purge the L.P. gas cylinder, the back-check module must be opened
with an evacuation device.
PURGING AND EVACUATION DEVICES FOR L.P. GAS
CYLINDER WITH TYPE 1 CYLINDER VALVES
A. Hose-end valve 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 using a Type 1 connection. The
Type 1 valve outlet has 1 5/16" external ACME
right-hand thread that will accept this connection.
Example A
Filling a Type 1 Cylinder Valve
Example A: shows a CGA-510 POL fitting.
Example B: shows using a Type 1 POL fitting.
Example B
CAUTION: After purging or filling an L.P. gas
cylinder, do not insert a POL plug into the valve
outlet. Insertion of this plug will prevent the
back-check from closing. Use ONLY the provided cap and strap attached to the outlet. Close
the cylinder valve knob before returning the
cylinder to the customer.
For proper purging procedures in the U.S.A.
refer to: Safety Bulletin NPGA #133, “Purging
L.P. Gas Cylinders,” and Safety Bulletin NPGA
#130, “Recommended Procedures for Filling
Cylinders.”
DANGER: Do not fill an L.P. gas cylinder
beyond 80% full. If this information is not
followed exactly, a fire causing serious injury
or death may occur.
9
Model 4000 Series
Assembly Instructions Chapter 2
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.
4. Have a friend help. An assistant can
make the assembly easier by holding the
parts in place while you fasten the nuts and
bolts.
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 operating to your satisfaction.
Tools needed to assemble grill:
• 3/8” open-end wrench*
• flat blade screwdriver
• 7/16" open-end wrench*
*HINT: A socket set or an adjustable
wrench may be used instead.
10
Assembly Instructions • Identify the Grill Parts
Locate these parts:
warming rack (1)
cooking grid (1)
ceramic briquettes
( 1 package )
rock grate (1)
left side table (1)
handle (1)
handle standoff (2)
grill lid (1)
grill bottom
assembly (1)
(burner assembly, heat
shield, collar gasket
and collar installed)
grease pan (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
pillar (1)
(knobs, ignitor, valve,
hose w/ regulator
installed)
X-brace
wire (1)
11
Assembly Instructions • Attach the Pillar to Grill Bottom.
tools needed:
3
⁄8" open-end wrench
flat-blade screwdriver
Locate these parts:
top
collar
assembly
back hinge
strut
grill bottom
( 1 )
shown right-
side up
Use hardware bag “B”:
1/4-20 x 3/4”
( 4 )
HINT: For the first portion of the
assembly you will be assembling
the grill bottom, pillar and base upside-down.
1. Position the grill bottom casting
upside down so that the heat collar
assembly is upward.
front
control
knobs
top
pillar
( 1 )
shown
right-
side up
12
2. Working from the back (open) side
of the pillar, set the pillar upside
down onto the collar assembly.
3. Locate the holes in the pillar bottom and align with holes in collar.
4. IMPORTANT:
Make sure the gas control valve
ends are inside the burner venturi tubes extending through the
grill bottom as shown. (See
Adjacent Page)
5. Thread screws into holes and tighten with a wrench / screwdriver.
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