Barbeques Galore DISCOVERER G4DISL User manual

WELCOME TO THE WORLD OF BARBEQUES GALORE
OUTDOOR COOKING
INSTRUCTIONS- DISCOVERER G4DISL
For The Safe Use And Enjoyment
Of Your New Barbeque
PRODUCT CODE：G4D SL
DISCOVERER 4 ON CART
WITH SIDE BURNER
Tools req ired:
1 adjustable spanner
1 phillips head screwdriver

2
Thank you and congratulations for choosing a quality barbeque as part of your outdoor entertaining world.
By following these instructions for safe and easy operation, you will enjoy years of satisfying, trouble-free outdoor
cooking.
And when you’re fully up and running, you can visit your retailer for some great accessories and cooking tips to make
your experience even more rewarding.
But first things first....
Australia has an excellent safety record when it comes to gas appliances. This reflects both the high quality of
appliances sold, as well as growing consumer awareness about safe practice. We urge you to follow the
guidelines below together with these instructions for safe use, to prevent overheating and to produce great
cooking results.
 This barbeque is an outdoor appliance only. Under no circumstances should it be used indoors.
 This barbeque has not been approved for marine use.
 Do not perform any servicing on the barbeque yourself. This includes internal adjustment of the regulator and gas
valves. Servicing can only be carried out by authorized technicians.
 t is important that you install your barbeque exactly as described in these instructions. n particular you should
keep the barbeque clear of combustible material, and you should check for leaks whenever a new connection is
made.
 Do not store chemicals or flammable materials near this appliance.
 Do not place articles on or against, or enclose this appliance.
 The barbeque gets extremely hot while in use. Keep children away from the appliance until it has cooled to normal
temperatures.
 t is a good idea to tie back long hair and loose clothing while cooking in case of unexpected flare ups.
 Fat fires are the most common cause of problems in barbeques. They are caused by a build up of grease in the fat
channeling tray and the inside of the barbeque frame. A fat fire can be difficult to put out, and will be dangerous if it
spreads to the gas hose. You should keep your barbeque clean to avoid this occurrence. Fat fires are not covered
by the warranty.
 Do not transport the barbeque whilst it is hot because there is a risk that the contents of the drip tray will fall out.
 NEVER leave a barbeque unattended with any burners switched on. Always switch off all burners and cylinders
when the barbeque is not in use.
 Take care when touching a hot barbeque, especially on surfaces close to the firebox or roasting hood.
 ts fine to pre-heat with all burners on Hi and the hood closed, but NEVER let the temperature on the hood
thermometer exceed 250°Celsius.
 When cooking with the hood closed, turn one or more burners to Low or OFF as required to keep the barbeque
from getting too hot. NEVER let the temperature on the hood thermometer exceed 250°Celsius.
 NEVER leave all burners on Hi for more than 15 minutes, always stay in control by adjusting burners to Low and
OFF as required to maintain suitable cooking temperatures.
 Follow all manufacturers’ instructions to periodically check for gas leaks as outlined on Page 20.

3
Most importantly, yo m st observe the clearances listed below and on the data sticker on yo r barbeq e.
t will tell you how close you can put the barbeque to combustible surfaces (wood, gyprock, trees, wooden fences etc).
f you don’t follow these clearances, there is a chance that nearby surfaces will heat up and catch fire. f you purchased
your barbeque in a cart, you don’t need to be concerned with side clearances. The barbeque-cart combination has
been laboratory tested, and complies with relevant Australian Standards.
 CLEARANCES FROM COMBUSTIBLE MATERIALS
Side and Back: 300mm. Vertically above: 900mm.
 Keep the barbeque sheltered from the wind. Wind interferes with the flames and can prevent your barbeque from
heating up properly and can even damage some components.
 Make sure the surface is level. This is safer, and makes cooking easier.
 Don’t put the barbeque too close to windows or anywhere else where cooking smoke is likely to cause a problem.
P tting Yo r Barbeq e In An Enclos re
This appliance must only be used in an above ground open-air situation with natural ventilation, without stagnant areas,
where gas leakage and products of combustion are rapidly dispersed by wind and natural convection.
Any enclosure in which the appliance is used must comply with one of the following:
(a) An enclosure with walls on all sides, but at least one permanent opening at ground level and no overhead cover.
(b) Within a partial enclosure that includes an overhead cover and no more than two walls.

4
(c) Within a partial enclosure that includes an overhead cover and more than two walls, the following shall apply—
( ⅰ ) at least 25% of the total wall area is completely open; and
( ⅱ ) at least 30% of the remaining wall area is open and unrestricted.
(d) n the case of balconies, at least 20% of the total of the side, back and
front wall areas shall be and remain open and unrestricted.
30 percent or more in total
of the remaining wall area
is open and
nrestricted
Open side at
least 25% of
total wall area
Open side at
least 25% of
total wall area
30 percent or more in total
of the remaining wall area
is open and nrestricted
Both ends open

5
STEP 1 OPEN THE CARTON, UNPACK AND CHECK THE PARTS.
 Start by opening the carton and preparing a flat clean surface for all the parts and to do the assembly.
 Once you open the top of the shipping box, slice down its four edges with a box cutter. Take out the BOLT
PACK(M), TOP PANEL(D),BASE(E) and DOORS(B)&(C).Next remove LEFT AND R GHT PANELS(F)&(G),
WARM NG RACK(H),FRONT RA L( ), BACK RA L(J) AND BACK PANEL(K).Remove all parts from plastic
bags.
LEFT DOOR
(B)
TOP PANEL
(
D
)
BOLT PACK
(M)
BACK PANEL
(
K
)
INSTRUCTION
(L)
BARBEQUE HEAD
(A)
BACK RAIL (J)
WARMING RACK
(H)
FRONT RAIL(I)
LEFT
PANEL
(
F
)
RIGHT
PANEL
(G)
RIGHT DOOR
(C)
BASE (E)

6
STEP 2 UNPACK AND CHECK THE OTHER PARTS
 Remove the styrofoam end caps from the BARBEQUE HEAD(A) and place it upright on the flat surface. Open the
hood, and take out the small boxes packed inside. Remove all packing materials, and remove all parts from boxes
as shown in the figures below.
Most importantly, yo sho ld completely remove all packaging materials incl ding plastic, foam and
cardboard from all parts and final assembly before first se of the barbeq e.
BARBEQUE HEAD
(
A
)
FLAME TAMER
(
A
C
)
LEFT SHELF
(P)
RIGHT SHELF
(O)
CASTOR
(AD)
TRIVET
(N)
DOOR
HANDLES
(Q)
MAGNET
(R)
FAT CHANELLING T
RAY (
U
)
HOT PLATE
(S )
COOKING GRILL
(
T
)
GREASE
CUP(W)
LEFT
FASCIA (V)
RIGHT FASCIA(AB)
SIDE BURNER
KNOB(X)
SIDE
BURNER BEZEL(Y)
CART BRACKET(AA)
SHELF BRACKET(Z)

7
STEP 3 OPEN THE BOLT PACK READY FOR ASSEMBLY
The following hardware is provided in a blister pack for convenient use.
STEP 4 ATTACH THE CASTORS AND MAGNET
 Turn the BASE(E) upside down. Attach the CASTORS (AD) to the base with sixteen M6x13 bolts.
Note: nstall each castor into the correct position as shown below. Tighten firmly.
 Turn the base right side up. Attach the MAGNET(R) to the base with two M4x10 bolts.
M4X10 bolt
Qty: 34 pcs
M4X10 countersunk head bolt
Qty: 8 pcs
AAA Battery
Qty: 1 pc
M5X10 bolt
Qty: 4 pcs
M5 washer
Qty: 4 pcs
M4X19 shoulder bolt
Qty: 6 pcs
M6X13 bolt
Qty: 32 pcs
M6 Red Fiber washer
Qty: 8 pcs
Front
SWIVEL NON LOCKING
CASTOR
FIXED CASTOR
SWIVEL LOCKING CASTOR
Back
Back
Front
MAGNET(R)
BASE(E)
M6X13 bolt X sixteen
M4X10 bolt X two

8
STEP 5 ATTACH THE SIDE AND BACK PANELS
 To attach the S DE PANELS (F) &(G), align the side panel bottom holes with the corresponding holes on each
side of base as shown below. Note that the LEFT PANEL(F) has the match holder attachment.
 Fix the side panels to base with fo r M6x13 bolts.
 Attach the BACK PANEL(K) to the base and the side panels with six M4x10 bolts.
LEFT PANEL(F)
FRONT
BACK PANEL(K)
MAGNET(R)
RIGHT PANEL(G)
(Note: Match holder on left panel)
M6X13 bolt X fo r
M4X10 bolt X six

9
STEP 6 ATTACH THE FRONT RAIL AND TOP PANEL
 Attach FRONT RA L( ) to the side panels as shown below with fo r M4x10 bolts.
 Attach the CART BRACKETS (AA) as shown below to the base and side panels with eight M4x10 bolts.
 Align the TOP PANEL(D) into place as shown below and secure with six M4x19 sho lder bolts.
FRONT RAIL(I)
Note: Magnets on top
TOP PANEL(D)
CART ANGLE BRACKETS(AA)
M4X10 bolt X twelve
M4X19 sho lder bolt X six

10
STEP 7 ATTACH THE DOORS
 Remove the fo r M5x15 bolts already pre-assembled to the DOOR HANDLES (Q), and use them to attach the
door handles to DOORS (B) & (C).
 Place either door on either side of the cart, align the door hinges holes with the corresponding holes on the door,
secure with eight M4x10 co nters nk head bolts. Do not fully tighten at this time.
 Repeat this for the other door.
 Close the doors and adjust the bolts so that the doors line up as necessary.
M4X10 co nters nk head
bolt X eight
DOORS (B) & (C)
DOOR HANDLE (Q)

11
STEP 8 ATTACH THE FIREBOX
 This step requires two people to lift and position BARBEQUE HEAD (A) onto cart.
 Remove the ties securing the hose to assembly underside of the firebox. Carefully uncoil the hose assembly and
igniter wires out to the side of the firebox as shown below.
 Carefully lower the barbeque head onto the cart. Make sure the hose assembly and igniter wires are hanging
outside the cart. Open the hood attach the firebox to the cart with fo r M6x13 bolts and fo r M6 Red fibre
washers.
 Align the BACK RA L (J) holes with the corresponding holes on the side panels and firebox as shown below.
Attach the back rail with fo r M4x10 bolts.
BARBEQUE
HEAD (A)
BACK RAIL (J)
M6X13 bolt X fo r
M6 Red Fibre Washer X fo r
M4X10 bolt X fo r

12
STEP 9 ATTACH THE LEFT SHELF
 Attach the LEFT FASC A (V) to LEFT SHELF(P) with two M5x10 bolts and two M5 washers.
 Attach the SHELF ANGLE BRACKET(Z) to left fascia and left shelf with fo r M4x10 bolts.
 Attach left shelf to the firebox as follows and as shown below:
- From inside to outside of firebox with two M6x13 bolts and two M6 red fibre washers.
- From outside to inside of firebox with two M6x13 bolts.
 Attach left fascia to control panel with one M4x10 screw as shown below.
M5X10 bolt X two
M6X13 bolt X fo r
M6 red fibre washer X two
M4X10 bolt X five
M5X10 washer X two
LEFT FASCIA (V)
LEFT SHELF
(
P
)
SHELF ANGLE
BRACKET
(
Z
)

13
STEP 10 ATTACH THE RIGHT SHELF
 Remove the trivet (N) from side burner.
 Attach R GHT FASC A (AB) to R GHT SHELF(O) with two M5x10 bolts and two M5 washers.
 Attach the SHELF ANGLE BRACKET(Z) to right fascia and right shelf with fo r M4x10 bolts.
 Attach right shelf to the firebox as follows and as shown below:
- From inside to outside of firebox with two M6x13 bolts and two M6 red fibre washers.
- From outside to inside of firebox with two M6x13 bolts.
 Attach right fascia to control panel with one M4x10 bolt.
RIGHT FASCIA (AB)
RIGHT
SHELF
(
O
)
SHELF ANGLE
BRACKET (Z)
M5X10 bolt X two
M6X13 bolt X fo r
M6 red fibre washer X two
M5X10 washer X two
M4X10 bolt X five

14
STEP 11A FIT THE SIDE BURNER AND HOSE ASSEMBLY (It’s best to do this with another person to help)
(a) Unscrew and remove two front screws and washers holding side burner in place. Note: Do not loosen
electrode screw.
(b) Loosen side burner in side shelf.
(c) Remove knob and bezel from side burner control valve. To remove, pull knob straight out from valve stem.
Unscrew bezel from valve face and set the two screws aside.
(d) nsert valve stem through hole in fascia.
(e) Place side burner tube over the valve, making sure that valve is inside side burner tube.
(f) Attach bezel to fascia and valve face with previously removed 2 screws.
(a)
(c) (d)
(f) (e)
(b)

15
STEP 11B FINISH THE SIDE BURNER
(g) Push control knob onto side burner valve stem.
(h) Reattach side burner to side burner shelf with the 2 previously removed screws and washers. Fit the side
burner TR VET (N).
( i ) nsert the small tip of the main burner wire and side burner wire into the two module sockets.
( j ) Unscrew igniter cap from control panel. nsert one AAA battery (provided in bolt pack) into battery slot with
positive end (+) facing outward. Screw igniter cap back onto panel.
(g) (h)
(i) (j)

16
STEP 12 FIT THE FLAME TAMERS, GRILL AND HOT PLATE
 Place two FLAME TAMERS(AC) over the two right hand side burners by inserting tabs into slots in front and back
of firebox.
 Place the COOK NG GR LL(T) onto the shoulders in the firebox, in place above the flame tamers.
 Place the HOT PLATE(S) onto the shoulders in the firebox on the left hand side as shown below.
 nsert the WARM NG RACK(H) into the brackets at the top of the firebox as shown below.
HOT PLATE (S) COOKING GRILL (T)
FLAME TAMERS
(AC)
WARMING RACK (H)

17
STEP 13 FIT THE FAT CHANELLING TRAY AND FAT CUP
 Slide the FAT CHANELL NG TRAY(U) into the bottom of the firebox from the rear. Place the GREASE CUP(W)
into place as figure show.
 Feed the regulator and hose through the hole in the right side panel.
 When the barbeque is in the desired location, lock the rear castors; this will help it stay in place for safe operation.

18
Checking The Gas Type
Before assembling your barbeque, you should ensure your barbeque is suited to the type of gas which you are going to
use.
LPG, Also Known As Propane:
Barbeques suited to LPG should have an orange sticker on the side saying “PROPANE ONLY”.
This is most commonly supplied as a portable 4 kg or 9 kg gas cylinder, which can be refilled or swapped at petrol
stations or your place of purchase when empty.
Some homes have twin 45 kg LPG cylinders permanently installed near an outside wall. These cylinders supply LPG
gas to many appliances in the home via copper pipes, and are filled as required by the gas supply company.
Nat ral Gas
This barbeque is not suitable for Natural Gas.
t is extremely dangerous to use the barbeque with the wrong type of gas. Fire or explosion may result.
Portable LPG Cylinders (S pplied Separately)
Fill and leak check the cylinder before placing it in or attaching to the barbeque.
Place the LPG cylinder into the well in the base of the cart, with the cylinder opening facing forwards.
Take the hose that came with the barbeque, check that it has a rubber seal on the regulator end of it, and connect this
end of the hose to the gas cylinder. You won’t need a spanner here. Just turn the fitting in an anticlockwise direction
and hand tighten as much as you can. This should seal it sufficiently.
Cond ct a leak test as o tlined on Page 20 before se.

19
Fixed LPG S pply
Barbeques which are connected to twin 45 kg LPG cylinders must be installed by a licensed gasfitter, in
accordance with the requirements of AS 5601, and local gas authority requirements.
There are two approaches to installation:
Permanent Piped Connection: Your barbeque may be permanently connected to the main gas lines or LPG cylinders
via copper pipe. This must be done entirely by the gasfitter, in accordance with requirements of AS 5601, and local gas
authority requirements. Your gasfitter will ensure that your barbeque is permanently connected to the supply via
copper pipe, the gas pressure in the lines is adequate, pipe sizes are correct, all connections are secure, and that all
necessary components (such as secondary regulators and manual shutoffs) are included where regulations require
them. Once this is done, the barbeque cannot be moved. t is a permanent fixture of the property.
Bayonet Point: Alternatively, you can have the gas fitter terminate the gas line using a “bayonet point”. This allows
you to connect and disconnect the barbeque using a special hose and bayonet termination. For LPG installations, an
appropriate hose and limiting chain to prevent the hose being overstretched is available from most barbeque retailers.
Always cond ct a leak test as o tlined on Page 20 before first se and at reg lar intervals after that.
To the installer: You must instruct the consumer on safe operation, and ensure these instructions are left with the
consumer before leaving the site.
Barbeque connected to twin 45 kg LPG cylinders.
Copper pipe brings the gas from the tanks to the
barbeque area. A flexible connects to a bayonet
fitting near the barbeque.

20
Leak Testing
Before proceeding, it is important that yo leak test the barbeq e. Make s re all the barbeq e control knobs
are OFF.
f you have a portable gas cylinder, turn the cylinder ON by rotating the knob anti-clockwise. f you have a wall
connection, ensure the bayonet fitting is connected.
Spray or pour soapy water (about the same concentration as washing up water) along the gas line including:
 The gas connection at the inlet of the barbeque.
 The gas hose or copper piping, including any joints or bends in the piping.
 The gas connection at the gas cylinder or the wall connection. f bubbles appear, there is a gas leak, turn the gas
supply OFF. f the leak is at a connection, tighten and retest. f the leak is anywhere else, or if you cannot resolve
the leak, do not proceed, turn the gas supply OFF and disconnect and consult your retailer.
You can also check for leaks using a Gas Safety Gauge, available at your Barbeques Galore store. This provides an
easier, quick way to check for leaks anytime.