Coleman 4000 Series LG40811E User manual

11412133 00/12
LOOK INSIDE FOR:
Easy Assembly Instructions
Warranty Information
Safety, Maintenance
an Cleaning Tips
GRILL
Coleman Company, Inc.
4101 Howard Bush Drive
Neosho, Missouri 64850
Internet site:
www.bbqhq.com
LOOK ON PAGE 2
Pre-cooking seasoning processes an
proper storage treatment of
Cast Iron Gri s.
9-Volt Battery Inclu e
Las Instrucciones e Ensamblaje en español en la pagina 13.
ASSEMBLY
INSTRUCTIONS
FOR
LG40811E
WARNING:
THE EDGES OF SHEET METAL PARTS CAN CAUSE INJURY
IF NOT HANDLED WITH CARE.
USE EXTREME CAUTION!
IMPORTANT!
TO ENSURE PROPER GAS FLOW, BURNER
CONTROL VALVES MUST BE “OFF” BEFORE
OPENING THE GAS CYLINDER VALVE.
ASSEMBLER/INSTALLER:
LEAVE THESE INSTRUCTIONS WITH THE CONSUMER.
CONSUMER/USER:
READ ALL THESE INSTRUCTIONS AND KEEP THEM IN A
SAFE PLACE FOR FUTURE REFERENCE.

11412133 (Pg. 2)
Two Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(16)
Three Main Control Knobs . . . . . . . . . . . . . . . . . . . . . .(32)
One Grease Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(48)
One Grease Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(49)
Three Heat Tents . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(61)
One Meat Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(57)
One Meat Probe Receptacle . . . . . . . . . . . . . . . . . . . . .(57a)
One Handle Assembly
One Literature Bag
One 6-lobe Screwdriver
Hardware bag(s)
Assorted assembly hardware - One Igniter Kit bag
Two Axle pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(3)
CARTON A - MISCELLANEOUS PARTS
BEFORE
YOU
BEGIN ASSEMBLING
YOUR
NEW QUALITY COLEMAN
GAS
BARBECUE GRILL:
ÖFOR EASE OF ASSEMBLY, leave the grill on
the inside bottom foam packing tray until the
wheels have been attached. (See representative
example at right). Remove the outside foam from
the right and left sides of the frame base at this
time.
ÖRemoveallcartonslocatedontopofthebarbecue
grill base and set aside.
Engineering Co e
LG114333
Tools Needed
Ö#20 6-Lobe Screwdriver (Included)
Ö#2 Phillips Screwdriver
ÖAn adjustable wrench
Ö9-Volt Battery (Included)
Optional Tools
Ö7/16" and 5/16" Box End Wrenches
Ö7/16" Nut Driver
ÖElectric or Cordless Screwdriver
Ö#20 6-Lobe driver bit
Ö#2 Phillips driver bit
START THE COOKING GRIDS
SEASONING PROCESS BEFORE
ASSEMBLING YOUR GRILL!
CAST
IRON GRIDS
ÖCast Iron grids are on select models only.
ÖYour cast iron grids may have some rusting.
This is normal. To remove the rust, scour the
rusty areas with steelwool, i.e. SOS pad, until
all traces of rust are gone. Wash, dry and
season grids.
SEASONING
CAST IRON GRIDS AND
GRIDDLE
SEASONING IS THE PROCESS OF ALLOWING OIL TO BE
ABSORBED INTO THE IRON, CREATING A NON-STICK,
RUSTPROOF FINISH. HERE’S HOW TO DO IT:
ÖPreheat Oven to 350ºF.
ÖWash with hot, soapy water and a stiff brush.
Rinse and dry completely.
ÖOil the grids (all surface top and bottom) with
MELTED solid vegetable shortening.
ÖTurn upside down on the top rack of a 350ºF
pre-heated oven.
ÖPut aluminum foil on the bottom rack to catch
any excess drippings.
ÖBake the grids for one hour at 350ºF.
ÖLet the grid cool slowly in the oven.
ÖStore, uncovered, in a dry place when cooled.
ONE CARTON - L.P.GAS CYLINDER
WARNING:
Combustion by-products produced when using
this product contain chemicals known to the State
of California to cause cancer, birth defects, or
other reproductive harm.
CARTON B - 2 SIDE TABLE
ASSEMBLIES
(FOR MODELS WITHOUT SIDE BURNER)
One pre-assembled right sidetable
One pre-assembled left sidetable

11412133 (Pg. 3)
4-A
WN WN
WN
3
3
16
16
3
1-A
1-A. Insert the AXLE PINS (3) into the wheels.
ÖInsert the wheels and axle pins into each side of the base and secure with two
clevis pins (WN). See diagram.
ÖRemove the remaining foam tray from under the barbecue grill now.
Left end
Back
Label
ÖAssemble WHEELS (16). See detail 1-A.
ÖAssemble BASKET (22) on the right end of base and legs. See detail 1-B.
Step
1
BEGIN WITH CARTON A - MISCELLANEOUS PARTS
Right end
1-B. Feed the BASKET (22) through the right legs with the basket
extensions on the outside of the legs. The extensions will rest against
the outside of the legs.
ÖPlace the Basket feet over the caster bolt and secure with two wing
nuts (DZ).
1-B
22 DZ
DZ
(2) Qty.
Hardware shown actual size
(2) Qty.
Back View
Right end

11412133 (Pg. 4)
ÖAssemble the one GREASE PAN (48) and one GREASE CUP (49) under the
bottom casting. See details 2-A and 2-B.
2-A. Secure two shoulder screws (DN) into the GREASE PAN (48) with
two hex nuts (GC), taking care not to damage the porcelain by
overtightening. A standard soup can may be used inside the
GREASE CUP (49) as a disposable liner. Attach the Grease Cup
to the shoulder screws on the bottom of the grease pan.
2-B. Slide Grease pan assembly into position past tab stops, from the back, on
flanges under bottom casting.
NOTE: When cleaning, hold the stops out to remove the Drip pan.
(2) Qty (2) Qty.
GC
GC
48
49
DN
DN
2-B
2-A
Step
2
Hardware shown actual size
Tab Stop
Tab Stop

11412133 (Pg. 5)
Step
3
3-A. Place CONTROL KNOBS (32) on valve stems.
ÖInsert MEAT PROBE RECEPTACLE (57a) into the right side of the control panel.
ÖPlace the MEAT PROBE (57) into the meat probe receptable.
ÖAssemble CONTROL KNOBS (32), MEAT PROBE RECEPTACLE (57a) and MEAT
PROBE (57). See detaill 3-A.
32
57
57a
32
32
3-A

11412133 (Pg. 6)
ÖAssemble HEAT TENTS (61) and DIVIDERS (62). See details 4-A and 4-B.
4-A. Set the HEAT TENTS (61) onto the bracket mount points. 4-B. Slide the DIVIDERS (62) into the Bottom casting.
61
61
61
61
4-A
Step
4
62
62
4-B

11412133 (Pg. 7)
Hardware shown actual size
(4) Qty.
(4) Qty.
Step
5
5-B. Place two GUARDS (42b) on the front lip of the Bottom
Casting (see fig. 1). Align the clip over grid lugs. Place the
COOKING GRIDS (63) in the Bottom casting with the
smooth surface down.
ÖSet the WARMING RACK (65) near the back of the bottom
casting.
ÖAssemble FRONT HANDLE Assembly to the GRILL LID (55) in detail 5-A.
ÖAssemble two GUARDS (42b), COOKING GRIDS (63) and WARMING
RACK (65). See detail 5-B.
5-A. The FRONT HANDLE (58), HANDLE SPACER (60),
HANDLE INSULATOR (59), four screws (DT) and four
hex nuts (AO) are PRE-ASSEMBLED at the factory.
ÖRemove the four hex nuts (AO) from the Handle
assembly.
ÖInsert the screws in the Handle assembly into the
GRILL LID (55) and secure with four hex nuts (AO).
ÖTighten with adjustable wrench or 7/16” wrench.
5-A
AO
55
AO
AO
DT 60
59
AO AO AO
DT
58
65
63
63
63
5-B
42b
1

11412133 (Pg. 8)
ÖAssemble Pre-Assembled RIGHT SIDETABLE in detail 6-A.
ÖAssemble Pre-Assembled LEFT SIDETABLE in detail 6-B.
ÖNote: Use both hands and lift with side table brackets. NEVER lift with plastic parts.
Step
6
BEGIN WITH CARTON B - SIDE TABLE ASSEMBLIES
6-A
6-A. Use the 6-lobe screwdriver to back out the outside screws located in
the top right legs (2 or 3 turns) just enough for the SIDE BRACKETS
(11 and 13) on the PRE-ASSEMBLED sidetable, to slide in place.
CAUTION: DO NOT Remove screws completely.
ÖPlace the bottom slot of the brackets on the screws first and then the
top slot. Note: The TOOL BAR (12) faces the front of the grill.
ÖGently slide the Bracket down and tighten screws.
Right
6-B
6-B. Use the 6-lobe screwdriver to back out the outside screws located in the top
left legs (2 or 3 turns) just enough for the SIDE BRACKETS (11 and 13) on
the PRE-ASSEMBLED sidetable, to slide in place.
CAUTION: DO NOT Remove screws completely.
ÖPlace the bottom slot of the brackets on the screws first and then the top slot.
Note: The TOOL BAR (12) faces the front of the grill.
ÖGently slide the Bracket down and tighten screws.
PRE- ASSEMBLED
SIDETABLE
PRE- ASSEMBLED
SIDETABLE
Grill
Front Grill
Front
12
12
Left
6-LOBE
SCREWDRIVER

11412133 (Pg. 9)
ÖAssemble the ELECTRODE WIRES (29), SWITCH WIRES (26) and the 9-VOLT BATTERY
(30) to the ELECTRONIC MODULE (28) in details 7-A.
ÖAssemble the ELECTRONIC MODULE (28) under the Left Side Table in detail 7-B.
Step
7
ELECTRONIC MODULE
ORANGE
ELECTRODE
WIRE 29
ORANGE
ELECTRODE
WIRE 29
7-A
7-B. Locate the left front SIDE BRACKET (13) and
attach the ELECTRONIC MODULE (28)
underneath the front bracket flange in the holes
indicated in the Mounting Holes detail, with two
screws (JS).
ÖBundle extra wire length with wire tie (LA) not
shown.
(2) Qty.
Hardware shown actual size
1MB 1SB
2MB 2SB
7-B
28
13
JS
JS
1MB 1SB
1SB
2MB
7-A. Attach the black SWITCH WIRES (26), with the
red connecters located on the left side of your
grill, to the two large pins on the ELECTRONIC
MODULE (28). Then attach the two orange
ELECTRODE WIRES (29) located on the left
side of your grill, to the pins on the module
marked 1MB and 2MB.
ÖInsert the 9-VOLT BATTERY (30) in the module,
it MUST snap in place.
Caution: Insure that the wires DO NOT
touch hot surfaces such as the grill casting.
Electronic Module
Side Frame 10
Screw (CW)
Side Frame 10
Screw (CL)
Tool Bar Tool Bar
Inside
Outside
Top View of Bracket (13)
LEFT SIDE OF
GRILL
Orange
Electrode
Wires (29)
Black
Switch
Wires (26)
9-VOLT BATTERY 30
ELECTRONIC MODULE 28
SWITCH WIRES 26
(BLACK WIRES WITH RED
FLAG CONNECTERS)
Left front
side of
grill
TEST THE IGNITER: A SPARK SHOULD APPEAR
AT ELECTRODE TIP.
IF THE SPARK DOES NOT APPEAR:
- CHECK THE WIRE CONNECTIONS TO THE
MODULE.
- CHECK PROPER ASSEMBLY OF FRESH 9-
VOLT BATTERY.

11412133 (Pg. 10)
ÖAssemble the CYLINDER (79) to the Cylinder caddy. See detail 8-A.
ÖAttaching TYPE 1 fitting to the fuel outlet valve in detail 8-B.
Step
8
8-A Set CYLINDER (79) in the cylinder caddy with the outlet valve
facing the front of the grill. Tighten the cylinder hold down bolt
against the bottom cylinder collar.
8-B Insert the TYPE 1 nipple of the regulator (27) into
the cylinder’s fuel valve outlet as shown. Turn the
regulator hand wheel clockwise to tighten. No
tools are needed. The Hand wheel will come to a
complete stop when the connection is secure and
gas will not flow until a positive seal is achieved.
WARNING: During assembly of grill and
when attaching or replacing the L.P. gas
cylinder, insure that the gas supply hose is
free of kinks and/or damage and is at least 3”
away from hot surfaces such as the grill
casting.
8-A
79
8-B
79 27
0utlet Valve
Outlet
Valve
TYPE 1
Nipple
IMPORTANT!
TO ENSURE PROPER GAS FLOW, BURNER
CONTROL VALVES MUST BE “OFF” BEFORE
OPENING THE GAS CYLINDER VALVE.