Great Outdoors Grill Company 4100 Series User manual

Assembly and
Owner’s Manual
Great Outdoors
the
Grill Company
®
Model
4100
Series
Portable
Gas Grill
FOR YOUR SAFETY: Never leave a grill unattended when in use.
FOR YOUR SAFETY
Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
An unconnected liquid propane
cylinder should not be stored in the
vicinity of this or any other appliance.
1
2
If you smell gas:
Shut off gas to the appliance.
Extinguish any open flame.
Open lid.
If odor continues, immediately call
your gas supplier or fire department.
1
2
3
4
CONSUMER / USER:
Read all of these instructions and keep them in a safe place for future reference.
ASSEMBLER / INSTALLER:
Leave these instructions with the consumer.
FOR YOUR SAFETY

Congratulations and thank you for your purchase
of your new Great Outdoors 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 among the finest on the
market.
We are committed to producing quality products
that your family will enjoy for years to come. If for
any reason we have failed to meet or exceed your
expectations, please allow us the opportunity to
make it right by calling us toll-free:
between the hours of 8:00 a.m. and 4:30 p.m.,
central time, Monday through Friday.
We want you to be completely satisfied with your
purchase so you will agree with our motto,
888-869-5454
“there’s nothing like...
the great outdoors.”TM
Statement of Commitment
7980 East American Drive
Joplin, Missouri USA 64804
For more information about our growing family
of barbecue grills, smokers, and outdoor
products, please visit our website at:
www.gogrills.com
Great Outdoors
the
Grill Company
®
- A CFM Company -

Table of Contents
Chapter 1 - INSTALLATION
Necessary Information ...........................
Choosing a Safe Location .........................
Portable L.P. Gas Grills ...........................
L.P. Gas Dealer Instructions .......................
Step 1 ( Identifying Parts ) .........................
Step 2 ( Assemble Pillar to Grill Bottom ) .............
Step 3 ( Attach Base ) ............................
Step 4 ( Side Tables ) ............................
Step 5 ( Assemble Grill Lid ) .......................
Step 6 ( Internal Parts ) ...........................
Installing an L.P. Gas Cylinder .....................
Connecting an L.P. Gas Cylinder . . . ................
Leak Testing ...................................
Lighting Instructions .............................
Using Your Grill .................................
Caring for Your Gas Grill ..........................
Cleaning and Maintenance ........................
Replacement Parts ..............................
Troubleshooting Guide and FAQ’s ..................
Recipes .......................................
Warranty ......................................
Chapter 2 - ASSEMBLY INSTRUCTIONS
Chapter 3 - USE and CARE
Chapter 4 - OUTDOOR COOKING / RECIPES
3
4
4
4
5-7
8
10
11-12
13
14
15-16
17-18
19
20
22
23-24
25
26
27
28-29
31-33
34-37
38
9
21
34
Page Number

·
·
·
·
·
Operating this or any gas-fired appliance
in an enclosed area can produce a build-up
of carbon-monoxide, which could result in
injury or death.
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.
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.
Do not use lighter fluid or charcoal
briquettes in a gas grill. The flow of
combustion and ventilation air is not to be
obstructed. The ventilation openings of the
cylinder enclosure must be kept free and
clear from other debris. Do not store grill
covers or other items in the cylinder area.
·Do not operate this barbecue in garages,
breeze ways, sheds or any enclosed area.
2. Installation must conform with local
codes
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.
5. The grill area must be clear and free from
combustible materials, gasoline, and any
other flammable liquids or vapors.
4
Installation 1Chapter
Model 4100 Series Gas Grill
1. The gas barbecue grill may only be used
for cooking out-of-doors.
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.
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
Necessary Information to
Safely Use a Gas Grill

Heat and hot drippings from cooking food
could damage the fuel supply system.
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.
An L.P. gas grill requires a fuel delivery
system made up of a L.P. gas supply
cylinder, a fuel regulator with hose and a
gas-control valve.
·
L.P. Gas
The L.P. Fuel Supply System
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.
Place your barbecue grill in a location
away from children and pets.
Do not leave grill unattended when in 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.
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.
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.
WARNING:
NEVER leave a grill
unattended when in use.
IMPORTANT:
5
6. Do Not store a spare L.P. gas cylinder
under or near this appliance.
7. NOT FOR USE BY CHILDREN.
8. The outside of the barbecue grill will
become hot during use.
Portable L.P. Gas
Barbecue Grills
The L.P. Fuel Supply System
The L.P. Fuel Supply System

Valve
Orifice
Dual Burner
Fuel-Control Valve
Fuel Supply
Hose
Type 1 Fuel
Regulator
The L.P. Fuel Supply System
(the fuel regulator and hose)
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).
L.P. Cylinders can be obtained at the store
where you purchased your grill or from an
authorized L.P. gas dealer.
Any L.P. gas-supply cylinder used with this
grill must be approximately 12 inches
diameter and 18 inches high.
L.P. GAS SUPPLY CYLINDER
L.P. GAS CYLINDER SPECIFICATIONS
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
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.
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.
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.
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.
WARNING:
6
NOTE: 4100W
Model grills
DO NOT
include an L.P.
gas cylinder
Cylinder Control
Valve
The L.P. Fuel Supply System
(L.P. gas cylinder)
L.P. Gas
Cylinder

TRANSPORTING A FULL CYLINDER
HEAT SHIELD, GASKETS AND COLLAR
You should transport only one cylinder at a
time. Transport the cylinder in an upright and
secure manner with the control valve turned
off and the POL plug in place.
Do not transport a cylinder in the passenger
compartment of a vehicle.
Do not leave cylinder in direct sunlight orin
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 the cylinder-valve
outlet during transport and when the cylinder
is not connected to the grill. Keep cylinder
valve closed when not in use.
Operating this grill without the heat shield,
gaskets and collar assembly attached to the
grill bottom would result in a hazardous
situation which could cause serious property
damage and possible physical injury.
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.
The cylinder must be arranged for vapor
withdrawal. It must also include a collar to
protect the cylinder valve. A safety-relief
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.
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 the cylinder
after filling to ensure that the cylinder is not
overfilled.
Allow only a qualified L.P. gas dealer to
fill or repair an L.P. gas-supply cylinder.
percent full.
c.) If the information in (a.) and (b.) Is not
followed exactly, a fire causing serious injury
or death may occur.
Handle a full cylinder with care.
Gas is under high pressure.
Do not remove the heat shield,
gaskets or collar assembly from the grill
bottom.
WARNING:
WARNING:
7
Do not insert any foreign objects
into the valve outlet. You may damage the
back check, A damagedback check can
cause a leak, which could result in explosion,
fire, severe personal injury or death.
DANGER:
a.) Do not store a spare L.P. gas cylinder
under or near this appliance.
b.) Never fill the gas cylinder beyond 80
DANGER:
The heat shield, gaskets, collar assembly
The heat shield, gaskets, collar assembly

Example B
Type 1
(cut away to see fitting)
Example A
CGA-510 POL
Filling a Type 1 Cylinder Valve
Example A: shows a CGA-510 POL fitting.
Example B: shows using a Type 1 POL fitting.
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.
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.
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 USA,
refer to: Safety Bulletin NPGA # 133, “Purging
L.P. Gas Cylinders,” and Safety Bulletin NPGA
#130, “Recommended Procedures for Filling
Cylinders.”
PURGING AND EVACUATION DEVICES
FOR L.P. GAS CYLINDER WITH TYPE 1
CYLINDER VALVES
CAUTION:
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.
Purge new cylinders before
filling. This tank is easily filled with a standard
CGA 510 POL filling connection.
FILLING AND PURGING
TYPE 1 L.P. GAS CYLINDERS
IMPORTANT:
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.
DANGER:
8
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.
DANGER:
Take These Instructions to the L.P. Gas Dealer

Getting Started
Unpacking the Grill Parts
Tools needed to assemble grill:
·
·
·
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,
have the L.P. gas cylinder filled by an
authorized L.P. dealer or cylinder exchange
center.
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.
3/8” open-end wrench*
flat-head screwdriver
7/16” open-end wrench*
*
Note: You may notice during assembly that hardware
bag “B” is used before hardware bag “A”. The
assembly procedure has been improved from the
original sequence to make assembly easier. However,
hardware packaging has not been changed.
A socket set or an adjustable wrench may be used
in place of the open-end wrenches.
9
Assembly Instructions 2Chapter
Model 4100 Series Gas Grill
3/8
7/16

10
Assembly Step 1 - Identifying the Grill Parts
warming rack (1)
cooking grid (1)
rock grate (1)
left side
table (1)
right side
table (1)
base (1)
(2 locking casters and
2 non-locking casters
installed)
handle (1)
handle
standoffs (2)
grill lid (1)
grill bottom
assembly (1)
grease
pan (1)
pillar (1)
(burner assembly, heat
shield, collar gasket
& collar installed)
(knobs, ignitor,
valve, hose
with regulator
installed)
Locate these parts:
Not Pictured:
(consisting of 1 each of A,B,C,D bags)
ceramic briquettes (1 pkg)
master hardware bag (1)
X-brace
wire (1)

HINT: For the first portion of the assembly you will be
assembling the grill bottom, pillar and base upside
down.
1.
2.
3.
11
Assembly Step 2 - Attach Pillar to Grill Bottom
Position the grill bottom casting upside down so
that the heat collar assembly is upward.
Working from the back (open) side of the pillar,
set the pillar upside down onto the collar
assembly.
Locate the holes in the pillar bottom and align
with holes in collar.
Tools Needed:
USE HARDWARE BAG B:
LOCATE THESE PARTS:
3/8”
wrench
back of grill bottom, upside down
back of pillar, upside down
pillar
assembly (1)
grill bottom
assembly (1)
1/4-20 x 3/4”
bolt (4)

4.
5.
6.
12
Assembly Step 2 - Continued
!
Burner Tube
(The control valve ends are
attached to the pillar; the burner tubes are
attached and extend through the grill
bottom.)
Insert the four bolts through the pillar holes
and thread them into the speed nuts on the
collar. Use a wrench to secure the bolts,
being careful not to over-tighten.
Locate the black igniter wires
beneath the grill bottom. Press
the metal contact of the loose
end of the wiresonto the
metal pinsof the igniter unit.
IMPORTANT: Make sure the control valve
ends are seated inside the burner tubes as
shown.
Control Valve

1.
2.
3.
4.
13
Assembly Step 3 - Attach the Base to the Pillar
Lock the pre-assembled casters on base by
pushing down on the latch.
Set the base upside down onto the pillar
bottom as shown, aligning the holes in the
base with holes in the pillar.
Insert the six bolts through the holes in the
pillar and base. Thread the locking hex nuts
onto bolts. Tighten the bolts and nuts with the
wrenches.
Carefully turn the grill upright onto the
casters.
USE HARDWARE BAG A:
LOCATE THESE PARTS:
1/4-20 x 3/4”
bolt (6)
7/16”
wrench
Tools Needed:
3/8”
wrench
base
assembly (1)
1/4-20 hex
nut (6)
locking
casters
back side of grill,
upside down

14
Assembly Step 4 - Attach the Side Tables
1.
2.
3.
Insert the 3/4” bolts through
the holes in the support
brackets of the side table.
Attach the side table to the
four holes located in the side
of the grill bottom using the
locking hex nuts provided.
Attach the opposite side
table the same way.
USE HARDWARE BAG C:1/4-20 x 3/4”
bolt (8)
1/4-20 hex
nut (8)
LOCATE THESE PARTS:
left side table
assembly (1)
7/16”
wrench
Tools Needed:
3/8”
wrench
right side table
assembly (1)

15
Assembly Step 5 - Assemble the Grill Lid
1.
2.
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.
Gently set the grill lid onto the grill bottom.
USE HARDWARE BAG D:
flat-head
screwdriver
standoff
gasket (2)
1/4-20 x 5/8”
bolt (4)
hairpin (2)
1/4-20 hex
nut (4)
LOCATE THESE PARTS:
1/4” x 1-1/8”
hinge pin (2)
7/16”
wrench
Tools Needed:
grill
lid (1)
handle
standoff (2)
handle (1)

16
Assembly Step 5 - continued
5
5
3
3
4
4
3.
4.
5.
6.
7.
8.
9.
10.
Hold the lid to align the hinge holes.
Insert a hinge pin through the hinge hole
in the lid and into the hole in the bottom
hinge strut.
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 the pins.
Repeat for the
opposite side.
Raise the lid to attach
the front handle.
Attach one handle
standoff to the front
of the grill lid, as shown.
Insert one end of the handle into the
hole of the mounted standoff.
Place the other standoff onto the handle,
and while holding the handle in place,
assemble the opposite standoff to the lid
in the same manner.
standoff
standoff
gasket
grill lid

17
Assembly Step 6 - Installing the Internal Grill Parts
cooking
grid (1)
LOCATE THESE PARTS:
rock grate
(1)
warming rack
(1)
ceramic
briquettes
(1 package)
1.
Place the single rock grate into the grill
bottom.
Place the single rock grate into the grill
bottom.
No Tools are Needed.
2.
Open the package containing the
ceramic briquettes and place them
evenly-spaced onto the rock grate.
Open the package containing the
ceramic briquettes and place them
evenly-spaced onto the rock grate.

4.
5.
18
Assembly Step 6 - continued
Set the porcelain coated cooking
grid on the front and back ledges
formed inside the grill bottom for
a level cooking surface.
Set the warming rack onto the
back of the cooking grid.
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.
5
5
5

19
Installing an L.P. Gas Cylinder
Obtain a filled L.P. gas cylinder. Read and
follow all directions on the cylinder and fuel
hose safety tags.
1.
2.
3.
4.
Connect the L.P. cylinder to the
grill outdoors only.
WARNING:
Working from behind the grill, set the
cylinder into the large round opening in
the grill base.
Position the legs of the X-brace wire in
the bottom rear corners of the pillar,
behind the bolts.
Insert the top left end of the X-brace wire
into the rear hole of the pillar, beneath the
collar.
Flex the right side of the X-brace so that
the end fits into the opposite hole.
1
1
2
2
3
3
4
4
Items Needed:
L.P. Gas Cylinder
(1 FILLED)
grease drip
pan (1)
LOCATE THESE PARTS:
NOTE: 4100W
Model grills
DO NOT
include an L.P.
gas cylinder
X-brace
wire (1)

1. The top knob on the supply cylinder must
be closed. See that the top cylinder knob is
turned clockwise to a full stop.
2. Check that all the grill burner knobs are
turned off.
3. Remove the protective caps from the
cylinder valve and coupling nut, if present.
4. Hold the regulator in one hand and insert
the nipple into the valve outlet. Be sure the
nipple is centered in the valve outlet. The
coupling nut connects to the large outside
threads on the valve outlet. Use care not to
cross thread the connection.
5. Hand tighten the coupling nut clockwise
until it comes to a full stop. Tighten by hand
only. Do not use tools.
6. CAUTION: In the connection process,
the grill side of the connection will seal on
the back check in the valve, resulting in a
slight resistance. The connection requires
about one-half to three-quarters additional
turn to complete the connection.
NOTE: If you cannot complete the final
connection, disconnect the regulator and
repeat steps 4 through 6. If you are still
unable to complete the connection, do not
use this valve and regulator.
20
Connecting the L.P. Gas Cylinder
7. Make sure the hose has no kinks or
sharp bends and clears any areas that will
become hot during use. Never put strain on
the hose where it joins a fitting. The rubber
fuel supply hose must not touch the bottom
grill casting during use.
8. Before lighting grill, check all connections
for leaks using a mild soapy-water solution.
9. Place an aluminum 3-1/2” x 6” loaf pan
into the opening in the heat shield located
beneath the grill bottom. During use the pan
will catch hot grease drippings that could
damage the fuel supply system.
Connecting the Regulator to Cylinder
Install a Drip Pan in the Heat Shield
The grease pan is a 3-1/2”x6” aluminum loaf
pan available at most grocery stores.
Grease
Drip Pan Heat
Shield
(Back Side, Under the Grill Bottom)