Vermont Castings VC400 Manual

Page 1
VC400 ASSEMBLY
VC400 ASSEMBLYPROCEDURES
Tools Required: Knife or Scissors, Hammer, 7/16” (11 mm) wrench/ratchet or an adjustable wrench,
Step 1: Unpack carton
Use the knife or scissors to cut the strapping on the package then lift off the cardboard cap. Remove the
cardboard sleeve lifting it straight over top of the barbecue. Check the 5 enclosed parts kits, against the
parts list (Appendix A) to ensure that no parts are missing.
Philips or Robertson screwdriver.
VERMONT
C
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Box
#
1
VERMONT
Castings
Box
#
2
Box
#
3
Box
#
4
Box
#
5
VERMONT CASTINGS

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VC400 ASSEMBLY
Step 2: Prop up left hand side of the barbecue
In order to attach casters and wheels to the barbecue,each side
of the unit must alternately be propped up to provide access to
the bottom of the legs. A block of wood or other solid item
about 4-6 inches high will suffice for this purpose.
The same process can be used with the right
legs for attachment of the unit’s wheels.
NOTE: BEFORE BEGINNING ANYASSEMBLY, REMOVE THE
BARBECUE’S SIDE PANELS TO PREVENT THEM FROM BEING
DAMAGED.
Step 3: Install Casters
Materials Required:
Two casters and two caster inserts.
Place a caster insert in the bottom of the
rear left leg and tap it into place with a
hammer. Tap the other caster insert into
the front left leg. Snap the casters into
the inserts.
VERMONT
Castings
VERMONT
C
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VERMONTVERMONT CASTINGS
Caster
Insert
Hand Hold
(Lift Up and Pull Out)
2
1
Shoulder
Screws

Page 3
VC400 ASSEMBLY
Step 4: Attach Wheels
Materials Required: 1/2” diameter axle; two
1/2” axle caps and two wheels.
Prop up the right hand side of the barbecue
using the method described in Step 2.
Tap a cap onto one end of the axle. Push
a wheel onto the axle flush against the
cap with the cone shaped side of the
wheel facing inward. Insert the axle
through the holes at the bottom of the
right hand legs. Finally slide the other
wheel into place on the axle, again with
the cone shaped side facing inward, and
tap the other axle cap
onto the axle.
Cap Wheel
Axle
Caps
Wheels
Axle
VERMONTVERMONT
C
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VERMONTVERMONT
C
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VERMONT CASTINGS
NOTE: PLACE THE UNIT ON LEVEL GROUND. LOCK CASTERS BEFORE
PROCEEDING TO STEP 5 AND BEGINNING FURTHER ASSEMBLY.

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VC400 ASSEMBLY
Step 5: Attach Shelf Supports Materials Required: Left and Right shelf supports and eight
Attach the right shelf support to the barbecue by loosening the 4 existing leg bolts, approximately 3 turns, so
that the shelf support can slide over the bolt heads. Insert a shim washer sideways behind the head of one of
the bolts and in front of the shelf support. Tighten the bolt using the 7/16” (11 mm) wrench/ ratchet or
adjustable wrench. Repeat inserting shim washers behind the heads of the remaining 3 bolts.
Attach the left shelf support in the same manner.
Step 6: Install Handle Grips
Place the top half of one handle grip, the half bearing the Vermont Castings logo, onto the right shelf support
handle. Use the holes provided as a guide. Snap the two halves of the handle grip together and secure them
using two Philips screws and a Philips screwdriver.
Repeat this procedure for the left shelf support handle grip.
Finally, attach the last handle grip set to the front lid handle.
Materials Required: Three handle
grip sets (six pieces total) and six
#4 x 3/4” Philips screws.
shim washers.
VERMONT
Castings
VERMONT CASTINGS
VERMONT CASTINGS
Shim

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VC400 ASSEMBLY
Step 7: Attach Front Condiment Shelves
Materials Required: Four #10-24 x 1/2” carriage bolts; two # 10-24 x 1/4” nylon bolts; two # 10-24 nylon
nuts; four #10-24 lock nuts; four 1” diameter rubber washers; the right front shelf; the left front shelf.
1 Align the two holes of the right front
condiment bin with those provided on the front
bracket of the right shelf support. Use two carriage
bolts (bolts with a squire shoulder below the head)
in the front; two rubber washers between the
condiment shelf and support bracket; and two
lock nuts at the rear to secure shelf to the unit at
each hole. Assemble loosely.
2 Next secure the shelf to the front
control panel by aligning the center hole on the
inside bottom side of the shelf with the hole
provided on the right side flange of the control
panel. Loosely assemble the pieces together
using a nylon nut & bolt.
Repeat to attach the left condiment shelf.
Do not tighten he fasteners yet.
Step 8: Attach Side Shelves
Materials Required: Nine #10-24 x 1/2” round head bolts; nine #10-24 lock nuts; and the left and right side
shelves and the Tool Holder.
NOTE: See separate rotiserie instructions to
assemble rotisserie bracket to left side shelf.
1 Fit the left side shelf onto the left shelf
support and secure it to the unit at the rear
using two bolts and two lock nuts. Assemble
loosely. 2Secure the left side shelf to the
left front shelf with one bolt and nut.
NOTE: The Tool Holder may be assembled
at this time to the left or right end. The top
of the Tool Holder fits under the edge of the
shelf. 3Finally, secure the left side shelf to
the side of the base using a bolt and nut.
Tighten all connections on both the condi-
ment bins and side shelf.
Repeat for the right side shelf.
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Castings
Bolt
Bolt
Nut
Bolt
Nut
Tool Holder
1
23
VERMONT CASTINGS
VERMONT
Castings
Carriage
Bolt
Roundhead
Bolt
Lock
Nut
Rubber
Washer
1
2

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VC400 ASSEMBLY
Bottom
Panel
Bottom Panel
For Propane
Models
Screws
Step 9: Attach the Handles to the Cabinet Doors
Materials Required:
Two door handles with four screws.
Attach a door handle to the left cabinet door by aligning
the ends of the handle with the two holes provided on
the top right side of the door. Secure the handle using the
screws provided and a Philips screwdriver.
Repeat for the right hand door handle.
Step 10: Insert the Bottom Panels and Install Tank Tip-out
Materials Required: Two bottom panels. Two #8-18 self-tapping screws for Propane Model Only.
Insert the bottom panels of the cabinet by placing the lips of the panels on the front and rear leg brace. For Natural
Gas models two shallow panels are used. For Propane models one shallow panel is used on the left side.
For Propane models the right hand cylinder base panel
has been loosely assembled at the factory. Push the base
pan down until the lips of the panel sit on the front and
rear leg braces. Tighten the four screws that secure the
base pan.
Attach the bracket of the tank tip-out assembly to the
right end brace with two self-tapping screws.
Bottom
Panel
Bottom
Panel
Natural Gas Model Propane Model
Screws

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VC400 ASSEMBLY
Step 11: Set up the Grease Pan and Grease Cup Holder
Materials Required: Grease pan; grease
cup, grease cup holder assembly.
Beneath the cooking unit a guide track has been
provided so that the grease pan can easily slide
in and out. This guide track can be accessed
from the left side of the barbecue. Slide the
grease pan halfway out to install the grease cup
assembly. Insert a disposable aluminum pan into
the grease cup holder then hook it onto the slots
provided on the end of the grease pan. Push the
grease pan back into place.
(Note: the grease cup should be hanging below
the square hole provided in the grease pan).
Step 12: Attach the Back Panel of the Cabinet
Materials Required: Two #8-18 self-tapping screws; two #8-18 self-tapping shoulder screws; back panel.
Grease Cup
Holder
Grease Cup
Grease Pan
Install the self-tapping shoulder screws into the lowest holes in the rear leg panels.
Place the back panel, with the louvres facing down and to the rear, on top of the rear leg brace. Ensure that
the slots at the lower side flanges of the panel fit over the shoulder screws just installed in the rear leg
panels. Secure the top of the panel using two self-tapping screws in the holes provided at the top right and
left hand corners of the panel.
Shoulder
Screws
Screws

Page 8
VC400 ASSEMBLY
Step 13: Install Sear Plates, Cooking Grates, Warming Rack, and Smoker Boxes
Materials Required: Two sear plates; smoker box with lid; three cooking grates, and the warming rack.
Place the sear plates into the barbecue ensuring that
their edges are facing downward. The sear plate with
the large square cutout will house the smoker box. The
plate with the smoker box hole should be placed so that
it is closer to the rear of the unit on the left side of the
Grill. If the plates have arrows stamped on them,
position the plates so the arrows point to each other.
Place the lid on the smoker box.
Position the 3 cooking grates in the base unit with the
finger holes to the front. These may be turned over to
provide an angled flat surface for delicate foods.
Slip the rear lip of the warming rack into the two
supports extruding above the rotisserie burning hous-
ing.
Let it rest in a level position.
To use the rotisserie smoker box. Remove the warming
rack, and sit the box and lid on top of the rotisserie housing.
Step 14: Insert the Gas
Tank
Materials Required: Gas tank.
(Not supplied with barbecue)
Rotate the tank tip-out down until
its pivoting handle contacts the
ground. Place your propane tank
on the cradle of the tip-out. Rotate
the tip-out back to the upright
position.
Connect the tank to the main
regulator.
VERMONT
Castings
Sear
Plates (2)
Smoker
Box
Cooking
Grates (3)
Finger
Hole
Warming
Rack (1)

Page 9
VC400 ASSEMBLY
APPENDIXA
The contents of the VC400 parts kits included in the appliance pack should be as follows:
Step 15: Reinstall the Base Panels of the Cabinet
Materials Required: 2 side panels
Take the smaller base panel with the louvres facing down and out and attach it to the right side of the cabinet
by sliding the holes on the side of the panel onto the shoulder screws protruding from the legs. Push the
panel down to secure it in position.
Repeat for the left base panel.
Hand Hold
(Lift Up and Pull Out)
2
1
Shoulder
Screws
Box 1:
Warming Rack (1)
Rear Lower Panel (1)
Left Stainless Steel Side Shelf (1)
Right Stainless Steel Side Shelf (1)
Axle (1)
Box 2:
Shelf Support Assembly (2)
Left Stainless Steel Condiment Shelf (1)
Right Stainless Steel Condiment Shelf (1)
Bottom Panel - Plain (1)
Sear Plate - Right Hand (1)
Sear Plate - Left Hand (1)
Smoker Box-Rotisserie-Body (1)
Smoker Box-Rotisserie-Lid (1)
Tool Holder (1)
Parts Bag
#50000030 Smoker Box (1)
#50000032 Smoker Box Lid (1)
#50000092 Wheels (2)
#50000090 Casters (2)
#50000091 Caster Inserts (2)
Grease Cup (2)
Grease Cup Holder (1)
Handle Grip Top (3)
Handle Grip Bottom (3)
Hardware Kit (1)
Door Handle and Mounting Screws (2)
Box 3:
Cooking Grates (3)
Box 4:
Rotisserie Motor (1)
Spit Rod (1)
Spit Fork Kit (1)
Rotisserie Support Bracket (1)
Rotisserie Motor Bracket (1)
Rotisserie Bracket Guide (1)
Box 5:
Side Burner Assembly (1)
Side Burner Cover (1)
Side Burner Bracket (1)
Hinge Rod (1)
Push Nut - 1/4” (2)

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VC400 ASSEMBLY
VC400 ASSEMBLY DRAWING
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