Vermont Castings VCS4000 Manual

Page 1
VCS4000/5000 ASSEMBLYPROCEDURES
Tools Required: Knife or scissors; hammer; Phillips or #2 Robertson (square) screwdriver
Step 1: Unpack carton.
Cut the strapping on the package, then lift off the carton cap. Remove the sleeve by lifting it straight over
the top of the Barbecue. Remove and unpack the enclosed parts boxes. Remove any protective covering
from stainless steel parts.
Box #1
Box #4
Box #3
Box #2
50002159 2/04 Rev.0 En
VERMONT
Castings

Page 2
Step 2: Install casters.
Required: (2) casters
Prop up the left end of the grill with a block of
wood or other solid item.
Position a caster stem into the hole in each corner
of the bottom panel, and push as far as possible
by hand. (The holes are located approximately
3” (7 cm) in from the edges.)
Fig. 2
Caster
6 to 8”
Step 4: Attach shelf supports.
Required: (2) left shelf supports; (2) right shelf supports;
(8) 1/4–20 x 1/2” truss head bolts
2
1
Fig. 4
(8) 1/4 – 20 x 1/2” Truss Head Bolt
Thread four (4) bolts halfway into the right side of the grill
base. Hook a left and a right shelf support over the bolts;
push downward on the supports, then fully tighten the bolts.
Repeat for left side.
Step 3: Install wheels.
Required: (2) wheels; (2) axle supports; (2) axle caps; (1) axle
Ensure the casters (Step 2) are in the locked position. Support the right end of the the grill as in Step 2.
Insert the two (2) axle supports into the holes in the corners of the bottom panel. Ensure the flanges with the
large hole are turned to the front and back of the grill (Fig. 3a).
Push a cap on to 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 in the axle supports. Finally slide the other
wheel into place on the axle, again with the cone-shaped side facing inward, then tap the other axle cap onto
the axle (Fig. 3b).
VCS4000/5000 ASSEMBLY
Fig. 3bFig. 3a
Axle supports Axle
Wheel
Axle cap

Page 3
Step 5: Attach front and side shelves.
Required: (2) side shelves; (1) left and (1) right front shelf; (1) shelf insert; (6) #10–24 x 1/2” bolts;
(6) spring clip fasteners
Push a spring clip (teeth facing up) onto the inside
return flange at the end of each shelf support
(Fig. 5a), until it is centered over the hole in the
flange. Repeat for the two holes (one each corner)
in the bottom flange of the control console.
Hook the left and right front shelves over the
corresponding front shelf supports; push towards
the grill base. Attach to the bottom of the control
console with (1) bolt through the assembled spring
clip (Fig. 5b).
Assemble the side shelves to the shelf supports by positioning them half way over the supports, then sliding
them towards the base, while pushing down firmly on the front edge. The slots at the front edge of the shelf
should align with the tabs at the back of the shelf supports (Fig. 5c).
Tap the shelf lightly to fully engage the slot and tab if necessary
(Fig. 5d). Once aligned, fasten with two (2) bolts to the underside
of the supports through the assembled spring clips (Fig. 5c).
(6) Spring clip fasteners
(6) #10–24 x 1/2” Bolt
Fig. 5b
Fig. 5c
(View rotated 90°)
Slot
Tab
Fig. 5d
2
1
Fig. 5a
(View rotated
90°)
VCS4000/5000 ASSEMBLY

Page 4
VCS4000/5000 ASSEMBLY
Step 7: Remove packing tape; assemble grease cup.
Required: (1) grease cup
From inside the grill, remove shipping tape from the grease pan and base assembly (Fig. 7a), and from the
warming rack. For Model VCS5000, remove the tape from the front pullout drawer.
Install a grease cup into the hole in the upper base panel (Fig. 7b). Ensure the opening in the grease pan is
positioned above the cup.
Step 6: Attach door handles,
(*drawer handle), and
knobs.
Required: (2) (3*) door handles;
(4) (6*) bolts; (5) (6*) knobs
Attach (2) door handles to the front doors
with (4) bolts provided.
Push the control knobs onto the valve
stems, ensuring the flats on the stems are
aligned to those in the knobs.
* Model VCS5000 has an additional
handle for the pull-out drawer, as
shown.
Fig. 7a Fig. 7b
Fig. 6
Remove
shipping
tape.
*

Page 5
VCS4000/5000 ASSEMBLY
Step 8: Install internal components.
Required: (4) (5 for VCS5000) sear plates; (3) (4 for VCS5000) cooking grates; (1) warming rack
Place the sear plates into the base unit,
ensuring the edge with the finger hole
faces the grill front.
Position the cooking grates into the base
with the finger holes facing the front.
NOTE: The cooking grates may be turned
over to provide a flat surface for cooking
delicate foods.
Set the warming rack into the two supports
in the ends of the rear lid (Fig. 8).
To use the rotisserie smoker box, remove
the warming rack and set the box and lid
on top of the rotisserie housing.
Step 9: Install the LP cylinder (LP Models only).
Required: LP gas cylinder
NOTE: Refer to the User’s Manual for the cylinder filling
requirements, regulator attachment, and leak testing
procedures, before lighting the grill.
Insert the propane (LP) cylinder into the hole provided
in the bottom panel. Connect the cylinder to the
regulator.
Warming
rack (1)
Finger
hole
Sear
plates (4/5)
Cooking
grates (4/5)
Fig. 9
Fig. 8

VCS4000/5000ASSEMBLY DRAWING
5
13
26
54
50
10
27
48
47
16
15
53
14
9 33
1 7
2
23
24
11
12
17
4 25
19
21
29
31
42
28 18
36
32
43
44
46
22
49
52
20
30
51 8
38
3
6
37
39
35
40
34
41
45

VCS4000/5000 PARTS LIST
ITEM DESCRIPTION No. Reqd. VCS4000 VCS5000
1 BaseAssembly 1 50001815 50001816
2 IgnitorAssembly Kit, 6-Pole 1 50001619 50001619
3 ConsoleAssembly 1 50002137 50002136
4 LidAssembly, Rear 1 50001537 50001538
5 Front Lip 1 50001818 50001819
6.a ValveAssembly, LP 1 50001402 50000803
6.b ValveAssembly, Natural Gas 1 50001423 50000852
7 Regulator - H 1 50000804 5000-804
8 Bezel 5/6 50001327 50001327
9 Burner MainAssembly 4/5 50000835 50000835
10 Gasket, Burner 4/5 50000892 50000892
11 Electrode, Main - Long 2/3 50000523 50000523
12 Electrode, Main - Short 2 50000431 50000431
13 Flash Tube 1 50000879 50000880
14.a Tube and OrificeAssembly - LP 1 50001415 50000819
14.b Tube and OrificeAssembly - Natural Gas 1 50001428 50000818
15 Rotisserie Housing/ ScreenAssembly 1 50001416 50000961
16 Burner RotisserieAssembly 1 50000047 50000875
17 Electrode, Rotisserie 1 50000981 50000981
18 Cabinet End 2 50001929 50001918
19 Cabinet Form Block 4 50001835 50001835
20 Strut 2/3 50001838 50001841
21 Panel, Tank 1 50001916 50001936
22 Panel Back 1 50001878 50001879
23 Hardware - Lid Set 1 50000355 50000355
24 LidAssembly, Front 1 50002115 50002116
25 Lid Bumpers 4/6 50000177 50000177
26 Warming Rack, Enamel 1 50000802 50000889
27 Cook Grate 1 50001226 50001227
28 Door Assembly - Right 1 50002107 50002142
29 DoorAssembly - Left 1 — 50002145
30 Support, Grease Pan 2 50001844 50001844
31 Front Warming DrawerAssembly 1 — 50001942
32 Grease PanAssembly 1 50001842 50002157
33 Gauge,Temperature 1 50000967 50000967
34 12’ Natural Gas Hose 1 50000198 50000198
35 Connector Hose - 3/8 Q.D.Assembly 1 50000915 50000915
36 Fascia Panel, Front 1 50002031 —
37 Axle 1 50000093 50000093
38 Axle SupportAssembly 2 50002148 50002148
39 Caster 2 50000090 50000090
40 Grease Cup 1 50001845 50001845
41 Hardware Bag 1 50002130 50002130
42 Shelf, Front, Left - HL 1 50000986 50000986
43 Shelf, Front, Right - HL 1 50000984 50000984
44 Shelf Insert - S/S 1 50000826 50000826
45 Shelf Top - H - S/S 1 50001412 50001412
46 Shelf Top Solid - H - S/S 1 50001413 50001413
47 Support, Shelf, Left - Black 2 50001418 50001418
48 Support, Shelf, Right - Black 2 50001419 50001419
49 Wheel - 6” Diameter 2 50002151 50002151
50 Plate, Heat - H - S/S 4/5 50000777 50000777
51 Knob - H Style 5/6 50001328 50001328
52 Handle, Door - Deluxe 2/3 50000313 50000313
53 Smoke Box Body 1 50001038 50001038
54 Smoke Box Lid 1 50001039 50001039
N/S Side Burner Kit - LP 1 — 50002215
N/S Side Burner Kit - Natural Gas 1 — 50002214

Vermont Castings, Majestic Products
410 Admiral Boulevard
Mississauga, Ontario, Canada L5T 2N6
Phone: [phone]
www.majesticproducts.com • www.vermontcastings.com