vcs4000/5000 assembly procedures

VCS4000/5000 ASSEMBLY PROCEDURES
Tools Required: Knife or scissors; hammer; Phillips or #2 Robertson (square) screwdriver
Step 1: Unpack carton.
VERM
O
C NT
astings
Box
#4
Box
#1
Box
#2
Box
#3
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.
Page 1
50002159 2/04 Rev.0 En
VCS4000/ 5000 ASSEMBLY
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.)
Caster
6 to 8”
Fig. 2
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).
Axle
Axle supports
Wheel
Axle cap
Fig. 3a
Fig. 3b
Step 4: Attach shelf supports.
Required: (2) left shelf supports; (2) right shelf supports;
(8) 1/4–20 x 1/2” truss head bolts
1
(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.
2
Repeat for left side.
Fig. 4
Page 2
VCS4000/ 5000 ASSEMBLY
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
Fig. 5a
(6) #10–24 x 1/2” Bolt
1
(6) Spring clip fasteners
(View rotated
90°)
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).
2
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).
Slot
Tab
(View rotated 90°)
Fig. 5d
Fig. 5c
Page 3
VCS4000/ 5000 ASSEMBLY
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. 6
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.
Remove
shipping
tape.
Fig. 7a
Page 4
Fig. 7b
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).
Sear
plates (4/ 5)
Cooking
grates (4/ 5)
Warming
rack (1)
Finger
hole
To use the rotisserie smoker box, remove
the warming rack and set the box and lid
on top of the rotisserie housing.
Fig. 8
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.
Fig. 9
Page 5
VCS4000/5000 ASSEMBLY DRAWING
15
14
4
16
25
47
23
17
48
24
53
12
11
54
27
50
1
7
2
26
33
9
10
13
40
6
5
41
3
34
32
35
43
51
19
8
37
30
38
20
42
39
36
52
22
31
49
44
29
28
18
21
46
45
VCS4000/5000 PARTS LIST
ITEM
1
2
3
4
5
6.a
6.b
7
8
9
10
11
12
13
14.a
14.b
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
N/S
N/S
DESCRIPTION
Base Assembly
Ignitor Assembly Kit, 6-Pole
Console Assembly
Lid Assembly, Rear
Front Lip
Valve Assembly, LP
Valve Assembly, Natural Gas
Regulator - H
Bezel
Burner Main Assembly
Gasket, Burner
Electrode, Main - Long
Electrode, Main - Short
Flash Tube
Tube and Orifice Assembly - LP
Tube and Orifice Assembly - Natural Gas
Rotisserie Housing/ Screen Assembly
Burner Rotisserie Assembly
Electrode, Rotisserie
Cabinet End
Cabinet Form Block
Strut
Panel, Tank
Panel Back
Hardware - Lid Set
Lid Assembly, Front
Lid Bumpers
Warming Rack, Enamel
Cook Grate
Door Assembly - Right
Door Assembly - Left
Support, Grease Pan
Front Warming Drawer Assembly
Grease Pan Assembly
Gauge, Temperature
12’ Natural Gas Hose
Connector Hose - 3/8 Q.D. Assembly
Fascia Panel, Front
Axle
Axle Support Assembly
Caster
Grease Cup
Hardware Bag
Shelf, Front, Left - HL
Shelf, Front, Right - HL
Shelf Insert - S/S
Shelf Top - H - S/S
Shelf Top Solid - H - S/S
Support, Shelf, Left - Black
Support, Shelf, Right - Black
Wheel - 6” Diameter
Plate, Heat - H - S/S
Knob - H Style
Handle, Door - Deluxe
Smoke Box Body
Smoke Box Lid
Side Burner Kit - LP
Side Burner Kit - Natural Gas
No. Reqd.
VCS4000
VCS5000
1
1
1
1
1
1
1
1
5/6
4/5
4/5
2/3
2
1
1
1
1
1
1
2
4
2/3
1
1
1
1
4/6
1
1
1
1
2
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
2
2
2
4/5
5/6
2/3
1
1
1
1
50001815
50001619
50002137
50001537
50001818
50001402
50001423
50000804
50001327
50000835
50000892
50000523
50000431
50000879
50001415
50001428
50001416
50000047
50000981
50001929
50001835
50001838
50001916
50001878
50000355
50002115
50000177
50000802
50001226
50002107
—
50001844
—
50001842
50000967
50000198
50000915
50002031
50000093
50002148
50000090
50001845
50002130
50000986
50000984
50000826
50001412
50001413
50001418
50001419
50002151
50000777
50001328
50000313
50001038
50001039
—
—
50001816
50001619
50002136
50001538
50001819
50000803
50000852
5000-804
50001327
50000835
50000892
50000523
50000431
50000880
50000819
50000818
50000961
50000875
50000981
50001918
50001835
50001841
50001936
50001879
50000355
50002116
50000177
50000889
50001227
50002142
50002145
50001844
50001942
50002157
50000967
50000198
50000915
—
50000093
50002148
50000090
50001845
50002130
50000986
50000984
50000826
50001412
50001413
50001418
50001419
50002151
50000777
50001328
50000313
50001038
50001039
50002215
50002214
Vermont Castings, Majestic Products
410 Admiral Boulevard
Mississauga, Ontario, Canada L5T 2N6
Phone: (905) 670-7777
www.majesticproducts.com • www.vermontcastings.com