Master Forge 1010037 Owner's Manual

Questions, problems, missing parts? Before returning to your retailer, call our

customer service department at 1-800-963-0211, 8 a.m. - 6 p.m., EST, Monday Thursday, 8 a.m. - 5 p.m., EST, Friday.

WARNING

Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Read this instruction manual thoroughly before installing or servicing this equipment.

DANGER

If you smell gas:

1. Shut off gas to the appliance.

2. Extinguish any open flames.

3. Open the lid.

4. If the odor continues, keep away from the appliance and immediately call your gas supplier or fire department.

WARNING

For Outdoor Use Only

ITEM #0097709

4-BURNER GAS GRILL

MODEL #1010037

WARNING

1, Do not store or use gasoline or other flammable liquids or vapors in the vicinity of this or any other appliance. 2, An LP tank not connected for use should not be stored in the vicinity of this or any other appliance.

ATTACH YOUR RECEIPT HERE

Serial Number________________ Purchase Date_________________

TABLE OF CONTENTS

Safety Information………………………………………………………………………………….3

Package Contents……………………………..…………………….…….……………………....5

Hardware Contents………………………………….……………………….…………..…….…..7

Preparation………………….…….………………………….………………….………...….….….7

Assembly Instructions……………………..………………………….……………….……..……8

Installation Instructions…………………………………………………………………………...17

Operating Instructions…………………………………………………………………………… 21

Care and Maintenance…………………………………………………………………………….24

Troubleshooting . ………………………………………………………………………………….30

Warranty………………………………………………………………………………………….…..32

Replacing Main Burner…………………………………………………………………………….33

Exploded View ……………………………………………………………………………….……34

Replacement Parts List………………………………………………………………………… 35

Converting to Natural Gas Kit #0050772……………………… ………………………….…... 37

18 in.

12.2 in.

8 in.

13.9 in.

Please read and understand this entire manual before attempting to assemble, operate or install the product. If you have any questions regarding the product, please call

customer service at 1-800-963-0211 Monday through Thursday from 8:00 a.m. to 6:00 p.m. EST, Friday from 8:00 a.m. to 5:00 p.m. EST.

1. The installation of this appliance must conform with local codes or, in the absence of local

codes, with either the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or Natural Gas and Propane Installation Code, CSA/CGA-B149.1.

2. This grill is intended for use outdoors and should not be used in a building, garage or any other enclosed or covered area.

3. This outdoor grill is not intended for installation in or on recreation vehicles and/or boats.

4. A minimum clearance of 48 in. from combustible constructions to the sides of the grill

and 48 in. from the back of the grill to combustible constructions must be maintained. This outdoor cooking gas appliance must not be placed under overhead combustible construction.

5. The use of an electrical source requires that when installed, the grill must be electrically

grounded in accordance with local codes or, in the absence of local codes, with ANSI/NFPA 70, or the Canadian Electrical Code, CSA C22.1. Keep electrical supply cords and the fuel supply hose away from heated surfaces.

6. Inspect the hoses before each use for excessive abrasion or wear, or cuts that may affect

safe operation of the grill. If there is evidence of excessive abrasion or wear, or the hose is cut, it must be replaced prior to the grill being put into operation. The replacement hose assembly must be those specified by the manufacturer.

7. Keep your grill in an area clear and free from combustible materials, gasoline and other

flammable vapors and liquids.

8. DO NOT obstruct the flow of combustion and ventilation air to this appliance.

9. Keep the ventilation openings of the tank enclosure free and clear from debris.

10. Check all gas connections for leaks with a soapy water solution and brush. Never use an

open flame to check for leaks.

11. Never use charcoal in the grill.

12. Never use the grill in windy areas.

13. Only a 20 lb. LP-gas cylinder is allowed. The cylinder must be

constructed and marked in accordance with the Specifications for LP Gas Cylinders of the U.S. Department of Transportation (D.O.T.) or the National Standard of Canada, CAN/CSA-B339, Cylinders, Spheres and Tubes for Transportation of Dangerous Goods; and Commission. A 20 lb. LP-gas cylinder dimensions are:

14. Never use the grill without the drip tray installed and hung under the burner box. Without

the drip tray, hot grease and debris could leak downward and produce a fire hazard.

15. Use only the gas pressure regulator supplied with this appliance. This regulator is set for

an outlet pressure of 11.0 wc.

16. The cylinder used must include a collar to protect the cylinder valve.

SAFETY INFORMATION

17. Do not store a spare LP-gas cylinder under or near this appliance.

18. Never fill the cylinder beyond 80 percent full.

19. If the information in “17” and “18” is not followed exactly, a fire causing death or serious

injury may occur.

20. The natural gas grill and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 0.5 PSI (3.5 KPa).

21. The outdoor cooking gas appliance must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply system at test pressures equal to or less than 0.5 PSI (3.5 KPa).

22. CALIFORNIA PROPOSITION 65 WARNING: The burning of gas cooking fuel generates some byproducts which are on the list of substances known by the state of California to cause cancer, reproductive harm, or other birth defects. To reduce exposure to these substances, always operate this unit according to the use and care manual, ensuring you provide good ventilation when cooking with gas.

IMPORTANT: We urge you to read this manual carefully and follow the recommendations enclosed. This will ensure you receive the most enjoyable and

trouble-free operation of your new gas grill. We also advise you retain this manual for future reference.

WARNING: Your grill has been designed to operate using only the gas specified by the manufacturer on the rating plate. Do not attempt to operate your grill on other gases. Failure to follow this warning could lead to a fire hazard and bodily harm and will void your warranty.

WARNING: Make certain your LP (propane) tank is filled by a reputable propane dealer. An incorrectly filled or an overfilled LP tank can be dangerous. The overfilled condition combined with the warming of the LP tank (a hot summer day, tank left in the sun, etc.) can cause LP gas to be released by the pressure relief valve on the tank since the temperature increase causes the propane to expand. LP gas released from the tank is flammable and can be explosive. Refer to your owner’s manual for more information concerning filling your LP tank.

PACKAGE CONTENTS

1Side burnerE11LP tank barrier barO

1Left side cart panelP

1Grease trayD11Left shelf frontN

1Grease cupC11Left shelf bracketM

1Right side cart panelB11Left shelfL

1Right cart doorA11Grill headK

2Straight casterZ1Back grill head coverJ

1Door catch plateY1Cart back panelI

1Cart support beamX1Control knobH

1Cart baseW1BezelG

2Locking casterV1Right shelf bracketF

2Cart support bracketU1Right shelf frontE

1Cart heat shieldT1Right shelfD

4Door handle grommetS4Flame tamerC

2Door handleR2Cooking grateB

1Left cart doorQ1Warming rackA

QuantityDescriptionPartQuantityDescriptionPart

HARDWARE CONTENTS

1/4-20 x 1/2 in.

Screw

Qty. 26

1/4-20 x 3/8 in.

Screw Qty. 23

5/32-32 x 3/8 in.

Screw Qty.16

1/4-20 Lock

Washer Qty. 22

1/4-20 x 5/16 in.

Screw Qty.10

Before beginning assembly of product, make sure all parts are present. Compare parts with package contents list and hardware contents list. If any part is missing or damaged, do not attempt to assemble the product.

Estimated Assembly Time: 40 minutes by two people Tools Required for Assembly: Phillips Screwdriver (not included).

PREPARATION

AA Battery

Allen Wrench

AA BB CC DD EE

ASSEMBLY INSTRUCTIONS

1. Fix the tank tray bolt

1/4-20 x 1/2 in. Screw

x 16

1/4-20 lock Washer

x 16

Tank tray bolt

Remove the LP tank bolt on the cart base (W) as shown in Fig. 1A and then reinstall as shown in Fig. 1B.

Note: For all of the following steps, do not tighten any screws completely until all screws for that step have been installed. Once all screws have been installed, then tighten them securely.

2. Install casters

a) With the cart base (W) laying as shown in Fig. 2, attach the 2 straight casters (Z) as shown to the left side of the cart base (W) using 8 1/4-20 x 1/2 in. screws (BB) and 8 1/4-20 lock washers (DD). Install all screws first and then tighten.

b) Attach the 2 locking casters (V) to the right side of the cart base (W) using 8 1/4-20 x 1/2 in. screws (BB) and 8 1/4-20 lock washers (DD). Install all screws loosely first and then tighten.

Hardware Used

Note: For ease of assembly, lock the 2 locking casters (V) prior to proceeding to

the next steps.

ASSEMBLY INSTRUCTIONS

x 7

1/4-20 x 3/8 in.

Screw

Hardware Used

x 2

5/32-32 x 3/8 in.

Screw

1/4-20 x 3/8 in.

Screw

x 6

3. Attach door catch plate

Turn the cart base (W) assembly right side up as shown in Fig. 3. Attach door catch plate (Y) to cart base (W) using 2 5/32-32 x 3/8 in. screws (AA).

Hardware Used

4. Install cart side panels

Attach left cart side panel (P) to cart base (W) using 3 1/4-20 x 3/8 in. screws (CC).

Attach right cart side panel (B1) to cart base (W) using 3 1/4-20 x 3/8 in. screws (CC) as shown in Fig. 4.

5. Install cart back panel

Attach cart back panel (I) to cart base (W) using 1 1/4-20 x 3/8 in. screw (CC). Fasten cart back panel (I) to the left side cart panel (P) and right side cart panel (B1) using 6 1/4-20 x 3/8 in. screws (CC) as shown is Fig. 5.

Install the top screw first when assembling and install all screws loosely first and then tighten.

ASSEMBLY INSTRUCTIONS

Hardware Used

x 2

5/32-32 x 3/8 in.

Screw

Hardware Used

x 4

5/32-32 x 3/8 in.

Screw

Hardware Used

1/4-20 x 3/8 in.

Screw

x 4

6. Install LP tank barrier bar

Attach the LP tank barrier bar (O) as the arrows indicate to the cart back panel (I) and the cart base (W) using 2 5/32-32 x 3/8 in. screws (AA) as shown in Fig. 6. The right install direction should be same as the indicate.

7. Install cart support beam

Attach the cart support beam (X) to the left and right side cart panels (P and B1) using 4 1/4-20 x 3/8 in. screws (CC) as shown in Fig. 7.

Make sure the magnets on the cart support beam (X) face outward and the holes face downward when assembling .

8. Install cart support brackets

Attach the cart support brackets (U) to the cart support beam (X) and to the left and right side cart panels (P and B1) using 4 5/32-32 x 3/8in. screws (AA) as shown in Fig. 8.

Install all screws loosely first and then tighten.

ASSEMBLY INSTRUCTIONS

1/4-20 x 1/2 in.

Screw

x 4

Hardware Used

x 4

5/32-32 x 3/8 in.

Screw

Hardware Used

9. Install cart heat shield

Attach the cart heat shield (T) to the cart back panel (I) using 2 5/32-32 x 3/8 in. screws (AA).

Note that the heat shield installs under the lip of the cart back panel (I) as shown in Fig 9A.

Next attach the cart heat shield (T) to the cart support beam (X) using 2 5/32-32 x 3/8 in. screws (AA) as shown

in Fig. 9B.

Note that the cart heat shield (T) installs on top of the lip of the cart support beam (X).

10. Install grill head to cart

Caution grill head is heavy. To avoid injury, obtain the help of an assistant for this step.

With the assistance of a helper, remove the grill head (K) from the packaging and place on top of the grill cart as shown in Fig. 10A. Attach the grill head (K) to the left and right side cart panels (P and B1) using 4 1/4-20 x 1/2 in. screws (BB) as shown in Fig. 10B.

10A

10B

ASSEMBLY INSTRUCTIONS

x 6

1/4-20 x 3/8 in.

Screw

K B1

Hardware Used

11. Install grease tray

Remove the pre-installed screw from the right of the greasy tray (D1).

From the back of the grill, slide the grease tray (D1) onto the ledges on the left and right sides of the grill head as shown in Fig. 11.

There are stops built into the ledges to hold the grease tray in place. Make sure the grease tray is slid all the way in and is resting securely between these stops.

From the front of the grill, reinstall the screw into the grease tray through the supporting ledge. This will prevent the grease tray from shifting during transport.

The correct direction is shown in the picture.

12. Install grease cup

Insert the grease cup (C1) onto the ledges of the grease tray (D1) underneath the grill head as shown in Fig. 12.

The handle of the grease cup needs to be tilted down slightly in order for it to slide into the grease tray ledges.

13. Install back grill head cover

Put the back grill head cover (J) into the hole on the back panel (I) first. Then attach the back grill head cover (J) as shown in Fig. 13 using 6 1/4-20 x 3/8 in. screws (CC).

Install all screws loosely first and then tighten.

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