Master Forge Cg2053401-mf Owner's Manual

ITEM #0182316

BARREL CHARCOAL GRILL

MODEL #CG2053401-MF

Français p. 25 Español p. 51

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.

Serial Number

_________________

Purchase Date

_________________

__________________________________________________________________________

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., Friday.

AB1311

TABLE OF CONTENTS_____________________________________________________

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

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

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

Preparation……………………………………………………………………………………

Assembly Instructions………………………………………………………………............. 9

Operating Instructions……………………………………………………………………….. 17

Care and Maintenance……………………………………………………………………… 21

Troubleshooting……………………………………………………………………………… 21

Warranty………………………………………………………………………………………. 22

Replacement Parts List……………………………………………………………………… 23

DANGER:

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING:

Be alert to the possibility of serious bodily injury if the instructions are not followed. Be sure to read and carefully follow all of the messages.

CAUTION:

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

PACKAGE CONTENTS_______________________________________________________

PART

DESCRIPTION QUANTITY

PART

DESCRIPTION QUANTITY

A Leg Brace 2 K Side Table 1 B Front Leg 2 L Chimney Cover 1 C Rear Leg 2 M Chimney 1 D Wire Rack 1 N Lid 1 E Stabilizing Plate 2 O Temperature Gauge 1 F Axle 1 P Handle 1

G Wheel 2 Q Lid Hinge 2 H Grill Body 1 R Charcoal Rack 1

I Body Hinge 2 S Cooking Grate 1

J Air Vent 1 T Handle Base 2

HARDWARE CONTENTS

(shown actual size)________________

__________________________

M6 x 12 M8 M6 M6 Spring

Insulation

Screw Cap Nut Lock Nut Flange Cotton Washer

M6 x 30

Hinge M6 x 40 Screw Pin Screw

SAFETY INFORMATION__________________________________________________

Please read and understand this entire manual before attempting to assemble, operate or

install the product. If you have any questions regarding this product, please call customer service at 1–800–963–0211, 8 a.m. - 6 p.m., EST, Monday - Thursday; 8 a.m. - 5 p.m., Friday.

1. Only use this grill on a hard, level, non-combustible, stable surface (concrete, ground, etc.) capable of supporting the weight of the grill. Never use on wooden or other surfaces that could burn.

2. DO NOT use grill without charcoal rack in place. DO NOT attempt to remove charcoal rack while coals are hot.

3. When grill is in use, keep clearance of 36 inches between the hot grill and any combustible materials, such as bushes, trees, wooden decks, wooden fences, buildings, etc. Do not place hot grill under roof overhang or in any other enclosed area.

4. For outdoor use only. Do not operate grill indoors or in an enclosed area.

5. For household use only. Do not use this grill for other than its intended purpose.

6. Use of a charcoal chimney starter is recommended to avoid the dangers associated with charcoal lighting fluid. If you choose to use charcoal lighting fluid, only use lighting fluid approved for lighting charcoal. Carefully read manufacturer’s warnings and instructions on the charcoal lighting fluid and charcoal prior to use. Store charcoal lighting fluid safely away from grill.

7. When using charcoal lighting fluid, allow charcoal to burn with grill lid and doors open until covered with a light ash (approximately 20 minutes). This will allow charcoal lighting fluid to burn off. Failure to do this could trap fumes from charcoal lighting fluid in grill and may result in a flash fire or explosion when lid is opened.

8. Never use charcoal that has been pre-treated with lighting fluid. Use only a high grade plain charcoal or charcoal/wood mixture.

9. Do not use gasoline, kerosene or alcohol for lighting charcoal. Use of any of these or similar products could cause an explosion possibly leading to severe bodily injury.

10. Never add charcoal lighting fluid to hot or even warm coals as flashback may occur causing severe burns.

11. Place grill in an area where children and pets cannot come into contact with unit. Close supervision is necessary when grill is in use.

SAFETY INFORMATION__________________________________________________

12. Do not leave grill unattended when in use.

13. When adding charcoal and/or wood, use extreme caution and follow instructions in “Adding Charcoal/Wood During Cooking” section of this manual.

14. Do not store or use grill near gasoline or other flammable liquids, gases or where flammable vapors may be present.

15. Do not store lighter fluid or other flammable liquids or materials under the grill.

16. Use caution when removing cooking grate and charcoal rack; use protective gloves or oven mitt. Cooking grate and charcoal rack will be hot when in use.

17. Grill is hot when in use. To avoid burns:

 DO NOT attempt to move the grill.  Wear protective gloves or oven mitts.  DO NOT touch any hot grill surfaces.  DO NOT wear loose clothing or allow hair to come in contact with grill.

18. When grilling, grease from meat may drip into the charcoal and cause a grease fire. If this should happen, close lid to suffocate the flame. Do not use water to extinguish grease fires.

19. Use caution when opening the lid, keeping hands, face and body a safe distance away. Flash flare-ups may occur when air comes into contact with fire or hot coals.

20. Never place more than 5 pounds on side shelf. Do not lean on the side shelf. Always ensure side shelf is securely fastened.

21. Do not allow charcoal and/or wood to rest on the walls of grill. Doing so will greatly reduce the life of the metal and finish of your grill.

22. Use caution during assembly and while operating your grill to avoid scrapes or cuts from sharp edges of metal parts. Use caution when reaching into or under grill.

23. When opening lid, be sure lid is fully opened and secure to prevent lid from closing unexpectedly.

24. In windy weather, place grill in an outdoor area that is protected from the wind.

25. Close lid to suffocate flame.

SAFETY INFORMATION__________________________________________________

26. Never leave coals and ashes in grill unattended. Before grill can be left unattended, remaining coals and ashes must be removed from grill. Use caution to protect yourself and property. Carefully place remaining coals and ashes in a non-combustible metal container and saturate completely with water. Allow coals and water to remain in metal container 24 hours prior to disposing.

27. Extinguished coals and ashes should be placed a safe distance from all structures and combustible materials.

28. With a garden hose, completely wet the surface beneath and around grill to extinguish any ashes, coals or embers which may have fallen during the cooking or cleaning process.

29. After each use, clean the grill thoroughly and apply a light coating of vegetable oil to all interior surfaces prevent rusting. Cover the grill to protect it from excessive rusting.

30. Use caution when lifting or moving grill to prevent strains and back injuries.

31. It is recommended that a fire extinguisher be kept on hand. Refer to your local authority to determine proper size and type of fire extinguisher.

32. Store the grill out of reach of children and in a dry location when not in use.

33. Do not attempt to perform services on the grill other than normal maintenance as explained in “After-Use Safety” and “Care & Maintenance” sections of this manual.

34. Properly dispose of all packaging material.

Failure to adhere to safety warnings and guidelines in this manual could result in bodily injury or property damage.

Save this manual for future reference.

PREPARATION____________________________________________________________

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 product.

Estimated Assembly Time: Less than 30 minutes

Tools Required for Assembly (not included): Pliers, Phillips Screwdriver, Flathead Screwdriver,

Adjustable Wrench.

ASSEMBLY INSTRUCTIONS__________ _____________________________________

1. Insert front legs (B) into leg braces (A).

Insert rear legs (C) into leg braces (A).

2. Insert corners of the wire rack (D) into the brackets on the legs. Rotate the assembled legs toward the center of the wire rack (D).

3. Attach stabilizing plates (E) on both ends of assembled legs using 8 screws (AA) and 8 flange nuts (FF).

HARDWARE USED______________

M6 x

Screw

x 8

Flange

Nut

x 8

4. Thread the axle (F) through the holes at the end of front legs (B). The axle will extend from the outside of both legs. Put a wheel (G) on both ends of the axle. Insert the cotter pin (II) in the end of each axle to hold wheels in place.

HARDWARE USED___ ______

Cotter

x 2

5. Set grill body (H) on the assembled leg frame and secure with 4 screws (AA) and 4 flange nuts (FF).

* Note: Holes for shelf bracket on grill body (H) need to face the opposite side as assembled wheels.

Tighten all hardware.

HARDWARE USED__________

M6 x

Screw

x 4

Flange

Nut

x 4

6. Attach air vent (J) to the grill body (H) with 1 screw (CC) and 1 lock nut (EE). The toggle must face and point outward from grill.

Attach each body hinge (I) to the back of the grill body (H) with 2 screws (BB) and 2 lock nuts (EE).

HARDWARE USED_________

M6 x 30

Screw

x 4

M6 x 12

Screw

x 1

Lock

Nut

x 5

7. Align the screw holes of the bracket of the side table (K) with the two pair of holes located on the side of the body (H). Use a pair of screws (CC) and a pair of flange nuts (FF) at each bracket to secure the side table (K) to the grill body (H).

HARDWARE USED_________

M6 x 12

Screw

x 4

Flange

Nut

x 4

8. Place chimney cover (L) on chimney (M) and secure with 1 spring (GG) and 1 cap nut (DD).

HARDWARE USED__________

Cap

Nut

x 1

Spring

x 1

9. Thread the two sidebolts of the chimney (M) through the two holes located on the side of the lid (N). Use a pair of flange nuts (FF) to secure the chimney (M).

HARDWARE USED__________

Flange

Nut

x 2

10. Remove the nut from the temperature gauge (O), attach the gauge to the front of the lid (N), replace nut and tighten.

Using 2 screws (CC), attach the handle (P) and insulation washer (JJ) and handle base (T) to the lid (N) via the two holes below the nameplate.

HARDWARE USED___

________

M6 x 12

Screw

x 2

Insulation

Washer

x 2

11. Attach the lid hinge (Q) to the lid (N) with 2 screws (BB) and 2 lock nuts (EE) for each hinge, on the outside of lid (N).

HARDWARE USED________ __

M6 x

Screw

Lock

Nut

12. Place the lid (N) on grill body (H). Align holes in the lid hinges (Q) with holes in body hinges (I) and insert hinge pins (HH) to connect hinges.

Insert a cotter pin (II) into the holes on each hinge pin (HH).

HARDWARE USED__________

Hinge

x 2

Cotter

x 2

13. Place the charcoal rack (R) inside the grill body (H), followed by the cooking grate (S).

14. If you find the lid (N) and the grill body (H) do not align properly, try the following steps to rectify the problem.

1. Loosen the bolts and

nuts on the lid hinge (Q) and the body hinge (I). Remove the hinge pins (HH).

2. Re-align the lid (N) and

the grill body (H). Then Insert the hinge pins (HH).

3. Tighten the bolts and

nuts on the lid hinge (Q) and the body hinge (I).

15. Tighten all hardware.

OPERATING INSTRUCTIONS_______________________________________________

WARNING: DO NOT use grill without charcoal rack in place. DO NOT attempt to remove charcoal rack

while rack contains hot coals.

WARNING: Place the grill outdoors on a hard, level, non-combustible surface away from roof overhang or any combustible material. Never use on wooden or other surfaces that could burn. Place the grill away from open windows or doors to prevent smoke from entering your house. In windy weather, place the grill in an outdoor area that is protected from the wind.

WARNING: Read all safety warnings and instructions carefully before operating your grill.

CURING YOUR GRILL

Prior to your first use of the grill, follow the instructions below carefully to cure your grill. Curing your grill will minimize damage to the exterior finish as well as rid the grill of paint odor that can impart unnatural flavors to the first meal prepared on the grill.

IMPORTANT: To protect your grill from excessive rust, the unit must be properly cured and covered

at all times when not in use.

Step 1

Lightly coat all interior surfaces of the grill with vegetable oil or vegetable oil spray. Do not coat charcoal rack.

Step 2 Follow the instructions below carefully to build a fire. You may use charcoal and/or wood as fuel in the grill (see “Adding Charcoal/Wood During Cooking” section of this manual).

WARNING: Never use charcoal that has been pre-treated with lighter fluid. Use only a high grade

plain charcoal or charcoal/wood mixture. If using a charcoal chimney starter, follow all manufacturer’s warnings and instructions regarding use. Start with 2.6 – 2.8 pounds of charcoal. This should be enough charcoal to cook with, once the curing process has been completed. When charcoal is burning strongly, carefully place hot coals on charcoal rack.

NOTE: To extend the life of your grill, make sure that hot coals and wood do not touch the walls of grill.

IF USING CHARCOAL CHIMNEY STARTER, PROCEED TO STEP 5.

If you choose to use charcoal lighting fluid, ONLY use charcoal lighting fluid approved for lighting charcoal. Do not use gasoline, kerosene, alcohol or other flammable material for lighting charcoal. Follow all manufacturer’s warnings and instructions regarding use. Start with 2.6 – 2.8 pounds of charcoal. This should be enough charcoal to cook with, once the curing process has been completed. Place the charcoal in the center of charcoal rack.

Step 3

Saturate charcoal with lighting fluid. With lid open, wait 2 to 3 minutes to allow lighting fluid to soak into charcoal.

Store lighting fluid a safe distance from the grill.

Step 4

With grill lid open, stand back and carefully light charcoal. Allow to burn until covered with a light ash (approximately 20 minutes).

WARNING: Charcoal lighting fluid must be allowed to completely burn off prior to closing grill lid (approximately 20 minutes). Failure to do this could trap fumes from charcoal lighting fluid in grill and may result in a flash-fire or explosion when lid is opened.

Step 5

With coals burning strong, close the lid. Allow the temperature to reach 225°F (107°C) on temperature gauge. Maintain this temperature for 2 hours.

Step 6

Increase the temperature to 400°F (205°C) on temperature gauge. This can be achieved by adding more charcoal and/or wood (see “Adding Charcoal/Wood During Cooking“ section of this manual). Maintain this temperature for 1 hour then allow unit to cool completely.

NOTE: It is important that the exterior of the grill is not scraped or rubbed during the curing process.

IMPORTANT: To protect your grill from excessive rust, the unit must be cured periodically and covered at all times when not in use.

COOKING WITH YOUR GRILL

Step 1

Lightly coat all interior surfaces of the grill including cooking grills with vegetable oil or vegetable oil spray. Do not coat charcoal rack.

Step 2 Follow the instructions below carefully to build a fire. You may use charcoal and/or wood as fuel in the

barrel grill (see “Adding Charcoal/Wood During Cooking” section of this manual).

WARNING: Never use charcoal that has been pre-treated with lighter fluid. Use only a plain charcoal or charcoal/wood mixture.

If using a charcoal chimney starter, follow all manufacturer’s warnings and instructions regarding use, and start with 2.6 – 2.8 pounds of charcoal. When charcoal is burning strong, carefully place hot coals in center of charcoal rack.

WARNING: DO NOT use grill without charcoal rack in place. DO NOT attempt to remove charcoal rack while rack contains hot coals.

NOTE: To extend the life of your grill, make sure that hot coals and wood do not touch the walls of grill.

IF USING CHARCOAL CHIMNEY STARTER, PROCEED TO STEP 5.

If you choose to use charcoal lighting fluid, ONLY use charcoal lighting fluid approved for lighting charcoal. Do not use gasoline, kerosene, alcohol or other flammable materials for lighting charcoal. Follow all manufacturer’s warnings and instructions regarding use. Start with 2.6 – 2.8 pounds of charcoal. Place the charcoal in center of each charcoal rack.

Step 3

Saturate charcoal with lighting fluid. With lid open wait 2 to 3 minutes to allow lighting fluid to soak into charcoal. Store charcoal lighting fluid a safe distance from the grill.

Step 4

With grill lid open, stand back and carefully light charcoal and allow to burn until covered with a light ash (approximately 20 minutes).

WARNING: Charcoal lighting fluid must be allowed to completely burn off prior to closing grill lid and doors (approximately 20 minutes). Failure to do this could trap fumes from charcoal lighting fluid in grill and may result in a flash-fire or explosion when lid is opened.

Step 5 Place cooking grates on grate supports.

WARNING: Always wear oven mitts/gloves when removing cooking grate to protect your hands from burns.

Step 6

Place food on cooking grates and close grill lid. Always use a meat thermometer to ensure food is fully cooked before removing from grill.

Step 7 Allow grill to cool completely, and then follow instructions in the “After-Use Safety” and “Care & Maintenance” sections of this manual.

REGULATING HEAT

To increase heat, more wood and/or charcoal may be needed. Follow instructions in “Adding Charcoal/Wood During Cooking” section of this manual.

To maintain the temperature, more wood and/or charcoal may need to be added during the cooking cycle.

Both dampers fully opened will generate higher temperatures while both dampers fully closed will lower cooking temperature and extinguish flames.

NOTE: Dry wood burns hotter than charcoal, so you may want to increase the ratio of wood to charcoal to increase the cooking temperature. When using wood as fuel, make sure the wood is seasoned and dry. DO

NOT use resinous wood such as pine as it will produce an unpleasant taste.

ADDING CHARCOAL/WOOD DURING COOKING

Additional charcoal and/or wood may be required to maintain or increase cooking temperature.

Step 1

Stand back and carefully open grill lid. Use caution since flames can flare-up when fresh air suddenly comes in contact with fire.

Step 2

Remove the cooking grate and place it on a clean and non-combustible surface. DO NOT touch the grate by hand without wearing oven mitts/gloves.

Step 3

Stand back a safe distance and use long cooking tongs to lightly brush aside ashes on hot coals. Use cooking tongs to add charcoal and/or wood to charcoal rack, being careful not to stir-up ashes and sparks. If necessary, use your charcoal chimney starter to light additional charcoal and/or wood and add to existing fire.

WARNING: Never add charcoal lighting fluid to hot or even warm coals as flashback may occur causing severe burns.

Step 4

When charcoal is burning strong again, wear oven mitts/gloves and carefully return charcoal rack to grill body. Extinguish any hot ashes, coals or embers which may have fallen from the grill or beneath and around grill.

AFTER-USE SAFETY

WARNING:

 Always allow grill and all components to cool completely before handling.  Never leave coals and ashes in grill unattended. Make sure coals and ashes are completely

extinguished before removing.

 Before grill can be left unattended, remaining coals and ashes must be removed from grill. Use

caution to protect yourself and property. Place remaining coals and ashes in a non-combustible metal container and completely saturate with water. Allow coals and water to remain in metal container 24 hours prior to disposing.

 Extinguished coals and ashes should be placed a safe distance from all structures and

combustible materials.

 With a garden hose, completely wet surface beneath and around the grill to extinguish any ashes,

coals or embers which may have fallen during the cooking or cleaning process.

 Cover and store grill in a protected area away from children and pets.

CARE AND MAINTENANCE__________________________________________________

• Cure your grill periodically throughout the year to protect against excessive rust.

• To protect your grill from excessive rust, the unit must be properly cured and covered at all times when

not in use.

• Wash cooking grate and charcoal rack with hot, soapy water, rinse well and dry. Lightly coat grate with vegetable oil or vegetable oil spray.

• Clean inside and outside of grill by wiping off with a damp cloth. Apply a light coat of vegetable oil or vegetable oil spray to the interior surface to prevent rusting. Do not coat charcoal rack.

• If rust appears on the exterior surface of your grill, clean and buff the affected area with steel wool or fine grit emery cloth. Touch-up with a good quality high-temperature resistant paint.

• Never apply paint to the interior surface. Rust spots on the interior surface can be buffed, cleaned, and then lightly coated with vegetable oil or vegetable oil spray to minimize rusting.

TROUBLESHOOTING_______________________________________________________

PROBLEM POSSIBLE CLAUSE CORRECTIVE ACTION

Difficult to assemble.

All screws and nuts are tightened before assembly is completed.

Loosen all screws and nuts. Complete assembly of the item. Tighten all screws and nuts.

Poor burning performance.

1. Grilling – air vent is closed.

2. Smoking – air vent and chimney cover are closed.

3. Charcoal in poor condition.

1. Open the air vent.

2. Open the air vent and chimney cover.

3. Change the charcoal.

Charcoal does not burn.

1. Wet/damp charcoal.

2. Dampers closed.

1. Replace coals with new dry charcoal.

2. Open the dampers on the grill body.

Low heat/flame.

Flame goes out.

1. Charcoal is burning out.

2. Dampers closed.

1. Replace old coals or add new

on top of old already hot coals.

2. Open the dampers on the grill

body.

Flare-ups.

1. Grease and/or residue build up.

2. Excessive fat in meats.

3. Excessive oils in marinades.

4. Excessive cooking temperature.

1. Clean internal components.

2. Trim fat from cuts of meat before grilling.

3. Use non-oil based marinades.

4. - Rotate and close the air dampers on the body.

- Leave lid open or lightly spray with water to cool.

WARRANTY______________________________________________________________

The manufacturer will repair or replace, without charge, this product which under normal usage has proven to be defective in its manufacture or workmanship for a period of 90 days from the date of initial retail purchase. Service, parts and labor on warranted parts will be covered for a period of 90 days. This warranty is valid only to the original purchaser. This warranty is not transferable and does not cover any parts that have been subjected to misuse, abuse, alteration, overload, accident or normal wear of moving parts. Tools that have been sold “as is,” sold reconditioned or used as rental equipment are not covered.

Service can be obtained by contacting the manufacturer at 1–800–963–0211. Any grill or part that is returned to the manufacturer, together with the original sales receipt as proof of initial retail purchase, postage prepaid, will be repaired or replaced without cost if the unit is found defective. This warranty does not apply to accessories or damage caused where repairs have been made or attempted by others. All warranty work will be completed in a reasonable time, not to exceed 60 days after receiving the product.

The manufacturer is not responsible for direct, indirect, incidental or consequential damages. Some states do not allow limitations on how long an implied warranty lasts and/or do not allow the exclusion or limitation of incidental damages, so the above limitations may not apply to you. This warranty gives you specific legal rights, and you may also have other rights, which vary from state to state.

WARRANTY VOID IF PRODUCT IS USED FOR COMMERICAL PURPOSES

For warranty assistance, call 1-800-963-0211, 8 a.m. - 6 p.m., EST, Monday - Thursday, 8 a.m. - 5 p.m., EST, Friday.

REPLACEMENT PARTS LIST_______________________________________________

For replacement parts, 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.

PART DESCRIPTION QUANTITY

A Leg Brace 2

B Front Leg 2

C Rear Leg 2

F Axle 1

G Wheel 2

I Body Hinge 2

J Air Vent 1

O Temperature Gauge 1

Q Lid Hinge 2

S Cooking grate 1

T Handle Base 2

Hardware Pack

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