Master Forge Gr2045402-mf-00 Owner's Manual

GR2045401-MF-00 / GR2045402-MF-00
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6-BURNER EVENT GRILL
MODEL# GR2045401-MF-00 / GR2045402-MF-00
DANGER
For Outdoor Use Only
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 cylinder not connected for use shall not be stored in the vicinity of this or any other appliance.
If you smell gas:
1. Shut off gas to the appliance.
2. Extinguish any open flame.
3. Open lid.
4. If odor continues, keep away from the appliance and immediately call your gas supplier or your fire department.
DANGER
Failure to follow these instructions
could result in fire or explosion which could cause property damage, personal injury or death.
Please read Safety and Precaution
statements, Grill Maintenance, Leak Testing Regulator/Cylinder connection and Lighting Instructions before using grill for first time, This instruction manual contains
important information necessary for the proper assembly and safe use of the appliance.
Read and follow all warnings and
instructions before assembling/using the appliance.
Follow all warnings and instructions
when using the appliance.
Keep this manual for further reference.
ITEM #0340113
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
Français p.
27 - 53
Español p. 54 - 79
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TABLE OF CONTENTS
Package Contents ………………………………………………………………….…...... 3
Hardware List ……………………………….…………………………………………..... 4
Safety Information …………………………….…………………………………............. 4
Preparation ………………………………………………….…………………................ 5
Assembly Instructions ………………………………………………………………….… 8
Installation Instructions……………………………………………………………….… 12
Operating Instructions ………………………………………………………….………… 18
Care and Maintenance …………………………………………………......................... 21
Troubleshooting …………………………………………………………………………… 24
Warranty …………………………………………………............................................... 26
Replacement Parts List ……………………………………………………..................... 26
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.
CALIFORNIA PROPOSITION 65
1. Combustion by-products produced when using this product contain chemicals known to the State of California to cause cancer, birth defects, and other reproductive harm.
2. This product contains chemicals, including lead and lead compounds, know to the State of California to cause cancer, birth defects or other reproductive harm.
Wash your hands after handling this product.
WARNING
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PACKAGE CONTENTS
Parts
Description Quantity
Parts
Description Quantity
A Grill Body 1 G Cooking Grid 3 B Cart 1 H Warming Rack 1 C Handle 2 J Gas Tank Holder 1 D Stationary Caster 2 K Grease Cup 1 E Universal Caster 2 L Towel Rack 2 F Heat Diffuser 6
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HARDWARE LIST
Hardware Description Quantity
Picture (Shown to size)
Bolt M6 x 12
18
Step Bolt M6 8
Bolt M5 x 8
4
Nut M6 8
SAFETY INFORMATION
WARNING:
1. This outdoor cooking gas appliance shall be used only outdoors and shall not be used in a building, garage or any other enclosed area.
2. This outdoor cooking gas appliance is not intended to be installed in or on boats or recreational vehicles.
3. Use your grill OUTDOORS in a well ventilated space away from dwellings or other buildings to prevent dangers associated with gas accumulation and toxic vapors. The grill should be situated at least 10 feet (3.1 m) from buildings. Not adhering to these clearances will prevent proper ventilation and may increase the risk of a fire and/or property damage, which could also result in personal injury.
4. Maintain a minimum clearance of 10 feet (3.1 m) between all sides of grill, deck railings, walls or other combustible material. DO NOT use grill under overhead unprotected combustible construction.
5. DO NOT obstruct the flow of combustion/ventilation air.
6. DO NOT leave the grill unattended while in use.
7. DO NOT use while under the influence of drugs or alcohol.
8. Keep the fuel supply hose away from heated surfaces
9. DO NOT put grill in storage or move it after use. Allow grill to cool to touch before moving/storing. Failure to do so could result in fire resulting in property damage,
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personal injury or death.
10. The appliance is for household use only. DO NOT use this grill for other than its intended purpose.
11. Never use natural gas in a unit designed for liquid propane gas.
12. Never use charcoal or wood briquettes in a gas grill. Flavoring chips must be contained in a metal smoking box to contain ash and prevent fires.
13. Leak test must be conducted prior to each use.
14. Keep a fire extinguisher on hand acceptable for use with gas products. Refer to your local authority to determine proper size and type.
15. Grill is hot when in use. To avoid burns:
DO NOT attempt to move the grill.  Lock the wheels so the unit does not accidentally move.  Wear protective gloves or oven mitts.  DO NOT touch any hot grill surfaces.
16. DO NOT wear loose clothing or allow hair to come in contact with grill.
PREPARATION
Before beginning assembly of product, make sure all parts are present. Compare parts with package contents list and diagram above. If any part is missing or damaged, do not attempt to assemble product. Contact customer service for replacement parts. Estimate Assembly Time: Less than 30 minutes. Tools Required: Pliers (not included), Phillips Screwdriver (not included). Adjustable Wrench (not included).
LP tank valve must have:
Type 1 outlet compatible with regulator or appliance.  Safety relief valve.  UL listed Overfill Protection Device (OPD). This OPD safety
feature is identified by a unique triangular hand wheel. Use only tanks equipped with this type of valve.
LP tank must be arranged for vapor withdrawal.
The LP 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, Cylinder, Spheres and Tubes for Transportation of Dangerous Goods; and Commission of Dangerous Goods; and Commission, as applicable.
The LP cylinder must include a collar to protect the cylinder
valve.
The LP cylinder must be stored outdoors out of the reach of children and SHALL NOT
be stored in a building, garage, shed, breezeway, or any other enclosed space. Cylinders can be stored indoors ONLY if cylinders are disconnected and removed from the appliance.
The cylinder should ALWAYS be put in an upright position.
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WARNING
Place dust cap on cylinder valve outlet whenever the cylinder is not in use. Only install the type of dust cap on the cylinder valve outlet that is provided with the cylinder valve. Other types of caps or plugs may result in leakage of propane.
DANGER
DO NOT connect this grill to an existing #510 POL cylinder valve with left hand
threads. The Type 1 valve can be identified with the large external threads on the valve outlet.
DO NOT connect to a propane cylinder exceeding this capacity.  DO NOT connect to a cylinder that uses any other type of valve c
onnection device.
Never store a spare LP gas cylinder under or near your grill. This could cause
pressure to be expelled through the vapor relief valve resulting in fire, explosion, or severe personal injury including death.
Keep the ventilation opening(s) of the LP gas cylinder enclosure free and clear from
obstructions and debris.
DO NOT insert any foreign objects into the valve outlet, damage to the back-check
could result. A damaged back-check can cause a leak, possibly resulting in explosions, fire, severe bodily harm, or death.
WARNING
FOR FILLING THE LP GAS CYLINDER
Allow only qualified LP gas dealers to properly fill or repair your LP cylinder.  DO NOT allow the cylinder to be filled beyond 80% capacity. Over-filled tanks can
create a dangerous condition. Over-filled tanks can build-up pressure and cause the relief valve to expel propane gas vapors. The vapor is combustible and if it comes in contact with a spark source or flame, an explosion causing severe burns, bodily harm, or death could occur.
Always use a safety cap when grill is not connected to cylinder.
If you exchange a cylinder with a qualified exchange program, be sure the cylinder has a Type 1 valve and an over-filling prevention device (OPD).
INSTALLING GAS CYLINDER
1. Check that cylinder valve is closed by turning knob
clockwise.
2. Place cylinder into tank holder in bottom cabinet.
3. Orient cylinder such that valve opening faces front
burners and so that hose is not kinked/damaged.
4. Attach or detach regulator to LP cylinder only when
cylinder is rested atop the tank holder.
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CONNECTION PROCEDURES
1. Make sure the tank valve is closed (turn valve clockwise till tight).
2. Check tank valve to ensure it has proper external male threads.
3. Make sure all burner valves are OFF.
4. Inspect valve connections, port, and regulator assembly. Look for any damage or debris. Remove any debris. Inspect hose for damage. Never attempt to use damaged or obstructed equipment. See local LP gas dealer for repair.
5. When connecting regulator assembly to the valve, hand tighten the quick coupling nut clockwise to a complete stop. Do not use a wrench to tighten. Use of a wrench may damage the quick coupling nut and result in a hazardous condition.
6. Open the tank valve fully (counterclockwise). Use a soapy water solution to check all connections for leaks before attempting to light the grill (see below). If a leak is found, turn the tank valve off and do not use the grill until a local LP gas dealer can make repairs.
To disconnect LP gas cylinder:
WARNING
If the grill is not in use, the gas must be turned off at the supply cylinder(s). Storage
of the grill is permissible only if the cylinder is disconnected and removed from the grill.
Cylinders must be stored outdoors out of the reach of children and must not be
stored in a building, garage or any other enclosed area.
1. Turn the burner valves off.
2. Turn the tank valve off fully (turn clockwise to stop).
3. Detach the regulator assembly from the tank valve by turning the quick coupling nut counterclockwise.
CAUTION
When installing LP cylinders the pressure regulator and hose assembly supplied
with this grill must be used. Replacement pressure regulators and hose assemblies must be those specified by the grill manufacturer.
Place dust cap on cylinder valve outlet whenever cylinder is not in use. Only install
the type of dust cap on the cylinder valve outlet that is provided with the cylinder valve. Other types of caps or plugs may result in leakage of propane.
LEAK TEST
Although all gas connections on the grill are leak tested at the factory prior to shipment, a complete gas tightness check must be performed at the installation site due to possible mishandling in shipment, or excessive pressure unknowingly being applied to the unit. Periodically check the whole system for leaks following the procedures listed below. If the smell of gas is detected at anytime you should immediately check the entire system for leaks.
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BEFORE TESTING
Make sure that all packing material is removed from the grill including the burner
tie-down straps.
Make a soap solution of one part liquid detergent and one part water. You will need a
spray bottle, brush, or rag to apply the solution to the fittings. For the initial leak test, make sure the LP cylinder is full.
WARNING
DO NOT SMOKE WHILE CONDUCTING LEAK TEST NEVER PERFORM LEAK TEST WITH AN OPEN FLAME If it is evident there is excessive abrasion or wear, or the hose is cut, it must be
replaced prior to the appliance being operational. The replacement hose shall be specified the by manufacturer.
TO TEST
1. Make sure the control valves are in the “OFF” position,
and turn on the gas supply.
2. Check all connections from the gas cylinder, LP gas
regulator and supply valve up to and including all the connections to the pipe that go to the burners (the diagram shows the point where the soap water mixture is being applied). Soap bubbles will appear where a leak is present.
3. If a leak is present, immediately turn off the gas
supply and tighten the leaky fittings.
4. Turn the gas back on and recheck.
5. If it is evident there is excessive abrasion or wear, or
the hose is cut, it must be replaced prior to the outdoor cooking gas appliance being put into operation. The replacement hose assembly shall be that specified by the manufacturer. Contact 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.
ASSEMBLY INSTRUCTIONS
Symbol: Some steps may require the assistance of a friend.
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3
Step 1
Assemble the stationary caster (D) and universal caster (E) to the grill cart with bolt (AA). HARDWARE USED
d
Step 2
Turn the grill cart upside down. Open the left and right cart supporting legs and then open the horizontal front and rear bar support to hold the left and right supporting legs in position. Make sure the bolts at the opposite ends of the horizontal bars go into the locking holes of the legs, per the diagram.
Step 3
Assemble the gas tank holder (J) to the left side of the grill cart (B) with bolt (AA).
HARDWARE USED
1
2
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4
6
Step 4
Assemble the handles (C) to the grill body (A) with bolt (BB) and nut (DD).
HARDWARE USED
Step 5
With the help of other people, place the grill body on the grill cart.
Make sure the four latches on the legs and grill body are tightly locked.
Step 6
1. Open the side shelves.
2. Open the wind shield.
3. Open the side wind shield.
5
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7
8
9
Step 7
1. Assemble the towel racks (L) to
the side shelves with bolt (CC).
2. Install a LR6/AA battery into the
igniter.
HARDWARE USED
Step 8
Place heat diffuser (F) onto the grill body. Make sure that the vertical pin goes through the holes of diffuser (F). Then place the cooking grid (G) onto the grill body.
Step 9
Hang the warming rack (H) on the windshield.
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10
Step 10
Place the grease cup (K) into the bottom bracket of grease collecting pan.
INSTALLATION INSTRUCTIONS
Folding Up Process
When the grill is not in use, please follow procedures below to fold up the grill.
Step 1
1. Remove the grease cup from
the bottom of grease collecting pan.
2. Remove the warming rack.
3. Close the side panel of wind
shield.
4. Fold down the wind shield.
1
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3
Step 2
Turn the warming rack upside down with hanging hooks downward. Then place it on the front part of cooking grid and with the hanging hooks going into the cooking grid.
Close the left side shelf and then close the right side shelf.
Step 3
Once the side shelves are closed, lock the latches on the front and rear of side shelves.
2
3
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4
Step 4
Unlock the latches on the four legs. With the help of other people, lift the grill body away from the grill cart and put it on a horizontal flat and rigid surface.
Step 5
1. Unlock the front and rear
horizontal bars and lay them onto the grill cart.
2. Fold down the left and right
legs of the grill cart.
3. Make sure the gas tank
hanging hook also goes inside the grill cart.
5
5
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6
9
Step 6 Place the Grease Cup to the grill cart per illustration.
Step 7
With the help of other people, place the grill body onto the grill cart again.
Step 8
Lock the 4 latches on the grill cart to the grill body tightly.
6
7
8
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1
Unfolding Process
To unfold the grill, please follow procedures below.
Step 1
Unlock the 4 latches on the grill cart.
Step 2
With the help of other people, lift the grill body up and away from the cart. Place it on a horizontal flat and rigid surface.
Step 3
Take out the Grease Cup from the grill cart.
2
3
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3
4
Step 5
With the help of other people, place the grill body onto the cart. Make sure the latches on the four legs are tightly locked.
Step 6
Unlock the latches on the front and rear of side shelves.
Step 4
Turn the grill cart upside down. Open the left and right cart supporting legs and then open the horizontal front and rear bar support to hold the left and right supporting legs in position. Make sure the bolts at the opposite ends of the horizontal bars go into the locking holes of the legs. Also turn the gas tank holding hook outward.
6
4
5
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6
7
Step 7
Open the side shelves.
Step 8
1. Open the wind shield main
panel.
2. Open the side wind shield.
3. Hang the warming rack (H)
on the wind shield.
4. Place the grease cup into
the bottom bracket of grease collecting pan.
OPERATING INSTRUCTIONS
LIGHTING INSTRUCTIONS
BEFORE LIGHTING
WARNING
Inspect the gas supply hose prior to turning the gas “ON”.  If there is evidence of cuts, wear, or abrasion, it must be replaced prior to use.  Do not use the grill if the odor of gas is present.  Only the pressure regulator and hose assembly supplied with the unit should be
used.
Perform the “LEAK TEST” according to instructions before operating the grill.
ALWAYS keep your face and body as far away from the burner as possible while
lighting.
7
8
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Electrode Check
With the assistance of another person, perform this Electrode Check before proceeding.
This test will ensure that the Spark Electrode Tips are properly positioned so your
grill lights easily and properly.
Be sure all Control Knobs are set to “OFF” and open the Grill Lids.  Have your assistant stand behind and to the left of the grill and look toward the front
of the grill box. Never put your face inside the Grill Head.
Press the Igniter Cap. You should hear a “clicking” sound. Your assistant should
see a blue spark from Electrode Tips to the burner port; if a spark is present Electrode Tips are properly positioned.
If no spark is seen, the ignition probe needs to be adjusted by using a collar to
adjust the ignition probe so that it is pointing to the burner port.
Recheck the Electrode; if no “clicking” sound is heard, check if (1) LR-6 /AA Battery
is installed backwards, and (2) electric wires may be loose. Remove the Battery and inspect the Igniter Junction Box found behind the Control Panel and reconnect any loose wires.
LIGHTING THE MAIN BURNER OF GRILL
1. Before each use, check all hoses for cracks, nicks, cuts, burns or abrasions. If a hose
is damaged in any way, do not use your grill before replacing the hose with an authorized part from the Parts List. Also make sure all gas supply connections are securely tightened.
2. For optimum performance this grill should be used only when outdoor temperatures
are 60 degrees or above.
3. Familiarize yourself with the Safety and Use and Care instructions in this manual. Do
not smoke while lighting grill or checking gas supply connections.
4. Be sure each LP Gas tank is filled, and lock Casters to prevent movement during grill
operation.
5. Open the left and right Lids before lighting the grill.
6. Check that the end of each Burner Tube is properly located over each Valve Orifice.
7. Set all Control Knobs to OFF and open the propane gas tank valve SLOWLY 1/4 of a
turn.
Electrode Tip
Burner Ports
Burner
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8. Light the “IGNITION BURNER” first, push and turn the left Control Knob to HIGH position.
9. Immediately press the Electric Igniter for 3-4 seconds to light the Burner.
10. If ignition does not occur in 5 seconds, turn the “IGNITION BURNER” Control Knob and gas source OFF and conduct a leak test of ALL gas connections and gas sources as explained in the Use and Care section of this manual. If no leaks are detected, wait 5 minutes for any gas to clear and repeat the lighting procedure.
11. After IGNITION BURNER is lit, turn the tank valve SLOWLY one more 1/4 of a turn for 1/2 of one complete turn.
12. Once the IGNITION BURNER is lit, you light all the burners 3,2,1,5 and 6 in that order by turning its Control Knob to HIGH.
LIGHTING USING MATCH LIGHT EXTENSION ROD
1. Turn OFF all burner valves.
2. Make sure the lid is open.
3. Place a lighted match between the coils on the Match Holder and hold next to the burner.
4. Turn the control knob(s) to the “HIGH” position. Burner should light immediately.
5. If the burner does not light in 5 seconds turn the knob off, wait 5 minutes and repeat above procedures.
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DANGER
Keep your face and hands as far away from the grill as possible when lighting it.
FLAME CHARACTERISTICS
This procedure outlines how to check for proper burner flame characteristics. Burner flames should be blue and stable with little yellow tips, with no excessive noise, or lifting. If the flame is yellow, it indicates insufficient air. If the flame is noisy and tends to lift away from the burner, it indicates too much air. If any of these conditions exist call our customer service line.
Visually check the burner flames prior to each use. The flames should be look like this picture. If they do not, refer to the burner maintenance part of this manual.
CARE AND MAINTENANCE
Before cleaning the grill, keep it in an area clear and free from combustible materials, gasoline and other flammable vapors and liquids.
GRILL RACK
The easiest way to clean the grill is immediately after cooking is completed and after turning off the flame. Wear a barbeque mitt to protect your hand from the heat and steam. Dip a brass bristle barbeque brush in tap water and scrub the hot grill. Dip the brush frequently in the bowl of water. Steam, created as water hits the hot grill, assists the cleaning process by softening any food particles. The food particles will “fall off” and burn. If the grill is allowed to cool before cleaning, cleaning will be more difficult.
GREASE TRAY
The grease tray should be emptied and wiped down periodically and washed with a mild detergent and warm water solution. A small amount of sand or cat litter may be placed in the bottom of grease tray to absorb the grease. Check the grease tray frequently. Don’t allow excess grease to accumulate and overflow out of the grease tray.
GRILL BURNERS
Extreme care should be taken when removing a burner as it must be correctly centered on the orifice before any attempt is made to re-light the grill. Frequency of cleaning will depend on how often you use the grill.
Spiders and small insects occasionally spin webs or make nests in the grill burner tubes during transit and warehousing. These webs can lead to gas flow obstruction which could result in a fire in and around burner tubes. This type of fire is known as flashback and can cause serious damage to your grill and create an unsafe operating condition for the user. Although an obstructed burner tube is not the only cause of flashback, it is the most common cause. To reduce the chance of flashback, you must clean the burner tubes before assembling your grill, and at least once a month in late summer or early fall when spiders are most active. Also, perform this burner tube cleaning procedure if your grill has not been used for an extended period of time.
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You should inspect the burners at least once a year or immediately after any of the following conditions occur:
1. The smell of gas in conjunction with the burner flames appearing yellow.
2. The grill does not reach temperature.
3. The grill heats unevenly.
4. The burners make popping noises.
WARNING
ENSURE that the gas supply and the knobs are in the “OFF” position.
Cleaning The Burner Tubes and Burner Ports
To reduce the chance of FLASHBACK FIRE you must clean the Burner Tubes as follows at least once a month in summer and fall or whenever spiders are active in your area, and if your grill has not been used for an extended period on time.
1. Turn all Burner Valves to the full OFF position.
2. Turn the LP Gas tank valve to the full OFF position.
3. Detach the LP Gas regulator assembly from your gas grill.
4. Remove the Cooking Grids and Heat Diffusers.
5. Remove the cotter pin from the rear of each Burner.
6. Carefully lift each Burner up and away from the Gas Valve Orifice.
7. Check and clean burner/venturi tubes for insects and insect nests. A clogged tube can lead to a fire beneath the grill.
8. Refer to diagram below and perform one of these three cleaning methods:
METHOD 1: Bend a stiff wire or wire coat hanger into a small hook as shown and run
the hook through each Burner Tube and inside the Burner several times to remove debris.
METHOD 2: Use a bottle brush with a flexible handle and run the brush through each
Burner Tube and inside the Burner several times to remove any debris.
METHOD 3: Use an air hose to force air through each Burner Tube. The forced air
should pass debris or obstructions through the Burner and out the Ports.
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BURNER REPLACEMENT
1. Remove the cotter pin from the burner holding pin.
2. Remove the burner as shown below.
WARNING
For safe operation ensure the Gas Valve Assembly Orifice is inside the Burner Tube before using your grill. See figure. If the Orifice is not inside the Burner Tube, lighting the Burner may cause explosion and/or fire resulting in serious bodily injury and/or property damage.
CAUTION
Keep outdoor cooking gas appliance area clear and free from combustible
materials, gasoline and other flammable vapors and liquids.
Do not obstruct the flow of combustible and ventilation air.  Keep the ventilation openings of the cylinder enclosure free and clear of debris.
Check and clean burner/venturi tubes for insects and insect nests. A clogged tube can lead to a fire beneath the grill.
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TROUBLESHOOTING If the grill fails to light:
1. Turn gas off at source and turn Control Knobs to OFF. Wait at least five minutes for
gas to clear, then retry.
2. If your grill still fails to light, check gas supply and connections.
3. Repeat lighting procedure. If your grill still fails to operate, turn the gas off at source,
turn the Control Knobs to OFF, then check the following:
Problem Possible Cause Corrective Action
Misalignment of Burner Tubes over Orifices.
Reposition Burner Tubes over Orifices.
Obstruction in gas line Remove fuel line from grill. Do not smoke! Open
gas supply for one second to clear any obstruction from fuel line. Close off gas supply at source and reconnect fuel line to grill.
Plugged Orifice
Remove the screw from the rear of each Burner using a Phillips Head Screwdriver. Remove the Orifice from gas valve and gently clear any obstruction with a fine wire. Then reinstall all Orifices, Burners, fixing bolts and cooking components. If an obstruction is suspected in Gas Valves or
Manifold, call customer service. Obstruction in Burner Tubes
Follow the Burner Tube cleaning procedure on
page 22 of this Operator’s Manual.
Misalignment of Igniter on Burner
Check for proper position of the Electrode Tip is
pointing to a burner port. The gap between the
Spark Electrode Tip and Spark Receiver should
be approximately 3/16 in. Adjust if necessary.
With the gas supply closed and all Control Knobs
set to OFF press the Electric Igniter cap and
check for the presence of a spark at the
Electrode. Disconnected Electric Wires
Inspect the Igniter Junction Box Found behind
the Control Panel. Connect loose Electric wires to
Junction Box and try to light the grill.
If the grill fails to light
Weak AA battery
Unscrew the Igniter Cap and replace the battery.
If the grill still does not light
Blocking of gas line You may need to purge air from the gas line or
reset the regulator excess gas flow device.
Note: This procedure should be done every time
a new LP Gas tank is connected to your grill.
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