Master Forge GR2045401-MF-00 User manual

GR2045401-MF-00 / GR2045402-MF-00 1 20121205
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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.
WARNING
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.
IMPORTANT
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.,
E T, Monday - Thursday; 8 a.m. - 5 p.m., E T, Friday
Français p.
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Español p. 54 - 79

GR2045401-MF-00 / GR2045402-MF-00 2 20121205
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

GR2045401-MF-00 / GR2045402-MF-00 3 20121205
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,

GR2045401-MF-00 / GR2045402-MF-00 5 20121205
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.

GR2045401-MF-00 / GR2045402-MF-00 6 20121205
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.

GR2045401-MF-00 / GR2045402-MF-00 7 20121205
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.

GR2045401-MF-00 / GR2045402-MF-00 8 20121205
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.

GR2045401-MF-00 / GR2045402-MF-00 9 20121205
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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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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

GR2045401-MF-00 / GR2045402-MF-00 11 20121205
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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.

GR2045401-MF-00 / GR2045402-MF-00 12 20121205
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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

GR2045401-MF-00 / GR2045402-MF-00 13 20121205
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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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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

GR2045401-MF-00 / GR2045402-MF-00 15 20121205
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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

GR2045401-MF-00 / GR2045402-MF-00 16 20121205
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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

GR2045401-MF-00 / GR2045402-MF-00 17 20121205
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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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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.
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8

GR2045401-MF-00 / GR2045402-MF-00 19 20121205
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.