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OWNER'S MANUAL Outdoor LP Gas Barbecue Grill Model No. NSG3902D WARNING FOR YOUR SAFETY: For Outdoor Use Only (outside any enclosure) Table of Contents Important Safeguards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Assembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installling LP Gas Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Insert LP Gas Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Secure LP Gas Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Connect LP Gas Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Operating Main Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Operating Side Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Cleaning and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Product Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Exploded View & Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix A WARNING FOR YOUR SAFETY: 1. Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. 2. Read the installation, operation, and maintenance instructions thoroughly before installing or servicing this equipment. 3. Failure to follow these instructions could result in fire or explosion, which could cause property damage, personal injury, or death. California Proposition 65: Chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm are created by the combustion of propane. Save these instructions for future reference. If you are assembling this unit for someone else, give this manual to him or her to read and save for future reference. The use and installation of this product must conform to local codes. In absence of local codes, use the National Fuel Gas Code, ANSI Z223.1/NFPA 54, CAN/CGA-B149.1, Natural Gas and Propane Installation Code. Manufactured in China for: Blue Rhino Global Sourcing, LLC 104 Cambridge Plaza Drive, Winston-Salem, NC 27104 USA 1.800.762.1142, www.bluerhino.com © 2005 Blue Rhino Global Sourcing, LLC. All Rights Reserved UniFlame® is a Registered Trademark of Blue Rhino Global Sourcing, LLC. All Rights Reserved NSG3902D-OM-102 ES Outdoor LP Gas Barbecue Grill Model No. NSG3902D WARNING FOR YOUR SAFETY If you smell gas 1. Shut off gas to appliance. 2. Extinguish any open flame. 3. Open lid. 4. If odor continues, immediately call your gas supplier or your fire department. 1. Do not store spare LP cylinder within 10 feet (3.05 m) of this appliance. 2. Do not store or use gasoline or other liquids with flammable vapors within 25 feet (7.62 m) of this or any other appliance. 3. An LP cylinder not connected for use shall not be stored in the vicinity of this or any other appliance. Safety First DANGERS and Cautions 1. This grill is for outdoor use only, and shall not be used in a building, garage, or any other enclosed area. 2. This grill is NOT for commercial use. 3. This grill is for use with liquid propane (LP) gas only. The conversion to or attempted use of natural gas in this LP gas grill is dangerous and will void your warranty. 4. LP gas Characteristics: a. LP gas is flammable and hazardous if handled improperly. Become aware of the characteristics before using any LP gas product. b. LP gas is explosive under pressure, heavier than air, and settles and pools in low areas. c. LP gas in its natural state has no odor. For your safety, an odorant is added that smells like rotten cabbage. d. Contact with LP gas can cause freeze burns to skin. 5. LP gas tank needed to operate. Only tanks marked "propane" may be used. 6. The LP gas supply tank must be constructed and marked in accordance with the Specifications for LP gas Cylinders of the U.S. Department of Transportation (DOT) or the National Standard of Canada, CAN/CSAB339, Cylinders, Spheres and Tubes for the Transportation of Dangerous Goods; and Commission. 7. LP gas tank must be arranged for vapor withdrawal. 8. The LP gas tank must have a listed overfilling prevention device (OPD). 9. Only use 20-pound cylinders equipped with a cylinder connection device compatible with the connection for outdoor cooking appliances. 10. The LP gas tank must have a tank collar to protect the tank valve. 11. Never use an LP gas tank with a damaged body, valve, collar, or footing. 12. Dented or rusted LP gas tanks may be hazardous and should be checked by your LP gas supplier prior to use. 13. The LP gas tank should not be dropped or handled roughly. 14. Tanks must be stored outdoors out of the reach of children and must not be stored in a building, garage, or any other enclosed area. Your tank must never be stored where temperatures can reach over 125°F. 15. Never keep a filled LP gas tank in a hot car or car trunk. Heat will cause the gas pressure to increase, which may open the relief valve and allow gas to escape. 16. Never attempt to attach this grill to the self-contained LP gas system of a camper trailer, motor home, or house. 17. The use of alcohol, or prescription or non-prescription drugs may impair the consumer's ability to properly assemble or safely operate the appliance. 18. Never use charcoal, lighter fluid, lava rocks, gasoline, kerosene, or alcohol with this product. 19. Your grill has been checked at all factory connections for leaks. Recheck all connections, as movement in shipping can loosen connections. 20. Check for leaks even if your unit was assembled for you by someone else. 21. Do not operate if gas leak is present. Gas leaks may cause a fire or explosion. 22. You must follow all leak-checking procedures before operating. To prevent fire or explosion hazard when testing for a leak: a. Always perform leak test before lighting the grill and each time the tank is connected for use. b. No smoking. Do not use or permit sources of ignition in the area while conducting a leak test. c. Conduct the leak test outdoors in a well-ventilated area. d. Do not use matches, lighters, or a flame to check for leaks. e. Do not use grill until any and all leaks are corrected. If you are unable to stop a leak, disconnect the LP gas supply. Call a gas appliance serviceman or your local LP gas supplier. 23. Do not store or use gasoline or other flammable liquids or vapors within 25 feet (7.62 m) of this appliance. 24. Do not use in an explosive atmosphere. Keep grill area clear and free from combustible materials, gasoline and other flammable vapors and liquids. 25. Keep all combustible items and surfaces at least 21 inches (53 cm) away from the grill at all times. DO NOT use this grill or any gas product under any overhead or near any unprotected combustible constructions. 26. It is essential to keep the grill's valve compartment, burners, and circulating air passages clean. Inspect grill before each use. 27. Do not alter grill in any manner. 28. Do not use the grill unless it is COMPLETELY assembled and all parts are securely fastened and tightened. 29. This grill should be thoroughly cleaned and inspected on a regular basis. Clean and inspect the hose before each use of the appliance. If there is evidence of abrasion, wear, cuts, or leaks, the hose must be replaced prior to the appliance being put into operation. 30. Use only the regulator and hose assembly provided. The replacement regulator and hose assembly shall be that specified by the manufacturer. 31. Use only Blue Rhino Global Sourcing, LLC. factory authorized parts. The use of any part that is not factory authorized can be dangerous. This will also void your warranty. Contact 1.800.762.1142. 32. Do not use this appliance without reading "Operating Instructions" in this manual. 33. Do not touch metal parts of grill until it has completely cooled (about 45 min.) to avoid burns, unless you are wearing protective gear (pot holders, gloves, BBQ mittens, etc.). 34. When cooking, fire extinguishing materials shall be readily accessible. In the event of an oil grease fire, do not attempt to extinguish with water. Use type BC dry chemical fire extinguisher or smother with dirt, sand or baking soda. 35. Do not install or use in or on boats or recreational vehicles. 36. Do not use grill in high winds. 37. Never lean over the grill when lighting. 38. Do not leave a lit grill unattended, especially keep children and pets away from grill at all times. 39. Do not attempt to move grill when in use. Allow the grill to cool before moving or storing. 40. Storage of grill indoors is permissible only if the tank is disconnected, removed from the grill and properly stored outdoors. 41. Always open grill lid carefully and slowly as heat and steam trapped within grill can severely burn you. 42. Do not attempt to disconnect the gas regulator from the tank or any gas fitting while the grill is in use. 43. Always place your grill on a hard non-combustible, level surface. An asphalt or blacktop surface may not be acceptable for this purpose. 44. Do not use on wooden decks. 45. Move gas hoses as far away as possible from hot surfaces and dripping hot grease. 46. Keep all electrical cords away from a hot grill. 47. Do not use grill for indoor cooking or heating. TOXIC fumes can accumulate and cause asphyxiation. 48. After a period of storage and/or nonuse, check for leaks, burner obstructions and inspect for any abrasion, wear, cuts to the hose. 49. Failure to open lid while igniting the grill's burners, or not waiting 5 minutes to allow the gas to clear if the grill does not light, may result in an explosive flame-up. 50. If grill is not in use, the gas must be turned off at the supply tank. 51. Never operate grill without heat plates installed. 52. Always use a meat thermometer to ensure food is cooked to a safe temperature. 53. Do not store a spare LP gas tank under or near this appliance. 54. Never fill the tank beyond 80 percent full. 55. Deaths, serious injury or damage to property may occur if the above is not followed exactly. Contact 1-800-762-1142 for assistance. Do not return to place of purchase. page no. 3 Assembly Instructions DO NOT RETURN PRODUCT TO STORE. For assistance call 1.800.762.1142 toll free. Please have your owner's manual and serial number available for reference. For Easiest Assembly: · To avoid losing any small components or hardware, assemble your product on a hard level surface that does not have cracks or openings. · Clear an area large enough to layout all components and hardware. · When applicable, tighten all hardware connections by hand first. Once the step is completed, go back and fully tighten all hardware. · Follow all steps in order to properly assemble your product. 4 Step Secure grill body to cart frame Note: 2 people required to put grill body onto cart. A. Place body assembly onto cart. B. Feed hose through right side of cart. C. Secure grill body to cart using 4 sets of large screws (E), lock washers (L), and extra large washers (K). 1 Step Attach wheels to cart Insert 4 wheel assemblies into cart legs. Note: cart is shown upside down. 5 Step Insert bolts Insert 4 bolts (G) into side of grill body. Note: Leave 0.3" (8 mm) of bolt threads exposed. Do not fully tighen until step 9. 2 Step Attach cross bar A. Insert tabs on cross bar into slots on inside of cart frame. B. Attach cross bar to cart by using 2 sets of extra large screws (F), lock washers (L), and extra large washers (K). 3 Step Attach doors and basket A. Install right and left doors by placing bottom pin into hole in cart, depress top spring pin and snap top pin into hole in cross bar. Note: Spring pins are located on top of doors. B. Hang basket on left door. 6 Step Assemble left side shelf A. Insert tabs on left condiment holder into slots on left side shelf and slide right. B. Attach left condiment baskets to left side shelf using medium screw (D), lock washer (L) and large washer (J). Note: shown from rear. Note: shown from below and rear. Outdoor LP Gas Barbecue Grill Model No. NSG3902D 7 Step Assemble right side shelf A. Attach control knob ring and control valve to right condiment holder using extra small screw 1 (A), extra small screw 2 (B), medium washer (I) and small washer (H). B. Insert tabs on right condiment holder into slots on side burner assembly and slide left. C. Insert control valve nozzle into venturi tube. D. Attach right condiment basket to right side shelf using medium screw (D), lock washer (L) and medium washer (J). 10 Step Secure side shelves Secure side shelves to grill body using 2 small screws (C). Note: view is from rear. 11 Note: view is from right side. Note: view is from below and rear. Step Attach side burner ignitor wire Attach side burner wire from control panel to ignitor on side burner. Note: view is from under right side shelf. 8 Step Attach side shelves Insert left and right side shelves onto bolts on grill body. 12 Step Insert heat plates Place 4 heat plates on tabs above burners. Note: view is from below and side. 9 Step Secure side shelves A. Secure side shelves to grill body using 4 bolts (G). B. Tighten bolts from Step 5. Note: view is from rear. 13 Step Insert cooking grids and warming rack A. Insert cooking grids. B. Place warming rack with legs down onto sides of grill body. Contact 1-800-762-1142 for assistance. Do not return to place of purchase. page no. 5 14 Step Attach tool holder Insert tool holder into holes in left side shelf. 18 Step Completed Congratulations your assembly is now complete. Read Operating Instructions before proceeding. 15 Step Attach tank retainer wire Insert legs of tank retainer wire into cart base. Installing LP Gas Tank Insert LP Gas Tank To operate you will need (1) precision-filled standard grill LP gas tank (20#) with external valve threads. Place precision filled LP gas tank upright into hole in grill body so it is arranged for vapor withdrawal. 16 Step Attach grease cup Hang grease cup from bottom of grill body. Secure LP Gas Tank Secure tank by sliding tank retainer wire over shoulder of LP gas tank. 17 Step Insert battery A. Unscrew ignition button on control panel. B. Remove protective cover from AA Battery. C. Insert battery with positive ( + ) end facing out. D. Replace ignition button turning clockwise. Connect LP Gas Tank Before connecting, be sure that there is no debris caught in the head of the gas tank, head of the regulator valve or in the head of the burner and burner ports. Connect gas line to tank by turning knob clockwise until it stops. Outdoor LP Gas Barbecue Grill Model No. NSG3902D Operating Instructions Checking for Leaks Burner Connections Make sure the regulator valve and hose connections are securely fastened to the burner and the tank. If your unit was assembled for you, visually check the connection between the burner pipe and orifice. Make sure the burner pipe fits over the orifice. Gas Valve with orifice Burner Venturi Direct Cooking 1. Light burners per lighting instructions. 2. Set burners to desired level and allow temperature to be reached. 3. Place food directly over burners. 4. With lid open or closed, cook untill desired internal temperatures are acheived. Indirect Cooking Ideal for roasts and larger cuts of meat. 1. Remove cooking grid. 2. Place metal tray in center, on heat plates. Gas Connections WARNING: Failure to inspect this connection or follow these instructions could cause a fire or an explosion which can cause death, serious bodily injury, or damage to property. Please refer to diagram for proper installation. If the burner pipe does not rest flush to the orifice, please contact 1.800.762.1142 for assistance. Tank/Gas Line Connection Make 2-3 oz. of leak solution by mixing one part liquid dishwashing soap with three parts water. Make sure control knobs are off. Turn LP gas tank ON at valve. Spoon leak check solution at all "x" locations 3. Replace cooking grid. 4. Light burners. 5. Turn center burner off. Set ouside burners to desired level and allow temperature to be reached. 6. Place food on cooking grid, directly over metal tray. 7. With lid closed, cook until desired internal temperatures are achieved. Tips For Better Cook Outs and Longer Product Life 1. Spray or coat cooking surfaces with vegetable oil before cooking to avoid sticking. 2. Place vegetables or delicate foods into aluminum foil pouches. Side Burner 3. Use a quality grill brush after each event to keep cooking surfaces clean and rust free. 4. Empty grease pan after every use. Main Burners Gas Connections Burner Venturi Gas Valve with orifice CAUTION: Do not cover grill until it is completely cool to the touch. X X X X X Operating Side Burner NOTE: Side burner can be used while main burners are operating. Never use side burner as a grill. Lighting 1. Open lid. Attempting to light the burner with the lid closed may cause an explosion! 2. Make sure there are no obstructions of airflow to the gas unit. Spiders and insects can nest within and clog the burner / venturi tube at the orifice. A clogged burner tube can lead to a fire beneath the appliance. 3. Control knob must be in the OFF position. 4. Turn on gas at LP gas tank. Flame Burner If any bubbles appear turn LP gas tank OFF, reconnect and re-test. If you continue to see bubbles after several attempts, disconnect LP gas source and contact 1.800.762.1142 for assistance. If no bubbles appear after one minute turn tank OFF, wipe away solution and proceed. Operating Main Burners Lighting 1. Open lid. Attempting to light the burner with the lid closed may cause an explosion! 2. Make sure there are no obstructions of airflow to the gas unit. Spiders and insects can nest within and clog the burner / venturi tube at the orifice. A clogged burner tube can lead to a fire beneath the appliance. 3. All control knobs must be in the OFF position. 4. Turn on gas at LP gas tank. 5. Push and turn control knob counterclockwise to HIGH. 6. Press the electronic igniter button and hold for 5 seconds to light burner. 7. If ignition does not occur in 5 seconds, turn burner control knob OFF, wait 5 minutes, and repeat lighting procedure. 8. If igniter does not light burner, use a lit match secured with the lighting rod provided to light burners manually. Access the burners through the cooking grid and heat plates. Position the lit match near side of the burner. Important: Always use the lighting rod provided when lighting burners with a match. 9. After lighting, observe the burner flame, make sure all burner ports are lit and flame height matches illustration. Flame Burner 12.7 mm 0 mm 0" 9.5 mm 3/8" 19 mm 3/4" Side burner proper flame height. 1/2" 1/4" 5. Push and turn control knob counterclockwise to HIGH. 6. Press the electronic igniter button and hold for 5 seconds to light burner. 7. If ignition does not occur in 5 seconds, turn burner control knob OFF, wait 5 minutes, and repeat lighting procedure. 8. If igniter does not light burner, use a lit match secured with the lighting rod provided to light burners manually. Position the lit match near side of the burner. Important: Always use the lighting rod provided when lighting burners with a match. 9. After lighting, please observe the burner flame, make sure all burner ports are lit and flame height matches illustration. 6.4mm 0mm 0" Main burner proper flame height. CAUTION: If burner flame goes out during operation, immediately turn the gas "OFF" and open lid to let the gas clear for about 5 minutes before re-lighting. Turning Off 1. Turn control knob clockwise to the OFF position. 2. Turn gas off at LP gas tank. Cooking 1. Light burner. 2. Set burner to desired temperature 3. Place pan on center of grid. 4. Cook and adjust temperature as needed. CAUTION: If burner flame goes out during operation, immediately turn the gas "OFF" and open lid to let the gas clear for about 5 minutes before re-lighting. Turning Off 1. Turn all control knobs clockwise to the OFF position one at a time. 2. Turn gas off at LP tank. Initial Use Before cooking on this grill for the first time, operate the grill for about 15 minutes with the lid closed and the gas turned on "HIGH." This will "heat clean" the internal parts and dissipate odor from the manufacturing processes. Contact 1-800-762-1142 for assistance. Do not return to place of purchase. page no. 7 Cleaning and Care Caution 1. All cleaning and maintenance should be done when grill is cool and with the fuel supply disconnected. 2. DO NOT clean any grill part in a self cleaning oven. The extreme heat will damage the finish. Notices 1. Abrasive cleaners will damage this product. 2. Never use oven cleaner to clean any part of grill. 3. Do not clean any grill part in a self cleaning oven. The extreme heat will damage the finish. Product Registration Limited Warranty Please register your product immediately at www.BlueRhino.com or call 1.800.762.1142. Cleaning Surfaces 1. Wipe surfaces clean with mild dishwashing detergent or baking soda. 2. For stubborn surfaces use a citrus based degreaser and a nylon scrubbing brush. 3. Rinse clean with water. Blue Rhino Global Sourcing, LLC ("Vendor") warrants to the original retail purchaser of this grill, and to no other person, that if this grill is assembled and operated in accordance with the printed instructions accompanying it, then for a period of one (1) year from the date of purchase, all parts in such grill shall be free from defects in material and workmanship. Vendor may require reasonable proof of your date of purchase from an authorized retailer or distributor. Therefore, you should retain your sales slip or invoice. This Limited Warranty shall be limited to the repair or replacement of parts, which prove defective under normal use and service and which Vendor shall determine in its reasonable discretion upon examination to be defective. Before returning any parts, you should contact Vendor's Customer Service Department using the contact information listed below. If Vendor confirms, after examination, a defect covered by this Limited Warranty in any returned part, and if Vendor approves the claim, Vendor will replace such defective part without charge. If you return defective parts, transportation charges must be prepaid by you. Vendor will return replacement parts to the original retail purchaser, freight or postage prepaid. This Limited Warranty does not cover any failures or operating difficulties due to accident, abuse, misuse, alteration, misapplication, improper installation or improper maintenance or service by you or any third party, or failure to perform normal and routine maintenance on the grill, as set out in this owner's manual. In addition, the Limited Warranty does not cover damage to the finish, such as scratches, dents, discoloration, rust or other weather damage, after purchase. This Limited Warranty is in lieu of all other express warranties. Vendor disclaims all warranties for products that are purchased from sellers other than authorized retailers or distributors. AFTER THE PERIOD OF THE ONE (1)-YEAR EXPRESS WARRANTY, VENDOR DISCLAIMS ANY AND ALL IMPLIED WARRANTIES, INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. FURTHER, VENDOR SHALL HAVE NO LIABILITY WHATSOEVER TO PURCHASER OR ANY THIRD PARTY FOR ANY SPECIAL, INDIRECT, PUNITIVE, INCIDENTAL, OR CONSEQUENTIAL DAMAGES. Vendor assumes no responsibility for any defects caused by third parties. This Limited Warranty gives the purchaser specific legal rights; a purchaser may have other rights depending upon where he or she lives. Some jurisdictions do not allow the exclusion or limitation of special, incidental or consequential damages, or limitations on how long a warranty lasts, so the above exclusion and limitations may not apply to you. Vendor does not authorize any person or company to assume for it any other obligation or liability in connection with the sale, installation, use, removal, return, or replacement of its equipment, and no such representations are binding on Vendor. Blue Rhino Global Sourcing, LLC 104 Cambridge Plaza Drive Winston-Salem, North Carolina 27104 USA (800) 762-1142 24 Hour Fax: (336) 659-6743 CustomerService@BlueRhino.com Cleaning Main Burner 1. Turn gas off at the control knobs and LP gas tank. 2. Remove cooking grates and heat plates. 3. Remove burner by removing the fasteners securing the burner to the grill bottom. 4. Lift burner up and away from gas valve orifice. 5. Disconnect wire from spark electrode. 6. Clean inlet (venturi) of burner with small bottle brush or compressed air. 7. Remove all food residue and dirt on burner surface. 8. Clean any clogged ports with a stiff wire (such as an opened paper clip) 9. Inspect burner for any damage (cracks or holes). If damage is found, replace with new burner. 10. Reinstall burner, check to insure that gas valve orifice is correctly positioned inside burner inlet (venturi). Also check position of spark electrode. Cleaning Side Burner 1. Turn gas off at the control knobs and LP gas tank. 2. Remove side burner grid. 3. Remove burner by removing the screws securing the burner to the side shelf. 4. Lift burner up and away from gas valve orifice. 5. Clean inlet (venturi) of burner with small bottle brush or compressed air. 6. Remove all food residue and dirt on burner surface. 7. Clean any clogged ports with a stiff wire (such as an opened paper clip) 8. Inspect burner for any damage (cracks or holes). If damage is found, replace with new burner. 9. Reinstall burner, check to insure that gas valve orifice is correctly positioned inside burner inlet (venturi). Also check position of spark electrode. Outdoor LP Gas Barbecue Grill Model No. NSG3902D Troubleshooting Problem Burner will not light using ignitor Possible Cause Wires or electrode covered with cooking residue. Electrode and burners are wet. Electrode cracked or broken - sparks at crack. Wire loose or disconnected. Wire is shorting (sparking) between ignitor and electrode. Bad ignitor. Wipe dry with cloth. Replace electrode.