Broilmaster P4BL-1 Gas Grill User Manual

Premium "P" Gas Grill
Owner’s Manual
MODELS:
P3S-1, P3SN-1
P3BL-2, P3BLW-2, P3BLN-2, P3BLWN-2
P3FBL-2, P3FBLN-2, P3FBLW-2, P3FBLWN-2
P4BL-1, P4BLN-1, P4BLW-2, P4BLWN-2
P4FBL-1, P4FBLN-1, P4FBLW-2, P4FBLWN-2
R
STE
ILMA GRILL
BROMIUM GAS
PRE
P4 Series Grill Shown With
Optional Accessories
GAS-FIRED
Page 1
IMPORTANT
This manual should be read thoroughly by the person installing the grill and all persons who will
use and maintain the grill. The installer should be sure the manual is left in the possession of the
user. The user should retain this manual for future reference when using or cleaning the grill and
to properly identify any repair parts that may be required.
WARNING
Reference this manual for proper installation and maintenance instructions. Improper installation, adjustment, alteration, service or maintenance can cause personal injury or property damage. For assistance or additional information consult a qualified installer, service agency or the
gas supplier.
CAUTION: FOR YOUR SAFETY
IF YOU SMELL GAS:
1. Shut off gas to the appliance.
2. Extinguish any open flame.
3. Open the grill lid.
4. If odor continues, immediately call your gas supplier or fire department.
5. Do not touch electrical switches.
CAUTION: FOR YOUR SAFETY
1. Do not store or use gasoline or other flammable vapors and liquids 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.
CAUTION:
Parts may have sharp edges. Wear leather work gloves and handle parts carefully during the
unpacking, assembly and installation.
WARNING
Broilmaster® Gas Grills must ONLY use propane cylinders equipped with an Overfill Protection
Device (OPD). Use only a reputable propane dealer when exchanging or filling cylinders. An
overfilled or improperly filled propane cylinder can be dangerous.
Page 2
B101362-2-0610
Congratulations!
Welcome to the beauty, durability, and prestige of a Premium Gas Grill by
Broilmaster®. With award-winning excellence built into every feature and
durability that surpasses other Premium gas grills, Broilmaster has
manufactured the ultimate gas grill for discriminating outdoor chefs for over
30 years.
At Broilmaster, we continually strive to enhance the performance and quality
of our products for your grilling enjoyment. Every effort will be made to
ensure that Broilmaster continues to be your choice as the Premium grill
of the future.
Whether you are at the lake or in the privacy of your own backyard, the
Broilmaster® Premium Gas Grill performs far beyond the ordinary and is
designed to provide your family with years of outdoor cooking pleasure.
Thank You!
Broilmaster® is a registered trademark of
Empire Comfort Systems, Inc.
918 Freeburg Ave.
Belleville, Illinois 62220
Telephone 800-851-3153
B101362-2-0610
Page 3
Table of Contents
Congratulations!
You have chosen the finest grill for your outdoor cooking pleasure. Please take time to read this entire manual
before assembling your Premium Broilmaster® gas grill.
Hardware Package............................................................................................................................................5
Parts Diagram...................................................................................................................................................6
Parts List ..................................................................................................................................................... 7 & 8
Grill Assembly . ......................................................................................................................................... 9-13
Propane Gas Grills.................................................................................................................................... 14-16
Gas Conversion...............................................................................................................................................17
Natural Gas Grills...........................................................................................................................................18
Operation- Propane & Natural Grills.................................................................................................... 19 & 20
Maintenance...................................................................................................................................................... 21
Troubleshooting . .............................................................................................................................................. 22
Warranty ........................................................................................................................................................... 23
Your Broilmaster® Premium Gas Grill is identified by model number, serial number, and gas
type. This information is provided on a product identification label located on the grill’s control
panel. For your convenience, complete this section for future reference when contacting your
dealer.
Page 4
Model No.
Dealer
Serial No.
Dealer Phone No.
Gas Type: Propane
Date of Purchase
Natural
B101362-2-0610
HARDWARE PACKAGE
B101022
B101362-2-0610
Stainless Steel HEX HEAD
Page 5
PARTS DIAGRAM
All repair part orders should be placed through your local Broilmaster® dealer. To locate a dealer in your area,
contact Broilmaster Customer Service at 800-851-3153 • www.broilmaster.com. To ensure prompt and accurate
service, please provide the following information when placing a repair part order: Model Number, Serial Number,
Part Name, Part Number, and Quantity of parts needed.
6B
6A
6C
Page 6
B101362-2-0610
PREMIUM "P" SERIES PARTS LIST
Part Number
Index
Part Description
P3BL &
P3BLN
P3HG &
P3HGN
P3GY &
P3GYN
P3FBL &
P3FBLN
P3FGY &
P3FGYN
P3S &
P3SN
1
Grill Body Top (with heat indicator, hinge,
and bridge pins)
B100453
B100455
B100454
B100453
B100454
B100453
B100453
B100453
1
Grill Body Top (casting only)
B100456
B100459
B100458
B100456
B100458
B100456
B100456
B100456
2
Heat Indicator (stainless)
B076625
B076625
B076625
B076625
B076625
B076625
B076625
B076625
3
Lid Handle (stainless)
B070486
B070486
B070486
B070486
B070486
B070486
B070486
B070486
4
Foam Grip
B073097
B073097
B073097
B073097
B073097
B073097
B073097
B073097
Retract-A-Rack (stainless)
B072695
B072695
B072695
B072695
B072695
B072695
B072695
B072695
Cooking Grid (2 piece Porcelain)
B101053
B101053
B101053
B101053
B101053
N/A
N/A
N/A
5
6A
P3BLW &
P3BLWN
P3FBLW &
P3FBLWN
6B
Cooking Grid (3 piece Porcelain)
N/A
N/A
N/A
N/A
N/A
B100589
N/A
N/A
6C
Cooking Grid (2 piece Stainless Steel
Rod)
N/A
N/A
N/A
N/A
N/A
N/A
B101282
B101282
7
Briquette Bag
B058122
B058122
B058122
N/A
N/A
N/A
B058122
N/A
8
Briquette Rack
B101061
B101061
B101061
N/A
N/A
N/A
B101061
N/A
9
Burner Assembly
DPP101
DPP101
DPP101
DPP101
DPP101
DPP101
DPP101
DPP101
10
Radiation Shield (Heat & Wind Deflector)
DPP6SS
DPP6SS
DPP6SS
DPP6SS
DPP6SS
DPP6SS
DPP6SS
DPP6SS
11
Bridge Pin
B057805
B057805
B057805
B057805
B057805
B057805
B057805
B057805
12
Hinge Pin
B057804
B057804
B057804
B057804
B057804
B057804
B057804
B057804
13
Lid Stop Kit
DPA106
DPA106
DPA106
DPA106
DPA106
DPA106
DPA106
DPA106
14
Orifice - LPG (#55 drill)
B056649
B056649
B056649
B056649
B056649
B056649
B056649
B056649
14
Orifice - NAT (#48 drill)
B056647
B056647
B056647
B056647
B056647
B056647
B056647
B056647
15
Manifold Mounting Plate
B100517
B100517
B100517
B100517
B100517
B100517
B100517
B100517
16
Manifold - LPG (includes orifice)
B069002
B069002
B069002
B069002
B069002
B069002
B069002
B069002
16
Manifold - NAT (includes orifice)
B069003
B069003
B069003
B069003
B069003
B069003
B069003
B069003
17
Electric Ignitor
B072218
B072218
B072218
B072218
B072218
B072218
B072218
B072218
18
Valve - LPG
B076790
B076790
B076790
B076790
B076790
B076790
B076790
B076790
18
Valve - NAT
B076789
B076789
B076789
B076789
B076789
B076789
B076789
B076789
19
Shelf Pin
B073963
B073963
B073963
B073963
B073963
B073963
B073963
B073963
20
Control Panel Assembly (with label)
B100751
B100751
B100751
B100751
B100751
B100751
B100751
B100751
20
Control Panel Label (not shown)
B072686
B072686
B072686
B072686
B072686
B072686
B072686
B072686
21
Valve Knob - Black
B070084
B070084
B070084
B070084
B070084
B070084
B070084
B070084
22
Grill Body Bottom (with Hinge and Bridge
Pins)
B100460
B100462
B100461
B100460
B100461
B100460
B100460
B100460
22
Grill Body Bottom (casting only)
B100463
B100466
B100465
B100463
B100465
B100463
B100463
B100463
23
Control Panel Shield
B100730
B100730
B100730
B100730
B100730
B100730
B100730
B100730
24
Ignitor Ground Wire
B072684
B072684
B072684
B072684
B072684
B072684
B072684
B072684
25
Ignitor Grounding Lug
B069747
B069747
B069747
B069747
B069747
B069747
B069747
B069747
26
Collector Box Spacer
B069743
B069743
B069743
B069743
B069743
B069743
B069743
B069743
27
Collector Box
B100446
B100446
B100446
B100446
B100446
B100446
B100446
B100446
28
Flavor Screen Rack
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
29
Flavor Screen
N/A
N/A
N/A
DPA103
DPA103
DPA103
N/A
DPA103
30
Smoker/Shutter (includes Actuator Arm
& Knob)
N/A
N/A
N/A
N/A
N/A
DPA100
N/A
N/A
31
Actuator Arm - Smoker/Shutter
N/A
N/A
N/A
N/A
N/A
B100408
N/A
N/A
32
Knob - Smoker/Shutter Knob
N/A
N/A
N/A
N/A
N/A
B100098
N/A
N/A
33
Hose & LPS Regulator
B069756
B069756
B069756
B069756
B069756
B069756
B069756
B069756
34
Hardware Package - LPG (not shown)
B101235
B101235
B101235
B101235
B101235
B101235
B101235
B101235
34
Hardware Package - NAT (not shown)
B100853
B100853
B100853
B100853
B100853
B100853
B100853
B100853
B101362-2-0610
Page 7
PREMIUM "P" SERIES PARTS LIST (cont.)
Index
Part Description
Number
Part Number
P4BL
P4BLN
P4HG
P4HGN
P4GY
P4GYN
P4FBL
P4FBLN
P4FGY
P4FGYN
P4BLW
P4BLWN
P4FBLW
P4FBLWN
1
Grill Body Top (with heat indicator, hinge, and
bridge pins)
B073286
B076830
B073282
B073286
B073282
B073286
B073286
1
Grill Body Top (casting only)
B076621
B100151
B100149
B076621
B100149
B076621
B076621
2
Heat Indicator (stainless)
B076625
B076625
B076625
B076625
B076625
B076625
B076625
3
Lid Handle (stainless)
B070486
B070486
B070486
B070486
B070486
B070486
B070486
4
Foam Grip
B073097
B073097
B073097
B073097
B073097
B073097
B073097
5
Retract-A-Rack (stainless)
B072696
B072696
B072696
B072696
B072696
B072696
B072696
6B
Cooking Grid (3 piece Porcelain)
B100497
B100497
B100497
B100497
B100497
N/A
N/A
6C
Cooking Grid (2 piece Stainless Steel Rod)
N/A
N/A
N/A
N/A
N/A
B101321
B101321
7
Briquette Bag
B058122
B058122
B058122
N/A
N/A
B058122
B058122
8
Briquette Rack
B067449
B067449
B067449
N/A
N/A
B067449
B067449
9
Burner Assembly
DPP102
DPP102
DPP102
DPP102
DPP102
DPP102
DPP102
10
Radiation Shield (Heat & Wind Deflector)
DPP6SS
DPP6SS
DPP6SS
DPP6SS
DPP6SS
DPP6SS
DPP6SS
11
Bridge Pin
B057805
B057805
B057805
B057805
B057805
B057805
B057805
12
Hinge Pin
B057804
B057804
B057804
B057804
B057804
B057804
B057804
13
Lid Stop Kit
DPA106
DPA106
DPA106
DPA106
DPA106
DPA106
DPA106
14
Orifice - LPG (#55 drill)
B056649
B056649
B056649
B056649
B056649
B056649
B056649
14
Orifice - NAT (#48 drill)
B056647
B056647
B056647
B056647
B056647
B056647
B056647
15
Manifold Mounting Plate
B100517
B100517
B100517
B100517
B100517
B100517
B100517
16
Manifold - LPG (includes orifice)
B069002
B069002
B069002
B069002
B069002
B069002
B069002
16
Manifold - NAT (includes orifice)
B069003
B069003
B069003
B069003
B069003
B069003
B069003
17
Electric Ignitor
B072218
B072218
B072218
B072218
B072218
B072218
B072218
18
Valve - LPG
B076790
B076790
B076790
B076790
B076790
B076790
B076790
18
Valve - NAT
B076789
B076789
B076789
B076789
B076789
B076789
B076789
19
Shelf Pin
B073963
B073963
B073963
B073963
B073963
B073963
B073963
20
Control Panel Assembly (with label)
B100752
B100752
B100752
B100752
B100752
B100752
B100752
20
Control Panel Label (not shown)
B072197
B072197
B072197
B072197
B072197
B072197
B072197
21
Valve Knob - Black
B070084
B070084
B070084
B070084
B070084
B070084
B070084
22
Grill Body Bottom (with Hinge and Bridge
Pins)
B073287
B076829
B073283
B073287
B073283
B073287
B073287
22
Grill Body Bottom (casting only)
B076622
B100150
B100148
B076622
B100148
B076622
B076622
23
Control Panel Shield
B100731
B100731
B100731
B100731
B100731
B100731
B100731
24
Ignitor Ground Wire
B072684
B072684
B072684
B072684
B072684
B072684
B072684
25
Ignitor Grounding Lug
B069747
B069747
B069747
B069747
B069747
B069747
B069747
26
Collector Box Spacer
B069743
B069743
B069743
B069743
B069743
B069743
B069743
27
Collector Box
B100446
B100446
B100446
B100446
B100446
B100446
B100446
28
Flavor Screen Rack
N/A
N/A
N/A
B100713
B100713
N/A
B100713
29
Flavor Screen
N/A
N/A
N/A
DPA104
DPA104
N/A
DPA104
30
Smoker/Shutter (includes Actuator Arm &
Knob)
N/A
N/A
N/A
N/A
N/A
N/A
N/A
31
Actuator Arm - Smoker/Shutter
N/A
N/A
N/A
N/A
N/A
N/A
N/A
32
Knob - Smoker/Shutter Knob
N/A
N/A
N/A
N/A
N/A
N/A
N/A
33
Hose & LPS Regulator
B069756
B069756
B069756
B069756
B069756
B069756
B069756
34
Hardware Package - LPG (not shown)
B101235
B101235
B101235
B101235
B101235
B101235
B101235
34
Hardware Package - NAT (not shown)
B100853
B100853
B100853
B100853
B100853
B100853
B100853
Page 8
B101362-2-0610
GRILL ASSEMBLY
Before You Begin
Recommended Tools
All Broilmaster grills require some assembly and installation.
Follow all instructions unless noted to apply only to other specific
models.
These items are recommended for the assembly of your grill:
Do NOT use power tools.
If you purchased an accessory with your Broilmaster, follow
the instructions provided with the accessory for assembly and
installation. If an instruction refers to a step that is not required
for your grill model, please continue to the next step.
Each step of the installation is illustrated. In each illustration
parts are identified with “Key” numbers. Key numbers appear in
parenthesis after a part name is mentioned for the first time in the
instructions and are labeled on the illustrations. You can reference
each part by its key number on the Parts List if you need help in
identifying a part.
Compare the parts found in the shipping container to the parts list
provided. If any parts are missing contact your Broilmaster® dealer
before beginning assembly.
• Phillips screwdriver
• Adjustable wrench set
• Socket set
• Soapy water solution (to test for leaks)
• Liquid soap (for foam grip)
Grill Mountings
Assemble your base option before assembling your Broilmaster®
grill head.
Refer to the Broilmaster® Cart, Base, and Post instructions provided with each accessory for assembly, installation, and mounting
procedures.
CAUTION: FOR YOUR SAFETY
Parts may have sharp edges. Wear leather work gloves and
handle parts carefully during the unpacking, assembly and
installation.
B101362-2-0610
Page 9
GRILL ASSEMBLY
Ignitor Assembly
Slide the collector box spacer (26) and nut (provided on assembly)
onto the collector box shaft and tighten. See Figure 1.
Figure 1
27
19
Note: Peel protective film from control panel label before
installing ignitor.
26
21
Nut
25
24
Figure 2
24
25
Installing the Ignitor
Caution: Do not cut or damage ignitor wire.
Carefully thread the end of the ignitor wire through the center hole
in the grill bottom. Slide the ground lug (25) over the ignitor wire
and fasten with nut provided.
Attach one end of the ground wire (24) to the terminal on the rear
of the electronic ignitor. Attach the remaining end to the ground
lug. See Figures 1 and 2.
Attach ignitor wire to the spark terminal on the rear of the electronic ignitor.
25
24
Page 10
B101362-2-0610
GRILL ASSEMBLY
Radiation Shield
Figure 3
Place the radiation shield (10) in the grill bottom (22). See Figure 3.
22
Installing the Burner
Insert the burner assembly (9) into the grill bottom (22) with the
venturi tubes facing the front of the grill. See Figure 4.
The gas jets from the control valve will be inside the ends of the
venturi tubes when properly installed. Attach venturi to manifold
mounting bracket (15) with two stainless steel hex washer screws.
Do NOT use power tools.
See Figure 5.
10
27
Figure 5
Figure 4
9
22
15
AIR
SHUTTER
B101362-2-0610
Page 11
GRILL ASSEMBLY
Handle
Figure 6
For your added comfort a foam grip (4) has been provided. See Figure 7.
1
Tip: For ease of installation, slightly lubricate the front handle with
liquid soap before pushing the foam grip into place.
Fasten the front handle (3) to the grill lid (1) with two #10-24 x 1"
screws. See Figure 6.
3
4
Figure 7
Install side shelves or side burner to side of grill at this
time.
Figure 8
Lid Stop
Attach the lid stop assembly to the grill bottom as shown. See Figure 8.
13
Page 12
32
33
28
B101362-2-0610
GRILL ASSEMBLY
Installing Racks
Place the briquet rack (8) or flavor screen rack (28) on the burner
assembly.
Position the flavor screen (29) on to flavor screen rack (28) or the
ceramic briquets (7) evenly on the briquette rack without overlapping.
For Smoker Shutter installation see DPA100 manual included
with your P3S grill.
Set the multilevel cooking grids. See Figure 9.
6B
4
Figure 9a
75
8
17
Installing Char-Master Briquets
Individually place the ‘Char-Master’ briquets in a single layer
evenly on your grill’s briquet rack; DO NOT dump them onto the
briquet rack. A single layer of ‘Char-Master’ briquets is all that’s
needed. DO NOT overlap or stack the briquets.
See Figure 9.
After properly placing the ‘Char-Master’ briquets on your grill’s
briquet rack, there may be some briquets left over. Save them for
future use.
Before cooking, always preheat the grill as directed by the grill’s
operating instructions. Hot briquets cause better, quicker cooking
and better flavor.
Cleaning
Routine preheating and routine burn-off (also called postheating)
of a grill will clean the ‘Char-Master’ briquets. Periodically turn
the briquets over while they are cool.
6
30
(P3S only)
29
Figure 9b
B101362-2-0610
Page 13
propane gas grills
Grill Location
Gas Type
When choosing the ideal location for your Broilmaster® Premium
Gas Grill, remember this grill is designed for outdoor use ONLY.
Never use Liquid Propane (LP) gas with a grill designed for Natural
gas, or Natural gas with a grill designed for Liquid Propane gas.
The type gas required for your grill can be determined from the
product identification label located on the grill’s control panel.
Questions regarding different types of gases should be directed to
your gas supplier.
You should never install or operate your grill in any building,
garage, or other enclosed area.
For your safety, this grill should not be installed or operated under any combustible materials, such as carports, covered porches,
awnings, or overhangs.
Never install or operate your grill in or on any recreational vehicle
or boat.
CAUTION: The installation and operation of this grill at
clearances less than specified below may lead to the possibility
of fire, property damage, or personal injury.
A minimum clearance of sixteen inches (16") is required from the
sides of the grill to any combustible material.
A minimum clearance of eighteen inches (18") is required from
the back of the grill to any combustible material.
Some examples of combustible materials are a wall, a fence, patio
furniture, or the wall of your home.
The area surrounding the grill should be clear to ensure proper
ventilation. Do not obstruct the flow of combustion and ventilation
air in any way. The ventilation openings on the propane cylinder
enclosure must also remain free and clear of debris.
Portable grills should be level and positioned away from direct
wind prior to each use.
WARNING: Do not install or operate this grill where gasoline or other flammable materials are used or stored. Failure
to comply with this warning could result in explosion or fire
causing property damage or personal injury.
Cylinder Requirements
Your Broilmaster® Premium Gas Grill requires a standard twenty
(20) pound propane gas cylinder.
The maximum height allowable for a replacement cylinder is approximately twelve (12") inches (30.5 centimeters).
The propane gas cylinder used must be:
1. Constructed and marked in accordance with the specifications
for LP gas cylinder of the U.S. Department of Transportation
(D.O.T.) or the National Standard of Canada, CAN/CSA-B339,
Cylinders, Spheres, and Tubes for Transportation of Dangerous
Goods; and Commission as applicable.
2. Provided with a listed overfilling protection device (OPD).
3. Provided with a listed safety device having direct access with
the vapor space of the cylinder and the cylinder supply system
must be arranged for vapor removal.
4. Provided with a shutoff valve terminating in a valve outlet as
specified in the Standard for Compressed Gas Cylinder Outlet
and Inlet Connections, ANSICGA-V-1.
5. Provided with a plug to effectively seal off the cylinder outlet
when the cylinder is being stored or transported.
6. Provided with a collar to protect the cylinder valve.
Caution: Do not use a propane gas cylinder which has a capacity greater than twenty (20) pounds with this grill and side
burner.
Page 14
B101362-2-0610
propane gas grills
Propane Cylinder Safety
Connection Requirements
Liquid Propane (LP) gas has a long history of safe use when the
safety precautions provided in this manual are followed.
Caution: Never use Liquid Propane (LP) gas in a grill designed
for Natural gas, or Natural gas in a grill designed for Liquid
Propane gas. Questions regarding different types of gases
should be directed to your local gas supplier.
Failure to follow these safety precautions could result in a fire
or explosion causing property damage or personal injury.
Propane gas cylinders should always be handled, stored, and transported with extreme caution in a secured upright position.
Never attempt to use or repair a propane gas cylinder that has been
damaged. Never attempt to use or repair a cylinder with a faulty or
damaged valve outlet. A cylinder that has been dropped, dented,
or otherwise damaged must be replaced.
A propane gas cylinder should never be transported in the passenger
area of a vehicle.
Keep cylinders out of direct sunlight and never apply any other
source of direct heat to them.
When refilling your cylinder, always insist on a reputable, qualified gas dealer. Your propane gas cylinder is filled by weight, and
should never exceed eighty percent (80%) of its weight limit. If
the cylinder is not completely empty, the gas dealer must make
necessary adjustments to ensure it is not overfilled. Never use an
overfilled Propane gas cylinder.
Cylinder Storage
Installation must conform to local codes or, in the absence of local
codes, with the National Fuel Gas Code, ANSI Z223.1. In Canada,
installation shall be in accordance with CAN/CGA-B149.2 Propane
Installation Code, or CAN/CGA-B149.1 Natural Gas Installation
Code, and local codes where applicable. Consult your local gas
supplier or propane gas dealer for code regulations and recommended procedures.
Warning: Broilmaster® Premium Gas Grills require Liquid
Propane (LP) cylinders equipped with an Overfill Protection
Device (OPD). An overfilled or improperly filled Propane
cylinder can be dangerous.
Always use the pressure regulator and hose assembly supplied with
your Propane gas grill.
Note: Not all valve and cylinder combinations are compatible.
Check warning tag on valve and cylinder as well as external fitting threads.
All Broilmaster® pressure regulators and hose assemblies require
Propane cylinders with a Type 1 connection device as illustrated.
See Figure 10.
Your grill must be stored outdoors in a well ventilated area if the
cylinder is attached to it.
Disconnected cylinders must have a threaded valve plug tightly
installed and must not be stored in any building, garage, or other
enclosed area.
Flammable materials (gasoline, grill covers, etc.) must not be stored
in the cylinder enclosure.
Figure 10
Always store Propane cylinders in a secured upright position, out
of the reach of children.
B101362-2-0610
Page 15
propane gas grills
Pressure Regulator and Hose Assembly
The pressure regulator has an outlet pressure of not more than eleven (11") inches water column. It must be connected to the Propane
gas cylinder’s female valve outlet before the grill can be operated.
Caution: Operation of a Propane gas grill without the pressure regulator and hose assembly will cause gas leaks which could
lead to fire or explosion, resulting in property damage or personal injury.
The pressure regulator’s fitting must remain clean and free of nicks and scratches. A dirty, nicked or scratched fitting can cause a gas leak,
resulting in an explosion or fire. Use only genuine Broilmaster® replacement parts unless otherwise specified by the manufacturer.
Connecting to Propane Gas / Cylinder Retention Means
ATTENTION: Propane gas cylinders that are acceptable for use with this grill must comply with Cylinder Requirements, Page 14,
and Connection Requirements, Page 15.
Position the cylinder in the opening in the bottom of the cart and secure with the cylinder retaining bracket. See Figure 11.
Cylinder
Retaining
Bracket
Figure 11
Attach the pressure regulator to the Propane gas cylinder’s valve
using the plastic handwheel. Tighten in a clockwise motion to
achieve a gas tight seal. See Figure 12.
Caution: Do not use a wrench or any other tool to tighten. Use
of a wrench or other tool will damage the plastic handwheel.
To disconnect the Propane gas cylinder, turn OFF the cylinder’s
valve and the grill’s control valve. Remove the regulator by turning
the plastic handwheel counterclockwise.
Caution: Assure hose does not touch the casting or
mounting components.
Clockwise
Clockwise
Figure 12
Page 16
B101362-2-0610
gas conversion
Gas Conversion
Remove the hose and regulator from the valve.
Propane grills include a conversion kit for natural gas. If you have
a natural grill and wish to convert it to propane you will need to
purchase the optional conversion kit BCK1003.
Begin by removing all the components from the inside of your grill.
Locate and remove the orifice hoods mounted on the underside of
the grill body, using 2 wrenches as shown. See Figure 13.
Replace the components inside of your grill.
Remove the knobs from the valve assembly and locate the adjustment screws on the inside of the valve stem. Using a small screw
driver, turn the screws clockwise until screw bottoms, then turn
the screws four (4) FULL turns counterclockwise. Do not back the
screws out more than 4 1/2 turns or a leak may result.
See Figure 15.
Connect the grill to the natural gas supply.
Important: Before lighting your grill, check the gas connections and the adjustment screws for leaks using a soapy water
solution.
Figure 13
Caution: Never use this or any gas appliance which may be
leaking gas.
Replace the knobs.
HOSE
REGULATOR
HOSE AAND
ND RE
GULA TOR
SUPPLY
TUBE
SUPP LY TUB
E
ORIFICE HOOD
Figure 15
CONTROL PANEL
ORIFICE HOOD
Before installing the natural hoods, inspect them for damage and
note the number stamped on the side. The correct hood will be
marked 48".
The hoods are self-sealing, requiring no additional pipe sealant. If
you wish to use sealant, take care to add it to the threads only to
avoid blocking the orifice.
LEFT
HI
OFF
HI
3
Thread the hoods onto the supply tubes leaving about a 1/8" gap
between the hood and the locking nut. See Figure 14.
RIGHT
OFF
3
2
1
2
LO
1
LO
VALVE STEM
ADJUSTMENT SCREW
Figure 14
NUT
1/8"
NOTE: When converting your grill to Natural gas and your incoming gas pressure is below 7" (water column), a DPA105 regulator
kit can be purchased.
48
SUPPLY
SUPPLY
TUBE
TUBE
Place the completed conversion label adjacent to the product identification label, located on the control panel (26).
ORIFICE
HOOD
B101362-2-0610
WRENCH
Page 17
natural gas grills
Grill Location
Gas Type
When choosing the ideal location for your Broilmaster® Premium
Gas Grill, remember this grill is designed for outdoor use ONLY.
The type gas required for your grill can be determined from the
product identification label located on the grill’s control panel.
Questions regarding different types of gases should be directed to
your local gas supplier.
You should never install or operate your grill in any building,
garage, or other enclosed area.
For your safety, this grill should not be installed or operated under any combustible materials, such as carports, covered porches,
awnings, or overhangs.
Caution: Never use Liquid Propane (LP) gas in a grill designed
for Natural gas, or Natural gas in a grill designed for Liquid
Propane gas. Questions regarding different types of gases
should be directed to your local gas company.
Never install or operate your grill in or on any recreational vehicle
or boat.
CAUTION: The installation and operation of this grill at
clearances less than specified below may lead to the possibility
of fire, property damage, or personal injury.
A minimum clearance of sixteen inches (16") is required from the
sides of the grill to any combustible material.
A minimum clearance of eighteen inches (18") is required from
the back of the grill to any combustible material.
Some examples of combustible materials are a wall, a fence, patio
furniture, or the wall of your home.
The area surrounding the grill should be clear to ensure proper
ventilation. Do not obstruct the flow of combustion and ventilation
air in any way. The ventilation openings on the propane cylinder
enclosure must also remain free and clear of debris.
Portable grills should be level and positioned away from direct
wind prior to each use.
WARNING: Do not install or operate this grill where gasoline or other flammable materials are used or stored. Failure
to comply with this warning could result in explosion or fire
causing property damage or personal injury.
Page 18
Connection Requirements
Installation must conform to local codes or, in the absence of local
codes, with the National Fuel Gas Code, ANSI Z223.1. In Canada,
installation shall be in accordance with CAN/CGA-B149.2 Propane
Installation Code, or CAN/CGA-B149.1 Natural Gas Installation
Code, and local codes where applicable. Contact your local gas
company for code regulations, recommended procedures, and the
installation of your grill’s gas supply line.
Broilmaster® grills are not equipped with pressure regulators.
Your gas grill operates at a manifold pressure of seven (7") inches
water column.
Connect cart mounted Natural gas grills to a pre-installed gas
supply line using the twelve (12’) foot flexible hose and quick
disconnect kit which can be purchased from your local dealer.
Caution: The grill and its individual shutoff valve must be disconnected from the gas supply piping system during any system
pressure testing at test pressures in excess of 1/2 PSIG.
Caution: The grill must be isolated from the gas supply piping
system by closing its individual manual shutoff valve during
any pressure testing of the gas supply piping system at test
pressures equal to or less than 1/2 PSIG.
B101362-2-0610
operation - propane & natural gas grills
Checking for Gas Leaks
Check for gas leaks every time you connect your Broilmaster®
propane gas grill to a Propane gas cylinder, when a connected
cylinder has not been used recently, or when either a natural or
propane grill is being used for the first time.
Caution: Do not use an open flame when checking for leaks.
Checking for leaks with an open flame may lead to a fire or
explosion, resulting in property damage or personal injury.
To check for gas leaks:
1. Use dish washing liquid and a little water to make a soapy
solution.
2. Turn OFF the knob on the control panel.
3. Turn ON the gas at the supply or cylinder. A hissing sound
indicates a leak. Turn OFF the gas and repair the leak.
4. Apply the soapy water solution to all gas connections.
5. Look for bubbles. Bubbles indicate a leak.
6. If there are bubbles turn OFF the gas and repair the leak.
7. Turn the gas back ON and repeat the above procedures until
all leaks are repaired.
Air Shutter Adjustment
The venturi air shutter(s) are preset at the factory so that after five
minutes the burner flames are blue with well defined cones. If,
after five minutes the flame is yellow, or there is a gap between the
burner and the flame, adjust the venturi air shutter as follows:
1. Turn gas OFF and let the burner cool.
2. Loosen shutter set screw
3. Close the air shutter to the minimum opening. See Figure 5.
4. Light the burner, wait five minutes and then carefully open the
air shutter until the flame is blue and well defined.
5. Retighten the set screw.
Operating Instructions
Using the Ignitor
Caution: If a burner fails to light after 5 seconds, turn the
burner OFF for 5 minutes, to allow the gas to clear, then try
again.
1. Turn knob on the grill CLOCKWISE to the OFF position.
2. Turn ON gas at the source.
3. With the grill lid open, push and turn the burner control knob
COUNTERCLOCKWISE to Hi.
4. Push and hold the ignitor button until the burner lights (approximately 5 seconds).
5. If a burner does not light, turn OFF all gas and refer to the
Troubleshooting section of this manual.
Operating Instructions
Using Matches
Caution: If a burner fails to light after 5 seconds, turn the
burner OFF for 5 minutes, to allow the gas to clear, then try
again.
1.
2.
3.
4.
Turn knob on the grill CLOCKWISE to the OFF position.
Turn ON gas at the source.
Open the grill lid.
Insert a burning long wooden match through the lighter hole
on either side of the grill.
5. Turn the burner control knob COUNTERCLOCKWISE to
HI.
6. If a burner does not light, turn OFF all gas and refer to the
Troubleshooting section of this manual. See Figure 16.
Figure 16
B101362-2-0610
Page 19
operation
Before Cooking
Electrical Accessories
Before cooking on a grill for the first time, it should be broken in
to burn off any oil residue from the manufacturing process.
If an electrical accessory (e.g. rotisserie) is used on your grill, the
accessory must be electrically grounded in accordance with local
codes or, in the absence of local codes, with the National Electric
Code, ANSI/NFPA 70. In Canada, the electrical accessory must
be electrically grounded in accordance with the applicable section
of the current Canadian Electrical Code, CSA C22.1.
1.
2.
3.
4.
5.
Raise the grill lid.
Light grill burner.
Burn on HI for ten minutes.
Close the lid and burn on HI for an additional ten minutes.
Turn OFF gas. The grill is now ready for use.
Preheating
Before cooking on a gas grill, allow the grill to preheat on HI for
5 minutes with the lid closed.
This uses very little fuel and provides better flavor.
Cooking
Broilmaster® is happy to provide a cookbook with each of its grills.
The cookbook contains helpful cooking tips and instructions as
well as great tasting recipes for preparing many delicious foods
on your grill.
Page 20
Any electrical accessory should be equipped with a three-prong
(grounding) plug, and plugged into a properly grounded three-prong
receptacle or wall outlet. Do not cut or remove the grounding
prong from the plug.
If an extension cord is required, use only a three-prong cord and
plug into a properly grounded receptacle as described above.
Do not expose an electrical accessory to water. Avoid using any
electrical accessory in wet weather as it may present a shock
hazard.
Keep any electrical cord and fuel supply hose away from all heated
surfaces.
B101362-2-0610
maintenance
Cleaning the Grill
Caution: To prevent injury, use care when cleaning a hot
grill.
Note: Do not use a commercial cleaner on the cooking grid. Do
not brush grids while they are hot. Do not scrape grids.
For baked on residue use a brass (NOT STEEL) brush on the
cooking grid and other components.
Burn Off
This process is much like that used in self-cleaning ovens and is
most efficient when completed after each use of the grill.
Caution: Do not open the grill during the burn off process.
Opening the grill during the burn off process may cause a
sudden grease fire flare up that could burn your face and arms.
Wait until the grill has cooled before opening.
1. Turn gas knob to HI. Close lid and allow the grill to burn for
ten minutes, or until no smoke is present. Do not allow the
grill to burn for more than 30 minutes.
2. Turn gas knob and supply to OFF and allow the grill to cool.
Venturi Tubes
The venturi tubes allow air and gas to mix prior to burning, thus
ensuring an efficient flame. Spiders or other small insects may
build webs or nests inside the tubes obstructing air flow. Fire, or
flashback, can occur, in and/or around obstructed venturi tubes and
can cause damage to components beneath the grill or an unsafe
condition. To reduce risk, inspections and cleaning should be
performed at least twice monthly when spiders are active. If the
grill has been unused for an extended period of time inspect the
tubes before using the grill.
Clean venturi tubes as follows:
1. Remove the cooking grids and briquette rack.
2. Remove the burner from the grill.
3. Lay the burner face down and remove the four retaining screws
from the venturi tube plate and the burner. See Figure 17.
4. Use a small flexible brush to remove any debris for the
tube(s).
5. Flush with water.
6. Allow the tube(s) to dry before reinstalling.
7. Reinstall the venturi tubes and burner.
3. Wipe COOL grill with a damp cloth to remove soot.
Grill Bottom
Periodically remove cooking grids and flare guard to clean the
interior of the grill. Scrape off baked on residue with a putty knife
or brass brush and rinse with water. Clean the bottom air holes
with a small knife.
Burner Maintenance
Stainless steel burners often turn reddish brown after use. This does
not effect the performance of the grill. When cleaning the interior
of the grill, remove the burners and clean with a brass brush. Wash
with water and a mild detergent.
Grease Tray
Empty periodically. Replacement tray liners can be purchased at
most supermarkets where disposable aluminum baking pans are
displayed.
Figure 17
Exterior
Clean regularly with a solution of mild detergent and hot water.
Touch-up paint is available from your dealer. Broilmaster® protective covers are recommended. Stainless steel components can
be easily cleaned with a spray-on stainless steel cleaner found in
most hardware stores.
Briquettes
If the briquettes did not come clean during burn off, after cooling
turn them over. The residue will burn off during warm-up for the
next use.
B101362-2-0610
Page 21
troubleshooting
Although the manufacturer has attempted to ensure that your grill will operate properly and satisfactorily, sometimes problems do arise. The following troubleshooting guide lists several possible problems and their probable
cause and solution.
Problem
Cause
Solution
Burner will not light.
Gas injector not inserted in venturi
tube.
Clogged gas injector.
Realign/engage gas injector with the
venturi tube.
Remove gas injector from gas control
assembly and clean.
For propane models, ensure gas valve
on cylinder is OFF. Remove flexible
hose and blow out any debris.
Clean venturi tubes. See Maintenance
Section.
Position electrode properly. Clean collector box.
Refill LP gas cylinder. If natural model,
turn on gas at source.
Replace with AA Alkaline battery.
Adjust air shutter.
Realign/engage gas injector with the
venturi tube.
Contact gas supplier for assistance.
Refer to gas conversion instructions in
this manual.
Preheat grill at least 5 minutes on HI
with the grill lid closed.
Realign/engage gas injector with the
burner tube.
Adjust air shutter.
Turn or shield grill.
Open air shutter
Clean venturi tubes. See Maintenance
Section.
Clean by washing burner with mild
detergent.
Allow burner to operate on HI for 1015 minutes.
Obstruction in gas line.
Spider webs in venturi tubes.
Misalignment of collector box and
burner.
Out of gas
Inadequate grill temperature.
Flames blow out.
Yellow flames.
Dead battery.
Poor combustion.
Misalignment of venturi tube and gas
injector.
Inadequate gas pressure.
Incorrect orifice/valve setting.
Cold grill.
Misalignment of burner tube and gas
injector.
Poor combustion.
Extreme wind.
Air shutter improperly set.
Spider webs in venturi tubes.
Seasoning salts on burner.
Oil film on burner.
Page 22
B101362-2-0610
WARRANTY TERMS
The Most Durable Grill Known
To Man
Lifetime •
•
•
•
•
•
•
10-Year •
Aluminum Grill Housing (except paint)
Cast Stainless Steel Cooking Grids
Porcelain-Coated Cast Iron Cooking Grids
Stainless Steel - Cart, Mounting, Bowtie Burner, T3 Burner
Side Burner (DPSBSS), Side Burner Housing, and Warming Rack
Stainless Steel Built-In Components: Built-In Kit for Broilmaster P3/T3
Grill Head, Door Kit, Tilt-Out LP Tank Door and Vent Register Kit
Built-In Kit (BSA) with Side Burner (DPASBC)
5-Year • Painted Electro-Galvanized Parts
• Stainless Steel Smoker Shutter
2-Year •
•
•
1-Year •
•
•
Porcelain-Coated Steel Briquet Racks
Stainless Steel Flavor Screen and Heat Shield
Chrome-Plated Warming Rack
All Other Parts
Painted Steel - Unless specified above
Paint on Aluminum Grill Head
WHAT IS COVERED AND FOR HOW LONG
• From the date this Broilmaster Premium Grill is first purchased, we will make available at our factory a
free replacement for any defective parts covered by this warranty on the following basis. Proof of purchase
required. Warranty applies to original owner and is not transferable.
WHAT IS NOT COVERED
• Removal and reinstallation cost.
• Labor for replacement or repairs
• The costs of a service call to diagnose a problem
• Transportation and shipping cost.
• Grills and finishes damaged by abrasive cleaning, improper installation, improper storage, accident, misuse,
abuse, alteration, commercial use, and unusually harsh environmental conditions. Harsh conditions could
include, but are not limited to: continual seawater spray, direct contact with pool chemicals or lawn chemicals, direct contact with corrosive materials.
• Inoperable due to improper or lack of cleaning
• Damage from accident, misuse, alteration, abuse, improper installation or storage.
This warranty does not imply or assume any responsibility for consequential damages that might result from misuse, or
improper installation of this cooking appliance.
This warranty does not cover claims which do not involve defective workmanship or materials.
A bill of sale, cancelled check, or payment record should be kept to verify purchase date and establish warranty period.
Note: Broilmaster, a Division of Empire Comfort Systems, Inc., has a policy of constantly improving quality and performance of its appliances; therefore, materials and specifications are subject to change without notice.
B101362-2-0610
Page 23
The Most Durable Grill
Known To Man
BROILMASTER®
A Division of Empire Comfort Systems, Inc.
918 Freeburg Ave.
Belleville, Illinois 62220
Visit our web site at www.broilmaster.com
if you have a general question about our products, please e-mail us at info@empirecomfort.com.
If you have a service or repair question, please contact your dealer.
Page 24
B101362-2-0610