Broilmaster P4, P3 User Manual

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PREMIUM "P" GAS GRILL

OWNER’S MANUAL

(NATURAL OR PROPANE GAS)

P3 AND P4 MODELS

NOW THAT YOU’VE FOUND EACH OTHER....

IMPORTANT

THIS MANUAL SHOULD BE READ THOROUGHLY BY THE PERSON INSTALLING THE GRILL AND ALL PERSONS

WILL USE AND MAINTAIN THE GRILL. THE INSTALLER SHOULD BE SURE THE MANUAL IS LEFT IN THE

WHO POSSESSION

OR CLEANING THE GRILL AND TO PROPERLY IDENTIFY ANY REPAIR PARTS THAT MAY BE REQUIRED.

USING

OF THE USER. THE USER SHOULD RETAIN THIS MANUAL FOR FUTURE REFERENCE WHEN

WARNING

REFERENCE THIS MANUAL FOR PROPER INSTALLATION AND MAINTENANCE INSTRUCTIONS. IMPROPER

INSTALLATION PROPERTY

SERVICE AGENCY OR THE GAS SUPPLIER.

, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE CAN CAUSE PERSONAL INJURY OR

DAMAGE. FOR ASSISTANCE OR ADDITIONAL INFORMATION CONSULT A QUALIFIED INSTALLER,

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 DEPARTMENT.

FIRE

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 OR ANY OTHER APPLIANCE.

THIS

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.

Congratulations!Congratulations!

Congratulations!

Congratulations!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

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!Thank You!

Thank You!

Thank You!Thank You!

your choice

as the premium grill

Broilmaster® is a registered trademark of

Empire Comfort Systems, Inc.

918 Freeburg Ave.

Belleville, Illinois 62220

Telephone 800-851-3153

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

Parts

Diagram ........................................................................................................3

List

................................................................................................................4

Grill Assembly .....................................................................................................5-9

gas grill.

Propane Gas Connection Gas Conversion Natural Gas Connection Operation

Maintenance ...................... ....................................... ........................................17

Troubleshooting ....................................................................................................18

Warranty ...........................................................................................................20-21

..................................................................................... ................15-16

..................................................................... ...............................13

.................. ..............................................................10-12

..................................................................... .................14

Y our 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 .

Model No. Dealer Serial No. Dealer Phone No. Gas Type: Propane Natural Date of Purchase

PARTS DIAGRAM

INSTALL THIS SIDE UP

All repair part orders should be placed through your local Broilmaster® dealer . To locate a dealer in your area, contact Broilmaster Customer Service at (618) 233-7420. To ensure prompt and accurate service, please provide the following information when placing a repair part order: Model Number, Part Name, Part Number, and Quantity of parts needed.

1 2

13 14

15 16

18 19

20 21

7 8 9

24 25 26

28 29

PREMIUM "P" SERIES PARTS LIST

1 2 3 4 5 6 7 8

9 10 11

12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

—

27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

P4HG

Part No.

P3GY

Part No.

P4BL

Part No. 057805 057804 072695

743100E

058122 064539 069756 076703

225 076521 076790 076789 056647 076702 076625 070282 073097 063066 878531 072701 063065 069743 073100 072218 069747 072684 076653 072686 070084 073967 073963 076535 076330 662325 076332 076331 076333 076522

HD156

HD492 073978 906180 905048

HD577

P3BL

Part No.

P3HG

Part No.

Part Name

Bridge Pin Hinge Pin Wire Retract-A-Rack Cooking Grid Briquette Bag Grid Lifter Assembly Hose & LP Regulator Grill Bottom Lid Stop Knob Lid Stop Control Valve Assembly (LP) Control Valve Assembly (NAT) Natural Orifice Hood * Grill Lid Heat Indicator Stainless Steel Handle Foam Grip Briquette Rack Burner Assembly Collector Box Assembly Radiation Shield Collector Box Spacer Pull Handle Electronic Igniter Igniter Ground Lug Igniter Ground Wire Control Panel Assembly Control Panel Label Valve Knob Keps Nut Shelf Pin Conversion Label * 1/4 -20 x 1 1/2 Bolt Spacer 9/32 ID x 5/8 OD Flat Washer 1/4-20 Hex Nut Lock Washer #10-24 x 3/4 Screw 3/8-16 x 1 1/2" Bolt 3/8 Star Washer #10-24 x 1 Screw Stabilizer Arm ** Stabilizer Bracket ** #10-24 x 3/8 Screw **

Key No.

057805 057804 072695

743100E

058122 064539 069756 073281

225 076521 076790 076789 056647 073280 076625 070282 073097 063066 878531 072701 063065 069743 073100 072218 069747 072684 076653 072686 070084 073967 073963 076535 076330 662325 076332

076331

076333 076522

HD156

HD492 073978 906180 905048 HD577

057805 057804 072695

743100E

058122 064539 069756 076828

225 076521 076790 076789 056647 076827 076625 070282 073097 063066 878531 072701 063065 069743 073100 072218 069747 072684 076653 072686 070084 073967 073963 076535 076330 662325 076332 076331 076333 076522 HD156 HD492 073978 906180 905048 HD577

057805 057804 072696

804687E

058122 064539 069756 076705

225 076521 076790 076789 056647 076704 076625 070486 073097 067449 814801 072701 063065 069743 073100 072218 069747 072684 076626 072197 070084 073967 073963 076535 076330

662325

076332 076331 076333 076522

HD156

HD492 073978 906180 905048

HD577

057805 057804 072696

804687E

058122 064539 069756 076830

225 076521 076790 076789 056647 076829 076625 070486 073097 067449 814801 072701 063065 069743 073100 072218 069747 072684 076626 072197 070084 073967 073963 076535 076330 662325 076332 076331 076333 076522

HD156

HD492 073978 906180 905048

HD577

057805 057804 072696

804687E

058122 064539 069756 076826

225 076521 076790 076789 056647 076825 076625 070486 073097 067449 814801 072701 063065 069743 073100 072218 069747 072684 076626 072197 070084 073967 076963 076535 076330 662325 076332 076331 076333 076522

HD156 HD492

073978 906180 905048

HD577

P4GY

Part No.

* Included with Propane Grills Only. ** Burner Stabilizer Kit is included with your cart.

Key No.

10 11

12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

—

27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

* Included with Propane Grills Only. ** Burner Stabilizer Kit is included with your cart.

Part Name

Bridge Pin

Hinge Pin

Wire Retract-A-Rack

Cooking Grid

Briquette Bag

Grid Lifter Assembly

Hose & LP Regulator

Grill Bottom

Lid Stop Knob

Lid Stop Control Valve Assembly (LP) Control Valve Assembly (NAT) Natural Orifice Hood * Grill Lid Heat Indicator Stainless Steel Handle Foam Grip Briquette Rack Burner Assembly Collector Box Assembly Radiation Shield Collector Box Spacer Pull Handle Electronic Igniter Igniter Ground Lug Igniter Ground Wire Control Panel Assembly Control Panel Label Valve Knob Keps Nut Shelf Pin Conversion Label * 1/4 -20 x 1 1/2 Bolt Spacer 9/32 ID x 5/8 OD Flat Washer 1/4-20 Hex Nut Lock Washer #10-24 x 3/4 Screw 3/8-16 x 1 1/2" Bolt 3/8 Star Washer #10-24 x 1 Screw Stabilizer Arm ** Stabilizer Bracket ** #10-24 x 3/8 Screw **

P3BL

Part No.

057805 057804 072695

743100E

058122 064539 069756 076703

HD156

HD492 073978 906180 905048

HD577

P3HG

Part No.

057805 057804 072695

743100E

058122 064539 069756 073281

225 076521 076790 076789 056647 073280 076625 070282 073097 063066 878531 072701 063065 069743 073100 072218 069747 072684 076653 072686 070084 073967 073963 076535 076330 662325 076332

076331

076333 076522

HD156

HD492 073978 906180 905048 HD577

P3GY

Part No.

057805 057804 072695

743100E

058122 064539 069756 076828

HD156

HD492 073978 906180 905048

HD577

P4BL

Part No.

057805 057804 072696

804687E

058122 064539 069756 076705

225 076521 076790 076789 056647 076704 076625 070486 073097 067449 814801 072701 063065 069743 073100 072218 069747 072684 076626 072197 070084 073967 073963 076535 076330

662325

076332 076331 076333 076522

HD156

HD492 073978 906180 905048

HD577

P4HG

Part No.

057805 057804 072696

804687E

058122 064539 069756 076830

HD156

HD492 073978 906180 905048

HD577

P4GY

Part No.

057805 057804 072696

804687E

058122 064539 069756 076826

HD156 HD492

073978 906180 905048

HD577

GRILL ASSEMBLY

Before You Begin

All Broilmaster grills require some assembly and installation. Follow all instructions unless noted to apply only to other specific models.

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 before beginning assembly .

dealer

Grill Mountings

Refer to the Broilmaster® Cart, Base, and Post instructions provided with each accessory for assembly , installation, and mounting procedures.

Pull Handle

Place two bolts (31) into holes in pull handle (22) and through holes on left side of grill bottom (8).

Fasten each bolt with a washer (33), lock washer (35), and nut (34). F

Repeat procedure for the right side.

FIGURE 1

IGURE 1.

CAUTION: FOR YOUR SAFETY PARTS MAY HAVE SHARP EDGES. WEAR LEATHER WORK

GLOVES UNPACKING

AND HANDLE PARTS CAREFULLY DURING THE

, ASSEMBLY AND INSTALLATION.

Recommended Tools

These items are recommended for the assembly of your grill:

• Phillips screwdriver

• Adjustable wrench set

• Socket set

• Soapy water solution (to test for leaks)

• Liquid soap (for foam grip)

GRILL ASSEMBLY

Nut

Igniter Assembly

Slide the collector box spacer (21) and nut (provided on assembly) onto the collector box shaft and tighten. FIGURE 5.

FIGURE 6

FIGURE 5

Installing the Igniter

AA ALKALINE BATTERY

GROUND

Battery Installation: Slide the spring onto the negative end of the battery. Drop the battery and spring into the igniter and replace the button.

Burner Stabilizing Arm

(Portable Cart Models Only)

On the burner assembly (18) remove the rear screw, insert the burner stabilizing arm (40), and reinstall the screw as shown. FIGURE 7.

Note: Burner Stabilizing Arm, Burner Stabilizing Bracket, and Securing the Burner sections of this manual apply only to portable cart models ONLY. Hardware is packaged with your cart.

SPARK

CAUTION: DO NOT CUT OR DAMAGE IGNITER WIRE.

Carefully thread the end of the igniter wire through the center hole in the grill bottom. Slide the ground lug (24) over the igniter wire and fasten with nut provided.

Attach one end of the ground wire (25) to the terminal on the rear of the electronic igniter. Attach the remaining end to the ground lug. F

IGURES 5 AND 6.

FIGURE 7

Venturi Tubes

GRILL ASSEMBLY

Air Shutter

Shutter Set Screw

Venturi Tube

Burner Stabilizing Bracket

(Portable Cart Models Only)

Remove the factory installed phillips screw and speed nut that are located in the grill bottom. FIGURE 8.

Tip: Test the alignment of the burner stabilizing brackets before tightening the burner stabilizing bracket.

Install the burner stabilizing bracket (41) and fasten with the phillips screw and speed nut.

Factory Installed Screw

FIGURE 8

FIGURE 9

INSTALL THIS SIDE UP

FIGURE 10

Radiation Shield

Place the radiation shield (20) in the grill bottom. FIGURE 9.

Installing the Burner

Insert the burner assembly into the grill bottom with the venturi tubes facing the front of the grill. FIGURE

10. The gas jets from the control valve will be inside the

ends of the venturi tubes when properly installed. F

IGURE 11.

FIGURE 11

GRILL ASSEMBLY

Securing the Burner

(Portable Cart Models Only)

Secure the burner by aligning the burner stabilizing bracket and the burner stabilizing arm and fastening with a screw (42) and a keps nut (28). F

IGURE 12.

FIGURE 13

FIGURE 12

Lid Stop

Attach the lid stop assembly to the grill bottom as shown. FIGURE 13.

Handle

For your added comfort a foam grip (16) has been provided. FIGURE 15.

Tip: For ease of installation, slightly lubricate the front handle with liquid soap before pushing the foam grip into place.

Fasten the stainless steel front handle (15) to the grill lid (13) with two #10-24 x 1" screws (39). FIGURE 14.

FIGURE 14

16 39

FIGURE 15

GRILL ASSEMBLY

Installing Racks

Place the briquette rack on the burner assembly. Position the ceramic briquettes evenly on the

briquette rack without overlapping.

FIGURE 17

Set the multilevel cooking grids F

IGURE 17.

Grid Lifter

Assemble the grid lifter as shown. FIGURE 18. When positioning or removing grids always use the

grid lifter provided with your grill.

FIGURE 18

38 37

PROPANE GAS GRILLS

Grill Location

When choosing the ideal location for your Broilmaster grill is designed for outdoor use ONL Y.

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

GRILL AT CLEARANCES LESS THAN SPECIFIED BELOW

THIS

LEAD TO THE POSSIBILITY OF FIRE, PROPERTY

MAY DAMAGE

A minimum clearance of sixteen (16”) inches is required from the sides of the grill to any combustible material.

A minimum clearance of eighteen (18”) inches 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.

Premium Gas Grill, remember this

, OR PERSONAL INJURY.

Gas Type

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.

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.

WARNING: D O NOT INSTALL OR OPERATE THIS GRILL

GASOLINE OR OTHER FLAMMABLE MATERIALS ARE

WHERE

OR STORED. FAILURE TO COMPLY WITH THIS

USED WARNING PROPERTY

COULD RESUL T IN EXPLOSION OR FIRE CAUSING

DAMAGE OR PERSONAL INJURY.

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

HAS A CAPACITY GREATER THAN TWENTY (20)

WHICH

POUNDS WITH THIS GRILL AND SIDE BURNER.

PROPANE GAS GRILLS

Propane Cylinder Safety

Liquid Propane (LP) gas has a long history of safe use when the safety precautions provided in this manual are followed.

FAILURE TO FOLLOW THESE SAFETY PRECAUTIONS

COULD PROPERTY

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. Y our propane gas cylinder is filled by weight, and should never exceed eighty (80%) percent 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.

RESULT IN A FIRE OR EXPLOSION CAUSING

DAMAGE OR PERSONAL INJURY.

Connection Requirements

CAUTION: NEVER USE LIQUID PROPANE (LP) GAS IN

GRILL DESIGNED FOR NATURAL GAS, OR NATURAL

IN A GRILL DESIGNED FOR LIQUID PROPANE GAS.

GAS

QUESTIONS REGARDING DIFFERENT TYPES OF GASES

SHOULD

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 WITH OVERFILLED CYLINDER

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 T ype 1 connection device as illustrated. FIGURE 19.

BE DIRECTED TO YOUR LOCAL GAS SUPPLIER.

LIQUID PROPANE (LP) CYLINDERS EQUIPPED

AN OVERFILL PROTECTION DEVICE (OPD). AN

OR IMPROPERLY FILLED PROPANE

CAN BE DANGEROUS.

Cylinder Storage

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.

Always store Propane cylinders in a secured upright position, out of the reach of children.

FIGURE 19

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 ASSEMBL Y

FIRE OR EXPLOSION, RESULTING IN PROPERTY

TO DAMAGE

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.

THE PRESSURE REGULATOR AND HOSE

WILL CAUSE GAS LEAKS WHICH COULD LEAD

OR PERSONAL INJURY.

Connecting to Propane Gas

(Continued)

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. F

CAUTION: DO NOT USE A WRENCH OR ANY OTHER TOOL

TIGHTEN. USE OF A WRENCH OR OTHER TOOL WILL

TO DAMAGE

IGURE 21

IGURE 21.

THE PLASTIC HANDWHEEL.

Clockwise

Connecting to Propane Gas

Position the cylinder in the opening in the bottom of the cart and secure with the cylinder retaining bracket. FIGURE 20.

FIGURE 20

Cylinder Retaining Bracket

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.

GAS CONVERSION

Gas Conversion

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 #CK195.

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 . F

IGURE 20.

FIGURE 20

HOSE AND REGULATOR

ORIFICE HOOD

SUPPLY TUBE

Remove the hose and regulator from the valve. 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 four (4) turns counterclockwise. Do not back the screws out more than 4˚ turns or a leak may result. F

IGURE 22.

Connect the grill to the natural gas supply .

IMPORT ANT: BEFORE LIGHTING YOUR GRILL, CHECK

GAS CONNECTIONS AND THE ADJUSTMENT SCREWS

THE

LEAKS USING A SOAPY WATER SOLUTION.

FOR

CAUTION: NEVER USE THIS OR ANY GAS APPLIANCE

MAY BE LEAKING GAS.

WHICH

Replace the knobs.

IGURE 22

CONTROL PANEL

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.

Thread the hoods onto the supply tubes leaving about a 1/8" gap between the hood and the locking nut. F

IGURE 21

IGURE 21.

NUT

1/8"

SUPPLY TUBE

LEFT

OFF

VALVE STEM

RIGHT

OFF

ADJUSTMENT SCREW

Place the completed conversion label adjacent to the product identification label, located on the control panel (26).

ORIFICE

HOOD

NATURAL GAS GRILLS

Grill Location

When choosing the ideal location for your Broilmaster® Premium Gas Grill, remember this grill is designed for outdoor use ONL Y.

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

GRILL AT CLEARANCES LESS THAN SPECIFIED BELOW

THIS

LEAD TO THE POSSIBILITY OF FIRE, PROPERTY

MAY DAMAGE

A minimum clearance of sixteen (16”) inches is required from the sides of the grill to any combustible material.

A minimum clearance of eighteen (18”) inches 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.

Portable grills should be level and positioned away from direct wind prior to each use.

W ARNING: DO NOT INSTALL OR OPERATE THIS GRILL

WHERE USED WARNING PROPERTY

, OR PERSONAL INJURY.

GASOLINE OR OTHER FLAMMABLE MATERIALS ARE

OR STORED. FAILURE TO COMPLY WITH THIS

COULD RESUL T IN EXPLOSION OR FIRE CAUSING

DAMAGE OR PERSONAL INJURY.

Gas Type

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.

CAUTION: NEVER USE LIQUID PROPANE (LP) GAS IN

GRILL DESIGNED FOR NATURAL GAS, OR NATURAL

IN A GRILL DESIGNED FOR LIQUID PROPANE GAS.

GAS

QUESTIONS REGARDING DIFFERENT TYPES OF GASES

SHOULD

BE DIRECTED TO YOUR LOCAL GAS COMPANY.

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 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

BE DISCONNECTED FROM THE GAS SUPPLY PIPING

MUST SYSTEM PRESSURES

CAUTION: THE GRILL MUST BE ISOLATED FROM THE

SUPPL Y PIPING SYSTEM BY CLOSING ITS INDIVIDUAL

GAS MANUAL

THE GAS SUPPL Y PIPING SYSTEM AT TEST PRESSURES

OF EQUAL

grills are not equipped with

DURING ANY SYSTEM PRESSURE TESTING AT TEST

IN EXCESS OF 1/2 PSIG.

SHUTOFF VALVE DURING ANY PRESSURE TESTING

TO OR LESS THAN 1/2 PSIG.

OPERATION - PROPANE & NATURAL GRILLS 15

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

LEAKS. CHECKING FOR LEAKS WITH AN OPEN FLAME

FOR

LEAD TO A FIRE OR EXPLOSION, RESULTING IN

MAY PROPERTY

To check for gas leaks:

1. Use dish washing liquid and a little water to

2. T urn OFF the knob on the control panel.

3. Turn ON the gas at the supply or cylinder. A

4. Apply the soapy water solution to all gas

5. Look for bubbles. Bubbles indicate a leak.

DAMAGE OR PERSONAL INJURY.

make a soapy solution.

hissing sound indicates a leak. Turn OFF the gas and repair the leak.

connections.

Operating Instructions

Using the Igniter

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. T urn 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 igniter 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

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.

Refer to Figure 11.

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.

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. T urn knob on the grill CLOCKWISE to the OFF position.

2. Turn ON gas at the source.

3. Open the grill lid.

4. Insert a burning long wooden match through the lighter hole on either side of the grill.

5. T urn 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. F

IGURE 23.

FIGURE 23

OPERATION

Before Cooking

Before cooking on a grill for the first time, it should be broken in to burn off any oil residue from the manufacturing process.

1. Raise the grill lid.

2. Light grill burner .

3. Burn on HI for ten minutes.

4. Close the lid and burn on HI for an additional ten minutes.

5. T urn 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 hot briquette cook quicker and provide 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.

Electrical Accessories

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.

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 threeprong 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.

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 ARE

For baked on residue use a brass (NOT STEEL) brush on the cooking grid and other components.

GRID. DO NOT BRUSH GRIDS WHILE THEY

HOT. DO NOT SCRAPE GRIDS.

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

PROCESS. OPENING THE GRILL DURING THE BURN

OFF

PROCESS MAY CAUSE A SUDDEN GREASE FIRE

OFF

UP THAT COULD BURN YOUR FACE AND ARMS.

FLARE

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.

3. Wipe COOL grill with a damp cloth to remove soot.

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. F

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.

IGURE 24.

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 24

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.

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.

Pr ob l em Solution

Burner will not light.

Inadequate grill temperature.

Cause

Gas injector not inserted in venturi tube.

Clogged gas injector.

Obstruction in gas line.

Spider webs in venturi tubes. Misalignment of collector box and

burner . Out of gas.

Dead battery. Replace with AA Alkaline battery.

Poor combustion.

Misalignment of venturi tube and gas injector.

Realign/engage gas injector with the v ent uri 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.

Adjust air shutter. Realign/engage gas injector with the venturi tube.

Flames blow out.

Y ellow flames.

Inadequate gas pressure. Incorrect orifice/valve setting. Refer to gas conversion instructions in this manual.

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.

Contact gas supplier for assistance.

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. See Maintenance Section.

Clean venturi tubes. See Maintenance Section. Clean by washi ng burner with mild detergent.

Allow burner to operate on HI for 10-15 minutes.

NOTES

WARRANTY

LIMITED WARRANTY

Manufactured by: BROILMASTER®, A Division of Empire Comfort Systems, Inc., 918 Freeburg Ave., Belleville, Illinois

62220.

WHAT IS COVERED AND FOR HOW LONG

From the date this gas grill is first purchased for use, BROILMASTER® will make available, at our factory, a free replacement for any defective part in accordance with the following limitations:

• PERMANENT MOLD ALUMINUM GRILL HOUSING -Lifetime by original purchaser for as long as grill is, and safely can be used as a residential grill.

• PORCELAIN COATED CAST IRON COOKING GRID - Lifetime by original purchaser for as long as grill is, and safely can be used as a residential grill. The use of a brass bristle brush in conjunction with regular burn off is recommended. Damage by dropping, scraping, or abrasive cleaning voids this warranty.

• STAINLESS STEEL BOWTIE BURNER - 15 years prorated with the following schedule: Years 1-5 = Full 100% replacement.

Years 6-10 = Consumer to pay 50% retail price in effect. Years 11-15 = Consumer to pay 75% retail price in effect. Warranty replacement claims in years 6-15 must be made directly to Empire Comfort Systems, Inc.

• STAINLESS STEEL CART - Lifetime by original purchaser for as long as grill is, and safely can be used as a residential grill.

• STAINLESS STEEL BODY, LID, AND MOUNTINGS - Lifetime, as long as grill is, and safely can be, used as a residential gas grill.

• PAINTED ELECTROGALVANIZED STEEL COMPONENTS - 5 years against perforation.

• PORCELAIN COATED STEEL COOKING RACKS - 2 YEARS (S5 MODELS)

• ALL OTHER PARTS - 2 years from date of purchase.

WHAT IS NOT COVERED

• Removal and reinstallation cost.

• Labor costs for replacement or repairs.

• Transportation or shipping cost.

• The cost of a service call to diagnose trouble.

• Finishes on surfaces.

• Damage caused by improper installation, improper storage, accident, misuse, abuse or alteration.

• Unsatisfactory performance due to improper or lack of cleaning.

WARRANTY 21

LIMITATIONS AND EXCLUSIONS

1. No one has authority to add to or vary this limited warranty, or to create for BROILMASTER® any other obligation of liability in connection with this grill.

2. ANY IMPLIED WARRANTY APPLICABLE TO THIS GRILL IS LIMITED IN DURATION TO THE SAME PERIOD OF TIME AS THIS WRITTEN WARRANTY. Some states do not allow limitations on how long an implied warranty lasts, so the above limitations may not apply to you.

3. BROILMASTER® SHALL NOT BE LIABLE FOR INCIDENTAL, CONSEQUENTIAL, SPECIAL OR CONTINGENT DAMAGES YOU MIGHT

SUFFER

the exclusion of limitation of incidental or consequential damages, so the above limitations may not apply to you.

4. This warranty applies only to the original purchaser and may not be transferred.

5. This warranty applies only to a grill sold and used in the United States or Canada.

6. This warranty applies only to a gas grill.

7. If you cannot verify the purchase date of the grill the warranty period will begin on the date the grill was manufactured.

8. Replacement or repair parts are warranted for the remaining period of the original part warranty.

YOUR DUTIES

AS A RESULT OF ITS BREACH OF THIS WRITTEN WARRANTY OR ANY IMPLIED WARRANTY. Some states do not allow

This grill must be assembled, installed, operated and maintained in accordance with all applicable codes and the instruction manual furnished with the grill. You must keep an invoice, canceled check or payment record to verify the purchase date of the grill.

IF YOU HAVE A PROBLEM WITH YOUR GRILL

1. Contact your BROILMASTER® dealer. If you cannot locate your dealer, call or write BROILMASTER® Technical Service Department as indicated below.

2. If you do not receive satisfactory service from the dealer within a reasonable time, write BROILMASTER® Technical Service Department and include the date you purchased your grill, its model and serial numbers, the name and address of the dealer from whom it was purchased, and a description of the problem you are having. Furnish a dated proof of purchase if your grill is within its warranty period.

3. In years six through fifteen all burner warranty claims are to be submitted directly to BROILMASTER® in Florence, Alabama, along with a copy of a dated receipt of bill of sale covering the purchase of the grill.

Technical Service Department

BROILMASTER

A Division of Empire Comfort Systems, Inc.

918 Freeburg Ave.

Belleville, Illinois 62220

Phone: 800-851-3153 Fax: 618-233-7097

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

KEEP THE RELATIONSHIP SOLID...

THE MOST DURABLE GRILL

KNOWN TO MAN

A Division of Empire Comfort Systems, Inc.

Phone: 800-851-3153 Fax: 618-233-7097 VISIT OUR WEB SITE AT WWW.broilmaster.com

FORM NO. 076813-01-0301

BROILMASTER

918 Freeburg Ave.

Belleville, Illinois 62220

Broilmaster P4, P3 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual