Broil King H4PK1N-4 User manual

GAS-FIRED
PREMIUM GRILLS
H3PK1(N)-5; H4PK1(N)-4
H(3,4)X GRILL WITH BLACK CART AND ONE BLACK SHELF

B102526-0-0219Page 2
IMPORTANT
This manual should be read thoroughly by the installer and by anyone who will use
or maintain the grill.
Installer - Write the model number, serial number, and date of installation in the manual.
If available, attach a copy of the receipt. Leave this manual with the grill owner.
Grill Owner - Read and retain this manual. It contains instructions on using and main-
taining your grill, plus information on ordering replacements parts. Attach a copy of
your receipt to this manual. Your receipt established the proof of purchase required
for warranty replacement parts.
WARNING
Follow the instruction in this manual for proper installation and maintenance of the
grill. Improper installation, adjustment, alteration, service or maintenance can cause
injury or property damage. For assistance or additional information consult a
qualied installer, service agency or the gas supplier.
DANGER: FOR YOUR SAFETY
IF YOU SMELL GAS:
1. Extinguish any open ame.
2. Shut off gas to the appliance.
3. Open the grill lid.
4. If odor continues, keep away from the appliance call
your gas supplier or your re department.
WARNING: FOR YOUR SAFETY
1. Do not store or use gasoline or other ammable vapors or liquids in the vicinity
of this or any appliance.
2. Only the LP tank connected for use shall be placed in the vicinity of this grill.
CAUTION:
Parts may have sharp edges. Wear leather work gloves and handle parts carefully
during unpacking, assembly and installation.
WARNING
For LP grills, use propane cylinders equipped with an Overll Protection Device (OPD).
An overlled or improperly lled propane cylinder can be dangerous.
IMPORTANT INFORMATION

B102526-0-0219 Page 3
Thank you for purchasing a Premium Gas Grill.
Broilmaster takes pride in its reputation as the The Most Durable Grill Known to Man.
From its thick aluminum casting to its massive cooking grids, your Broilmaster
is built to last. In fact we still make replacement parts for Broilmaster grills built
more than 30 years ago.
Visit www.broilmaster.com and click on the Hall of Fame to see a sampling of
our long-time customers. We hope you enjoy years of great meals prepared on
your Broilmaster. And we hope to add your photo to the Hall of Fame one day.
Thank You!
BROILMASTER
is a registered trademark of
Empire Comfort Systems, Inc.
Belleville, Illinois

B102526-0-0219Page 4
Y ou have chosen the nest grill for your outdoor cooking pleasure.
Please take time to read this entire manual before assembling your Premium Broilmaster gas grill.
TABLE OF CONTENTS
ASSEMBLY INSTRUCTIONS..................................................................................................... 5
H3PK1 SERIES PARTS DIAGRAM ........................................................................................... 6
H4PK1 SERIES PARTS DIAGRAM ........................................................................................... 7
CART HARDWARE PACK - B102002 ....................................................................................... 8
GRILL HEAD HARDWARE PACK - B102530 ........................................................................... 9
SHELF HARDWARE PACK - B101658.................................................................................... 10
UNPACK AND REMOVE LID ................................................................................................... 11
CART BASE ASSEMBLY......................................................................................................... 12
CART WALLS ASSEMBLY ...................................................................................................... 13
ATTACH WALLS TO BASE...................................................................................................... 14
INSTALL REAR BRACE .......................................................................................................... 15
INSTALL RUBBER GUARD AND BUSHING........................................................................... 16
INSERT BURNER HOLD-DOWN BOLT .................................................................................. 17
ATTACH BOTTOM CASTING TO CART ................................................................................. 18
ATTACH SIDE SHELF......................................................................................................... 19-22
WIND DEFLECTOR PLACEMENT .......................................................................................... 23
INSERT COLLECTOR BOX..................................................................................................... 24
ATTACH IGNITOR WIRE, INSERT CONTROL PANEL........................................................... 25
INSTALL BURNER ASSEMBLY............................................................................................... 26
CONNECT IGNITOR LEADS ................................................................................................... 27
KNOB AND BATTERY PLACEMENT ...................................................................................... 28
HEAT SHIELD PLACEMENT ................................................................................................... 29
TANK RETAINER AND GREASE CUP INSTALLATION ......................................................... 30
HANDLE INSTALLATION ........................................................................................................ 31
REINSTALL LID........................................................................................................................ 32
INSTALL RACKS...................................................................................................................... 33
INSTALL WARMING RACK ..................................................................................................... 34
PROPANE GAS GRILLS..................................................................................................... 35-37
CONNECTING PROPANE GAS GRILL .............................................................................. 38-39
CONNECTING NATURAL GAS GRILL.................................................................................... 40
NATURAL GAS GRILLS .......................................................................................................... 41
COMPLETED ASSEMBLY ....................................................................................................... 42
OWNER’S MANUAL FOR H(3,4)PK1 GRILLS................................................................... 43-52
OPERATION - PROPANE AND NATURAL GAS GRILLS .............................................. 43-44
MAINTENANCE................................................................................................................... 45
TROUBLESHOOTING......................................................................................................... 46
IMPORTANT SAFETY INFORMATION .......................................................................... 47-48
COOKING TIPS ................................................................................................................... 49
WARRANTY TERMS ........................................................................................................... 50
MASTER PARTS DISTRIBUTOR LIST ............................................................................... 51
HOW TO ORDER REPAIR PARTS ..................................................................................... 51
GRILL MAINTENANCE HISTORY....................................................................................... 52

B102526-0-0219 Page 5
ASSEMBLY INSTRUCTIONS
BEFORE YOU BEGIN
This Grill Head requires Broilmaster Mounting (Cart, Post, or a Built-In Kit).
See Mounting Instructions to assemble mounting before Assembling Grill Head.
Compare the parts in the box to the parts list provided in this manual. If any are missing, contact your
Broilmaster dealer before beginning assembly.
All Broilmaster grills require some assembly. For the best results, follow the step-by-step instructions.
For natural gas grills and for permanently mounted LP grills, have your gas supplier run service to the desired
location first.
If you purchased an accessory with your Broilmaster, follow the instructions provided.
TOOLS
REQUIRED
3/8”, 7/16”and
REQUIRED
3/4” 3/8” and 7/16”
REQUIRED
3/8” and 7/16”
REQUIRED
3/8”and 7/16”
REQUIRED
CAUTION:
Parts may have sharp edges. For your safety
wear leather work gloves and handle parts
carefully during unpacking and assembly.
BEFORE YOU BEGIN
This Grill Head requires Broilmaster Mounting (Cart, Post, or a Built-In Kit).
See Mounting Instructions to assemble mounting before Assembling Grill Head.
Compare the parts in the box to the parts list provided in this manual. If any are missing, contact your
Broilmaster dealer before beginning assembly.
All Broilmaster grills require some assembly. For the best results, follow the step-by-step instructions.
For natural gas grills and for permanently mounted LP grills, have your gas supplier run service to the desired
location first.
If you purchased an accessory with your Broilmaster, follow the instructions provided.
TOOLS
REQUIRED
3/8”, 7/16”and
REQUIRED
3/4” 3/8” and 7/16”
REQUIRED
3/8” and 7/16”
REQUIRED
3/8”and 7/16”
REQUIRED
CAUTION:
Parts may have sharp edges. For your safety
wear leather work gloves and handle parts
carefully during unpacking and assembly.
5/16”
REQUIRED
BEFORE YOU BEGIN
This Grill Head requires Broilmaster Mounting (Cart, Post, or a Built-In Kit).
See Mounting Instructions to assemble mounting before Assembling Grill Head.
Compare the parts in the box to the parts list provided in this manual. If any are missing, contact your
Broilmaster dealer before beginning assembly.
All Broilmaster grills require some assembly. For the best results, follow the step-by-step instructions.
For natural gas grills and for permanently mounted LP grills, have your gas supplier run service to the desired
location first.
If you purchased an accessory with your Broilmaster, follow the instructions provided.
TOOLS
REQUIRED
3/8”, 7/16”and
REQUIRED
3/4” 3/8” and 7/16”
REQUIRED
3/8” and 7/16”
REQUIRED
3/8”and 7/16”
REQUIRED
CAUTION:
Parts may have sharp edges. For your safety
wear leather work gloves and handle parts
carefully during unpacking and assembly.

B102526-0-0219Page 6
B100561 (1)
SIDE SHELF
B073097 (1)
FOAM GRIP
B102492 (1)
LID HANDLE (W/SCREWS)
B101473 (1)
GREASE CUP
B102122 (1)
CART SHIELD
B100993 (1)
SHELF SUPPORT STIFFENER
B101969 (1)
BRACKET ATTACH ASSEMBLY
B100559 (1)
SUPPORT BRACKET FRONT
DPP7SS (1)
WIND DEFLECTOR
B100594(1)
RETRACTING RACK
B101635 (1)
RUBBER GUARD
B057804 (2)
HINGE PIN
B057805 (2)
COTTER PIN
DPA120 (1)
COOKING GRID (2) PIECES
B070084 (2)
VALVE KNOB
B072218 (1)
ELECTRONIC IGNITOR
B101622 (1)
CONTROL PANEL SHIELD
B101879 (1)
GRILL BODY BOTTOM
B101061 (1)
BRIQUETTE RACK
B101417 (2)
CASTER W/O BRAKE
B101416 (2)
CASTER WITH BRAKE
B101415 (1)
PLASTIC BASE
B100560 (1)
SUPPORT BRACKET BACK
B069756 (1)
HOSE & LPS REGULATOR
B100456(1)
GRILL BODY TOP
DPP109 (1)
BURNER ASSEMBLY
DPP118 (1)
BURNER BRACKET
B102049 (1)
RIGHT SIDE PANEL
B101584 (1)
FRONT PANEL
B102048 (1)
LEFT SIDE PANEL
B101514 (1)
CONTROL PANEL ASSEMBLY
B101582 (1)
REAR BRACE
B101420 (1,LP) OR B101421 (1,NAT)
VALVE LPG OR NATURAL
P182 (2, LP) P265 (2, NAT)
ORIFICE LPG OR NATURAL
DPA34 (1)
BRIQUETTE BAG
B064791 (1)
CYLINDER RETAINER
B102171 (1)
REAR LIP ASSEMBLY
DPP158 (1)
COLLECTOR BOX ASSEMBLY
DPP155
H3PK1 SERIES PARTS DIAGRAM

B102526-0-0219 Page 7
B100561 (1)
SIDE SHELF
B073097 (1)
FOAM GRIP
B102492(1)
LID HANDLE (W/SCREWS)
B101473 (1)
GREASE CUP
B102122 (1)
CART SHIELD
B100993 (1)
SHELF SUPPORT STIFFENER
B101969 (1)
BRACKET ATTACH ASSEMBLY
B100559 (1)
SUPPORT BRACKET FRONT
DPP7SS (1)
WIND DEFLECTOR
B101635 (1)
RUBBER GUARD
B057804 (2)
HINGE PIN
B057805 (2)
COTTER PIN
DPA114 (1)
COOKING GRID (2) PIECES
B070084 (2)
VALVE KNOB
B072218 (1)
ELECTRONIC IGNITOR
B101621 (1)
CONTROL PANEL SHIELD
B101443 (1)
GRILL BODY BOTTOM
B067449 (1)
BRIQUETTE RACK
B101417 (2)
CASTER W/O BRAKE
B101416 (2)
CASTER WITH BRAKE
B101415 (1)
PLASTIC BASE
B100560 (1)
SUPPORT BRACKET BACK
B069756 (1)
HOSE & LPS REGULATOR
B076621 (1)
GRILL BODY TOP
DPP115 (1)
BURNER ASSEMBLY
DPP118 (1)
BURNER BRACKET
B102049 (1)
RIGHT SIDE PANEL
B101584 (1)
FRONT PANEL
B102048 (1)
LEFT SIDE PANEL
B101515 (1)
CONTROL PANEL ASSEMBLY
B101582 (1)
REAR BRACE
B101420 (1,LP) OR B101421 (1,NAT)
VALVE LPG OR NATURAL
P312 (2, LP) P245 (2, NAT)
ORIFICE LPG OR NATURAL
DPA34 (1)
BRIQUETTE BAG
B060757(1)
RETRACTING RACK
B064791 (1)
CYLINDER RETAINER
DPP155
DPP158 (1)
COLLECTOR BOX ASSEMBLY
H4PK1 SERIES PARTS DIAGRAM

B102526-0-0219Page 8
WING NUT,
1/4-20
R1123
(1)
SNAP BUSHING,
1/2"
R896
(1)
KEPS NUT,
SS,10-24
B073967
(8)
KEPS NUT,
SS,1/4-20
B100385
(4)
HEX HEAD BOLT,
SS,1/4-20 X 3/4
B063096
(4)
LOCK WASHER,
1/4 ID X 1/2 OD
B100139
(1)
PHILLIPS PAN HEAD SCREW,
SS,1/4-20 X 1-1/4
B100113
(1)
FLATWASHER,
SS,1/4 ID X 5/8
OD
B076332
(4)
PHILLIPS PAN HEAD SCREW,
SS, 10-24 X 1/2
R4056
(6)
PHILLIPS PAN HEAD SCREW,
SS,1/4-20 X 3/4
B072217
(8)
CART HARDWARE PACK - B102002
Standard hardware items such as bolts, screws, washers, and nuts can be purchased at your local hard-
ware store. Do not order individual pieces of standard hardware. A replacement hardware pack may be
ordered using the hardware pack part number at the top of the page.

B102526-0-0219 Page 9
COTTER PIN
B057805
(1)
FOAM GRIP
B073097
(1)
KNOB
B070084
(2)
HEX NUT,
SS,1/4-20
B076331
(1)
GROUND
WIRE
B072684
(1)
KEPS NUT,
SS,10-24
B073967
(2)
BATTERY, AA
B076529
(1)
PHILLIPS PAN HEAD SCREW,
SS,10-24 X 1
B073978
(2)
PHILLIPS PAN HEAD SCREW,
SS,1/4-20 X 1-1/2
B101649
(1)
GROUND LUG
B069747
(1)
SPACER, IGNIT
OR
B102488
(1)
COLLECTOR BOX ASSY
B102490
(1)
GRILL HEAD HARDWARE PACK - B102530
Standard hardware items such as bolts, screws, washers, and nuts can be purchased at your local hard-
ware store. Do not order individual pieces of standard hardware. A replacement hardware pack may be
ordered using the hardware pack part number at the top of the page.

B102526-0-0219Page 10
SELF-DRILLING PHILLIPS PAN HEAD SCREW,
SS,10-16 X 1/2
R4059
(2)
LOCK WASHER,
1/4 ID X 1/2 OD
B076333
(2)
PHILLIPS TRUSS HEAD SCREW,
SS,1/4-3/4
B072217
(2)
HEX NUT,
SS,1/4-20
B076331
(2)
FLATWASHER,
1/4 ID X 5/8 OD
B076332
(2)
FLATWASHER,
SS,1/4 ID X 1
OD
B101640
(2)
PHILLIPS PAN HEAD SCREW,
10-16 X 3/4
B100563
(4)
SHELF HARDWARE PACK - B101658
Standard hardware items such as bolts, screws, washers, and nuts can be purchased at your local hardware store. Do
not order individual pieces of standard hardware. A replacement hardware pack may be ordered using the hardware
pack part number at the top of the page.

B102526-0-0219 Page 11
BROILMASTER
PREMIUM GRILLS
REMOVING LID
To ease assembly, remove Grill Lid
and Warming Rack. Remove Warming
Rack and set aside. Remove the two
Pins and Clips at the rear of the Grill
Lid and set aside. After Pins, Lid and
Warming Rack have been removed,
remove the contents from inside the
Grill.
UNPACK AND REMOVE LID

B102526-0-0219Page 12
FRONT
Install the two Casters with Brakes in
the front of the Base.
BRAKE
CART BASE ASSEMBLY

B102526-0-0219 Page 13
Be careful when handling parts, as
they may contain sharp edges. Work
gloves are recommended to prevent
injury.
3/8”
CART WALLS ASSEMBLY
PHILLIPS PAN HEAD SCREW,
SS,10-24 X 1/2
R4056 (6)
KEPS NUT,
SS, 10-24
B073967(6)

B102526-0-0219Page 14
Install all four Screws before tightening.
ATTACH WALLS TO BASE
PHILLIPS PAN HEAD SCREW,
SS,1/4-20 X 3/4
B072217 (4)

B102526-0-0219 Page 15
Make sure the Rear Brace goes in the
cutout of the Support Bracket.
REAR BRACE
7/16”
INSTALL REAR BRACE
PHILLIPS PAN HEAD SCREW,
SS,1/4-20 X 3/4
B072217 (2)
KEPS NUT,
SS, 1/4-20
B100385 (2)
Make sure the Rear Brace goes in the
cutout of the Support Bracket.
REAR BRACE
7/16”

B102526-0-0219Page 16
RUBBER GUARD BUSHING
Insert Bushing in the Front Panel on the
right.
Install Rubber Guard over Cart cut out.
INSTALL RUBBER GUARD AND BUSHING
SNAP BUSHING,
1/2”
R896(1)
RUBBER
GUARD,
B101635(1)

B102526-0-0219 Page 17
7/16”
INSERT BURNER HOLD-DOWN BOLT
PHILLIPS PAN
HEAD SCREW
SS, 1/4-20 X 1-1/2
B101649 (1)
HEX NUT,
SS, 1/4-20
B076331(1) .
RUBBER GUARD BUSHING
Insert Bushing in the Front Panel on the
right.
Install Rubber Guard over Cart cut out.

B102526-0-0219Page 18
7/16”
ATTACH BOTTOM CASTING TO CART
HEX HEAD BOLT
SS, 1/4-20 X 3/4
B063096 (4)
FLAT WASHER,
SS, 1/4 ID X 5/8 OD
B076332 (4)
.

B102526-0-0219 Page 19
CORRECT INCORRECT
Ensure that the Side
Shelf Bracket Assembly
is installed so that the
Match Light Access
Hole is on the bottom.
7/16”
LARGE
WASHER ON
INSIDE
ATTACH SIDE SHELF
PHILLIPS TRUSS HEAD SCREW,
SS, 1/4-20 X 3/4
B072217 (2)
FLAT WASHER,
1/4 ID X 5/8 OD
B076332 (2)
..
FLAT WASHER,
SS, 1/4 ID X 1 OD
B101640 (2)
. .
LOCK WASHER,
1/4 ID X 1/2 OD
B076333 (2)
.. ..
HEX NUT,
SS, 1/4-20
B076331 (2) . . .

B102526-0-0219Page 20
ATTACH SIDE SHELF
PHILLIPS PAN HEAD SCREW,
10-16 X 3/4
B100563 (4)