Empire Comfort Systems Broilmaster OPTIONS PCB1-3 User manual

Page 1
Cart With Base
retain OWner’sManual fOr future referenCe.
PCB1-3
DCB1-3
PREMIUM GRILLS

B102345-1-0616Page 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.
WARNING: FOR YOUR SAFETY
Do not store or use gasoline or other ammable vapors or liquids in the vicinity of
this or any appliance.
CAUTION:
Parts may have sharp edges. Wear leather work gloves and handle parts carefully
during unpacking, assembly and installation.
IMPORTANT INFORMATION

B102345-1-0616 Page 3
Thank you for purchasing a Broilmaster Grill Accessory.
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.
918 Freeburg Ave.
Belleville, Illinois 62220
Telephone [phone]

B102345-1-0616Page 4
Y ou have chosen the nest grill for your outdoor cooking pleasure.
Please take time to read this entire manual before assembling your Broilmaster Grill Accessory.
TABLE OF CONTENTS
ASSEMBLY INSTRUCTIONS............................................................................................... 5
IMPORTANT INFORMATION ............................................................................................... 6
PCB1,DCB1 CART ASSEMBLY .......................................................................................... 7
CART PARTS DIAGRAM................................................................................................. 7
CART HARDWARE PACK - B102002 ............................................................................. 8
CART BASE ASSEMBLY (ALL GRILLS) ......................................................................... 9
CART WALLS ASSEMBLY (ALL GRILLS)..................................................................... 10
ATTACH WALLS TO BASE (ALL GRILLS) ..................................................................... 11
INSTALL REAR BRACE ................................................................................................ 12
(ALL GRILLS EXCEPT C3) (C3 SERIES skip to page 15)
INSTALL RUBBER GUARD AND BUSHING................................................................. 13
(ALL GRILLS EXCEPT C3)
ATTACH BOTTOM CASTING TO CART ....................................................................... 14
(ALL GRILLS EXCEPT C3)
INSTALL REAR BRACE AND REAR CART COVER .................................................... 15
(C3 ONLY)(ALL ONLY OTHER GRILLS SKIP to PAGE 18)
INSTALL FRONT CART COVER (C3 ONLY) ................................................................ 16
ATTACH BOTTOM CASTING TO CART (C3 ONLY)..................................................... 17
HEAT SHIELD PLACEMENT (ALL GRILLS) ................................................................. 18
INSERTING CONTROL HOUSING (R3 ONLY)............................................................. 19
TANK RETAINER AND GREASE CUP INSTALLATION................................................ 20
(ALL GRILLS EXCEPT C3)
COMPLETED ASSEMBLY............................................................................................. 21
GRILL MAINTENANCE HISTORY ..................................................................................... 22
MASTER PARTS DISTRIBUTOR LIST.............................................................................. 23
HOW TO ORDER REPAIR PARTS .................................................................................... 23

B102345-1-0616 Page 5
Before You Begin
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.
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.
TOOLS
REQUIRED
3/8”and 7/16”
REQUIRED
3/8” and 7/16”
REQUIRED
3/8” and 7/16”
REQUIRED
7/16”
REQUIRED
CAUTION:
Parts may have sharp edges. For your safety
wear leather work gloves and handle parts
carefully during unpacking and assembly.
ASSEMBLY INSTRUCTIONS

B102345-1-0616Page 6
your Broilmaster dealer.)
CAUTION
The grill and its individual shutoff valve must be discon-
nected 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 sys-
tem 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.
Cleaning
The exterior of your cart may be cleaned with hot water and mild
detergent as needed.
Stainless steel surfaces may be cleaned with a spray-on stain-
less steel cleaner available at most hardware stores.
Important: Do not use harsh or abrasive cleaners! Your cart or
post has a highly polished surface and may be easily scratched.
Periodic Inspection and
Maintenance
Periodic inspections and maintenance are essential. All Broil-
master Grill products or mechanical devices eventually begin
to wear due to environment, contaminants, corrosion or aging.
Inspect all components at least twice per year and replace any
that show wear.
If any parts are damaged or missing, you may order parts from
your local Broilmaster®dealer. Please refer to the Parts Dia-
gram and Parts List sections of this manual for more detailed
information.
Grill Location
This grill is designed for outdoor use only.
Never operate your grill in any building, garage, or other
enclosed area. Never operate your grill in a recreational vehicle
or boat. Never operate your grill under any combustible materials,
such as carports, covered porches, awnings, or overhangs.
CAUTION
Keep the sides of the grill at least 16 inches from any
combustible material. Keep the back of the grill at least
18 inches from any combustible material. Placing a hot
grill too close to a building or other combustible mate-
rial may lead to re, property damage, or personal injury.
Combustible materials include fences, patio furniture,
and your home.
Keep the area around the grill clear to ensure proper ventilation.
WARNING
Do not install or operate this grill where gasoline or other
ammable materials are used or stored. Failure to comply
with this warning could result in explosion or re causing
property damage or personal injury.
Gas Type
The type gas required for your grill can be determined from the
product identication 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 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.
Connection Requirements
Broilmaster natural gas grills are not equipped with pressure
regulators. Your gas grill operates at a manifold pressure of
seven inches water column. (Your natural gas technician will
understand what this means.)
Arrange with your local gas company or licensed contractor to
have a gas supply line connected to the inlet of the stainless
steel ex tube assemble. The gas supply must have a shutoff
valve that is close to the post in case of emergency and must
be shutoff when the grill is not in use.
Connect your grill this coupling using the twelve foot exible
hose with a quick disconnect tting (available for purchase from
IMPORTANT INFORMATION

B102345-1-0616 Page 7
B101416 (2)
CASTER WITH BRAKE
B101417 (2)
CASTER W/O BRAKE
B102050 (1)
LEFT SIDE PANEL, PAINTED
B101635 (1)
RUBBER GUARD
B102122 (1)
CART SHIELD
B101583 (1)
REAR BRACE, PAINTED
B101473 (1)
GREASE CUP
B064791 (1)
CYLINDER RETAINER
B101414 (1)
PLASTIC BASE (PCB1, DCB1)
B101582 (1)
REAR BRACE, SS
B101651(1)
RIGHT SIDE PANEL, PAINTED
B101642(1)
RIGHT SIDE PANEL, SS
B101585 (1)
FRONT PANEL, PAINTED
B101588 (1)
FRONT PANEL, SS
B101641 (1)
LEFT SIDE PANEL, SS
CART PARTS DIAGRAM
PCB1,DCB1 CART ASSEMBLY

B102345-1-0616Page 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.

B102345-1-0616 Page 9
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)
Install the two Casters with Brakes in
the front of the Base.
FRONT
BRAKE
CART BASE ASSEMBLY (ALL GRILLS)

B102345-1-0616Page 10
Be careful when handling parts, as
they may contain sharp edges. Work
gloves are recommended to prevent
injury.
Remove protective plastic covering.
3/8”
CART WALLS ASSEMBLY (ALL GRILLS)
PHILLIPS PAN HEAD SCREW,
SS,10-24 X 1/2
R4056 (6)
KEPS NUT,
SS, 10-24
B073967(6)

B102345-1-0616 Page 11
Install all four Screws before tightening.
ATTACH WALLS TO BASE (ALL GRILLS)
PHILLIPS PAN HEAD SCREW,
SS,1/4-20 X 3/4
B072217 (4)

B102345-1-0616Page 12
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)
ALL GRILLS EXCEPT C3 (C3 SERIES SKIP TO PAGE 15)

B102345-1-0616 Page 13
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)
(ALL GRILLS EXCEPT C3)

B102345-1-0616Page 14
7/16”
For Grill Heads other than the C3
Series see Grill Instructions.
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)
.
(ALL GRILLS EXCEPT C3)

B102345-1-0616 Page 15
2
REAR BRACE
7/16”
REAR CART COVER
Make sure the Rear Brace goes in the
cutout of the Support Bracket.
1
INSTALL REAR BRACE AND REAR CART COVER
PHILLIPS PAN HEAD SCREW,
SS,1/4-20 X 3/4
B072217 (2)
KEPS NUT,
SS, 1/4-20
B100385(2)
.
(C3 ONLY)(ALL ONLY OTHER GRILLS SKIP TO PAGE 18)

B102345-1-0616Page 16
FRONT CART
COVER
CART FRONT
Insert Front Cart Cover behind the Cart front
so that the tabs allow it to hang in place.
Fold Tabs on Front Cart Cover as shown.
INSTALL FRONT CART COVER (C3 ONLY)
SELF-DRILLING PHILLIPS PAN HEAD SCREW,
SS, 10-16 X 1/2
R4059 (2)

B102345-1-0616 Page 17
7/16”
ATTACH BOTTOM CASTING TO CART (C3 ONLY)
HEX HEAD BOLT
SS, 1/4-20 X 1-1/2
B102098 (4)
FLAT WASHER,
SS, 1/4 ID X 5/8 OD
B076332 (4)
.

B102345-1-0616Page 18
2
1
3
4
Make sure Heat Shield is resting on the
cutout in the Side Panels before
tightening the screws and nuts.
For C3 Series Grills Heads: Aseembly
is Complete.
7/16”
HEAT SHIELD PLACEMENT (ALL GRILLS)
PHILLIPS PAN HEAD SCREW,
SS,1/4-20 X 3/4
B072217 (2)
KEPS NUT,
SS, 1/4-20
B100385 (2)

B102345-1-0616 Page 19
It may be easier to insert one side of
the control housing first, and the press
in the other side using the cart as a
brace for the inserted side.
R3 Head must be fully assembled before completing this step.
INSERTING CONTROL HOUSING (R3 ONLY)

B102345-1-0616Page 20
Install Grease Cup by sliding it in
thecutout in the Heat Shield.
TANK RETAINER AND GREASE CUP INSTALLATION
PHILLIPS PAN HEAD SCREW
SS,1/4-20 X 1-1/4
B100113 (1)
WING NUT,
1/4-20
R1123 (1)
.
LOCK WASHER,
1/4 ID X 1/2 OD
B100139 (1)
.
(ALL GRILLS EXCEPT C3)