Brinkmann Elite Series 4685 User manual

3067441
Elite Series
4685
Natural Gas
Conversion Kit
PROFESSIONAL INSTALLATION MANUAL
WARNING
HAZARDOUS EXPLOSION MAY RESULT IF THESE WARNINGS AND
INSTRUCTIONS ARE IGNORED. READ AND FOLLOW ALL WARNINGS AND
INSTRUCTIONS IN THIS MANUAL TO AVOID PERSONAL INJURY, INCLUDING
DEATH OR PROPERTY DAMAGE.
ASSEMBLY AND OPERATING INSTRUCTIONS
SAVE THIS MANUAL FOR FUTURE REFERENCE
NOTICE TO
PROFESSIONAL INSTALLER:
LEAVE THESE INSTRUCTIONS WITH
THE GRILL OWNER FOR FUTURE
REFERENCE.
THIS NATURAL GAS CONVERSION KIT CAN BE USED ONLY WITH
MODEL 810-4685-0 PRO SERIES GRILL

1
WE WANT YOU TO USE YOUR CONVERSION KIT FOR YOUR GRILL AS SAFELY AS
POSSIBLE. THE PURPOSE OF THIS SAFETY ALERT SYMBOL IS TO ATTRACT THE
ATTENTION TO POSSIBLE HAZARDS AS THE GRILL IS CONVERTED AND USED AS A
NATURAL GAS GRILL. WHEN YOU SEE THE SAFETY ALERT SYMBOL
PAY CLOSE ATTENTION TO THE INFORMATION WHICH FOLLOWS!
READ ALL SAFETY WARNINGS AND INSTRUCTIONS CAREFULLY
BEFORE CONVERTING AND OPERATING YOUR GRILL.
DANGER
IMPORTANT SAFETY
WARNINGS
FOR YOUR SAFETY:
IF YOU SMELL GAS:
1. Shut off gas to the appliance.
2. Extinguish any open flame.
3. Open the Lid.
4. If odor continues, leave the area and immediately call your gas supplier or your fire department.
FOR YOUR SAFETY:
1. DO NOT store or use gasoline or other liquids with flammable vapors 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 to avoid the possibility of explosion.
WARNING
Installer Company
or Service Name: __________________________________________________________
________________________________________________________________________
Technician Name: __________________________________________________________
Installation Date: __________________________________________________________
Failure to follow the instructions as written, or installation by other than a trained
professional, will void all manufacturer warranties.

2
General Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation Information and Safe Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–14
Connecting to Natural Gas Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Leak Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15–18
Pre-start Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Lighting Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19–21
Operating Grill and Helpful Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22–26
Warranty Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover
TABLE OF CONTENTS
DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING: Be alert to the possibility of serious bodily injury if the instructions are not followed. Be sure to read and
carefully follow all of the messages.
CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
WARNING
This conversion kit shall be installed by a professional service technician in accordance with
the manufacturer's instructions as specified by the codes and requirements of the authority
having jurisdiction. The information in these instructions must be followed to minimize the risk
of fire or explosion or to prevent property damage, personal injury or death. The qualified
service agency performing this conversion assumes responsibility for the proper conversion
of the appliance of this kit.
Model Number: ____________________________________________________________
Serial Number: ____________________________________________________________
Date Purchased: __________________________________________________________
IMPORTANT: Fill out product record information below.
A replacement Rating Label is provided with this kit and needs to be applied when the
conversion is completed.

3
WARNING
• Never use liquid propane gas in a unit designed for natural gas.
• Never use charcoal briquets or lighter fluid in a gas grill.
• Leak test all connections before first use, even if grill was purchased fully assembled.
• Never check for leaks using a match or open flame.
CAUTION! Strong odors, colds, sinus congestion, etc. may prevent the detection of natural
gas. Use caution and common sense when testing for leaks.
• Always keep your gas grill free and clear of gasoline, paint thinner, or other flammable vapors
and liquids or combustible materials.
• Always check the grill prior to each use as indicated in the "Pre-Start Check List" section of this
manual.
• DO NOT use back rotisserie burner when main burners are in use.
•DO NOT obstruct the flow of combustion or ventilation air.
• Never place more than 15 pounds on the side burner. DO NOT lean on the side burner shelf.
• Keep children and pets away from hot grill. DO NOT allow children to use or play near this grill.
• DO NOT leave the grill unattended while in use.
• DO NOT allow the gas hose to come in contact with hot surfaces.
• DO NOT allow grease from drain hole to fall on hose.
• Keep any electrical supply cords away from water or heated surfaces.
• Keep a fire extinguisher on hand acceptable for use with gas products. Refer to your local
authority to determine proper size and type.
• For household use only. DO NOT use this grill for anything other than its intended purpose.
• DO NOT use while under the influence of drugs or alcohol.
• Grill is hot when in use. To avoid burns:
• DO NOT attempt to move the grill.
• Lock the wheels so the unit does not accidentally move.
• Wear protective gloves or oven mitts.
• DO NOT touch any hot grill surfaces.
• DO NOT wear loose clothing or allow hair to come in contact with grill.
USE CAUTION AND COMMON SENSE WHEN OPERATING YOUR GAS GRILL.
FAILURE TO ADHERE TO THE SAFETY WARNINGS AND GUIDELINES IN THIS
MANUAL COULD RESULT IN SEVERE BODILY INJURY OR PROPERTY DAMAGE.
SAVE THIS MANUAL FOR FUTURE REFERENCE.
GENERAL WARNINGS

4
WARNING
INSTALLATION INFORMATION:
The installation of this appliance must be in accordance with:
All applicable local codes, or in the absence of local codes, either:
• National Fuel Gas Code ANSI Z223.1 NFPA 54
• Natural Gas and Propane Installation Code: CAN/CGA B149.1
• Natural Gas Installation Code: CAN/CGA B149.1 (Canada)
This kit converts your grill for natural gas use at 7 inch water column supply pressure. To check your
pressure contact your local natural gas company. If the supply pressure is different than 7 inch,
contact a certified plumber for assistance. Not for use with LP gas.
• FOR OUTDOOR USE ONLY. DO NOT operate indoors or in an enclosed area such as a garage,
shed or breezeway.
• Use your grill OUTDOORS in a well ventilated space away from dwellings or other buildings to
prevent dangers associated with gas accumulation and toxic vapors. We recommend your grill
be situated at least 10 feet (3.1 m) from buildings.
• Maintain a minimum clearance of 24 inches (61 cm) between all sides of grill and walls or other
combustible material. DO NOT use grill under overhead unprotected combustible construction.
• DO NOT use or install this grill in or on a recreational vehicle and/or boat.
Connection should be made by a certified plumber. Supply the plumber with a copy of these
instructions. Incorrect connection can result in a gas leak with possibility of fire.
DANGER

Natural Gas Manifold
Natural Gas Side Burner Valve
Natural Gas Rotisserie Burner Orifice
12' Hose with Quick Disconnect Coupler
PARTS BAG CONTENTS
Make sure you have all items listed under PARTS LIST before you begin
the installation process.
Your parts will include:
5
ASSEMBLY INSTRUCTIONS
YOU MUST BE A LICENSED PLUMBER TO CONVERT THIS GRILL.
READ ALL SAFETY WARNINGS & ASSEMBLY INSTRUCTIONS CAREFULLY
BEFORE ASSEMBLING OR OPERATING THE CONVERTED GRILL.
The following tools are required to assemble the Elite Series 4685 Conversion Kit:
• Phillips Head Screwdriver
• Adjustable Wrench
(Proof of purchase will be required.)
Inspect contents of the box to ensure all parts are included and undamaged.
FOR MISSING PARTS, PLEASE CALL CUSTOMER SERVICE AT 800-527-0717.
1
2
3
44
2
1
3

6
CAUTION! Some parts may
contain sharp edges.
Wear protective gloves
if necessary.
NOTE: Make sure all control knobs are
in the off position, LP tank valve
is closed and tank is
disconnected from regulator and
removed from grill.
Step 1
Remove hose / regulator from side
burner valve and main burners
manifold by unscrewing hose /
regulator nuts. Remove igniter wire
from electrode.
Step 2
Remove control knobs and bezels
from main control panel. Set aside for
later use.
NOTE: It is helpful to keep the screws
with the components as they
are removed for ease of
reassembly.
Hose / Regulator Nuts
Main Control
Panel Bezels
Igniter Wire

7
Step 3
Remove M4 X 10mm bolt from side
table front panel and grill body.
Loosen four M6 X15mm bolts
halfway. Lift table up and slide over
bolts. Remove side table from left
side of grill body.
Step 4
Remove M4 X 10mm bolt from side
burner assembly front panel and
grill body. Loosen four M6 X15mm
bolts halfway. Lift side burner
assembly up and slide over bolts.
Remove side burner assembly from
right side of grill body.
Left Side Of Grill
Right Side Of Grill

8
Step 5
Remove control knob and bezel from side
burner assembly. Remove old burner valve,
then insert the conversion side burner valve
assembly through the hole in the side burner
table base. Firmly seat the valve nozzle into the
burner venturi. Replace side burner bezel with
screws used previously and re-attach side
burner control knob.
Step 6
Remove igniter cap and battery from igniter.
Remove lock nut to allow igniter to hang freely
from control panel.
Step 7
Loosen gas manifold nut.
Igniter Cap Battery Lock Nut
Gas Manifold Nut
Side
Burner
Valve
Burner Venturi
Valve
Nozzle
Side
Burner
Control
Knob
Bezel

Step 8
Remove six bolts from control panel on
both right and left side of grill body.
Step 9
Detach the back rotisserie gas supply
line, by loosening the gas line nut. Let
the supply line hang freely.
NOTE: Bending the hose could damage
the supply line.
Gas Line Nut
9
Right side
of grill
Left side
of grill
Bolts
Bolts
Manifold Nut

10
Step 10
Carefully pull gas manifold out from
burner tubes to allow access to the
thermal couple nut. Remove
thermal couple nut from back
rotisserie burner valve. Remove
existing LP manifold.
Step 11
Open lid to loosen top back panel
bolts halfway. Loosen bottom back
panel bolts halfway and slide panel
upwards to remove.
Step 12
With the orifice now exposed,
remove orifice from the mounting
bracket and gas supply line of the
back rotisserie burner.
Thermal Couple Nut
Back Panel Bolts
Orifice

11
Step 13
Reattach natural gas orifice to gas
supply line and mounting bracket in
the back rotisserie burner.
NOTE: Leave the back panel off
until the end of conversion
and all gas leak testing has
been done.
Step 14
Attach thermal couple to natural
gas manifold by securing thermal
couple nut to the back rotisserie
burner valve.
Step 15
Carefully set the natural gas
manifold into place by aligning the
burner valves with the burner tubes.
Secure manifold to grill body by
tightening manifold nut.
Re-connect Rotisserie gas supply
line to natural gas manifold.
NOTE: Rotisserie gas supply line nut
must be gas leak tested
before first use.
Orifice
Thermal Couple Nut
Gas Line Nut
Manifold Nut
Rotisserie Gas Supply Line

12
Step 16
Replace six bolts from side panel
on both right and left side of grill
body.
Step 17
Install igniter through hole in control
panel and tighten lock nut to control
panel. Replace battery, spring and
igniter cap.
Step 18
Place side table on left side of grill
body by lifting table up and sliding
down over bolts. Replace
M4 X 10mm bolts from side table
front panel and grill body. Tighten
four M6 X15mm bolts.
Igniter Cap Battery Lock Nut
Left Side Of Grill
Right side
of grill
Left side
of grill
Bolts
Bolts

13
Step 19
Place side burner assembly on
right side of grill body by lifting
assembly up and sliding down
over bolts. Replace M4 X 10mm
bolt into side burner assembly front
panel and grill body. Tighten four
M6 X15mm bolts.
Step 20
Reattach bezels and control knobs
to main control panel.
Main Control
Panel Bezels
Right Side Of Grill

14
Step 21
Connect 12' Hose with quick
disconnect to side burner valve and
main burner gas manifold by tightening
hose nuts. Re-connect igniter wire to
electrode.
NOTE: Leave the back panel off until
the end of conversion and all
gas leak testing has been done.
Step 22
Reattach back panel by placing panel
over bolts and siding down. Secure
four back panel bolts.
Hose Nuts
Back Panel Bolts
Igniter Wire

• Never use your grill without leak testing all gas connections and hoses. See the section on
“Leak Testing” in this manual for proper procedures.
• Visually inspect the hose assembly prior to each use for evidence of damage, excess wear or
deterioration. If found, replace the assembly before using your grill. Only the Brinkmann
supplied replacement should be used.
WARNING
CONNECTING YOUR GRILL TO THE NATURAL GAS SOURCE
1. Coat pipe nipple with gas resistant teflon tape or pipe dope. Tighten quick-disconnect coupling onto
pipe nipple that leads to natural gas supply (Figure A).
2. After grill is completely assembled, make sure natural gas supply valve is “OFF” and then connect
natural gas hose to socket. Push sleeve back on socket (Figure B) and insert plug until sleeve snaps
forward, locking plug into socket. Be sure to leak test these connections prior to use.
Pipe nipple
Quick-disconnect
coupling Plug
Push sleeve back to attach
Sleeve
Socket
Natural gas supply
Natural gas supply Hose
Hose
Insert cover when hose is disconnected
DISCONNECTING YOUR GRILL FROM THE NATURAL GAS SOURCE
1. Turn natural gas supply valve “OFF”
2. To disconnect, push sleeve back and pull plug out of sleeve.
(Figure A)
(Figure B)
Supply valve
Supply valve
15

16
During assembly or conversion to natural gas, keep the supply hoses free of kinks and/or damage.
Visually inspect the hose assembly prior to each use for evidence of damage, excess wear, or
deterioration. If found, replace the assembly before using your grill. Only the manufacturer's supplied
replacement should be used.
AVOID HARD METAL PIPING
• DO NOT use hard metal piping of any kind to connect this converted natural gas grill. Use only
natural gas hose specified by the manufacturer. Using hard metal piping or convoluted metal
tubing is an unsafe practice. Movement of the grill can cause breakage of metal pipe.
WARNING
WARNING
For safe use of your grill and to avoid serious injury:
• DO NOT let children operate or play around grill.
• Keep grill area clean and clear of combustible materials.
• DO NOT block holes in bottom or back of grill.
• Check burner flames regularly.
• Use grill only in well ventilated area. Never use in enclosed space such as a carport, garage,
porch, covered patio or and overhanging structure.
• NEVER attempt to light grill with lid closed. A build-up of gas may cause explosion.
LEAK TESTING:
To prevent fire or explosion hazard:
• DO NOT smoke or permit ignition sources in the area while conducting a leak test.
• Perform test OUTDOORS only in a well ventilated area.
• Never perform a leak test with a match or open flame.
• Never perform a leak test while the grill is in use or while grill is still hot.
DANGER

WHEN TO PERFORM A LEAK TEST:
• After assembling or converting your natural gas grill and before lighting for the first time, even if
purchased fully assembled.
• Any time the gas components are replaced.
• Any time your grill has been moved.
• At least once per year or if your grill has not been used for more than 60 days.
CHECKING FOR LEAKS:
1. Create a mixture of 50% water and 50% liquid dishwashing soap.
2. Open the lid.
3. Ensure all control knobs are set to the "OFF" position.
4. Ensure gas hose is tightly connected to gas source.
5. Turn on the fuel supply on at the source.
6. Apply the soap water mixture to the following:
Hose connection to gas manifold.
Gas supply hose connection to
side burner valve assembly.
Side burner valve stem cap.
Side burner connection to hose.
The full length of gas supply hose.
Rotisserie orifice connection.
Rotisserie supply line connection
to rotisserie valve assembly.
NOTE: Rotisserie gas supply line can be gas leak tested by removing the tool drawer
and appling soap water mixture from under the control panel.
Quick disconnect coupler.
H
G
F
E
D
C
B
A
17
WARNING
Watch For Bubbles
B
C
D
A
E
Before first use, check gas supply line connection to rotisserie burner
valve (under control panel) and gas supply line connection to the
orifice (back of grill body).
CAUTION!
H
GF

WARNING
18
6. Check each place listed (A–H) for growing bubbles which indicates a leak.
7. Turn off gas supply at source.
8. Turn on control knobs to release gas pressure in hose.
9. Turn control knobs to "OFF" position.
10. Tighten any leaking connections.
11. Repeat soapy water test until no leaks are detected.
12. Turn off gas supply at source until you are ready to use your grill.
13. Wash off soapy residue with cold water and towel dry.
14. Wait 5 minutes to allow all gas to evacuate the area before lighting grill.
CAUTION!DO NOT use the grill if leaks cannot be stopped.
NOTE: The leak test must be performed in an area that has adequate lighting in order to see if
bubbles are developing. DO NOT use a flashlight to check for bubbles.
PRE-START CHECK LIST:
Property damage, bodily harm, severe burns, and death could result from failure to follow these
safety steps. These steps should be performed after the grill has been assembled and prior to each
use. DO NOT operate this grill until you have read and understand ALL of the warnings and
instructions in this manual.
PRE-START CHECK LIST:
•Ensure that the grill is properly assembled.
•Inspect the gas supply hose for burns, chaffing, kinks, and proper routing before each use. If it is
evident there is excessive abrasion or wear, or the hose is cut, it must be replaced prior the grill being
used.
•Leak check all gas connections and hose. See section on "Leak Testing".
•Ensure that all electrical supply cords are properly grounded. Keep any electrical supply cord and the
fuel supply hose away from any heated surfaces. Hose should be at least 3 inches from hot surfaces.
•Position your grill on level ground in a well ventilated location, a safe distance from combustible
materials, buildings and overhangs.
•Properly place the empty grease tray under the grease drain hole in the bottom of the
grill to catch grease during use.
• DO NOT obstruct the flow of combustion and ventilation air.

LIGHTING INSTRUCTIONS:
Follow the instructions exactly.
1. OPEN THE GRILL LID before attempting to light a burner so that fumes do not accumulate inside
the grill. An explosion could occur if grill lid is down.
2. Check that all burner control knobs and the cylinder valve are turned to the "OFF" position.
3. DO NOT stand with head, body, or arms over the grill when lighting.
LIGHTING THE MAIN BURNERS:
1. Open lid before lighting burner.
2. Make sure all control knobs are in the "OFF" position.
3. Select the burner to be lit. Push and turn the control knob of that burner to
the "HIGH" position.
4. Press the electronic igniter and hold for 3–5 seconds to light burner.
5. If ignition does NOT occur in 5 seconds, turn control knob to "OFF", wait 5
minutes to allow gas to dissipate and repeat lighting procedure.
6. Repeat Steps 3–5 for lighting each burner. Always use the electronic igniter
for lighting each burner. If burner does not ignite using push-button igniter,
wait 5 minutes, see ” Match Lighting the Main Burners” section.
7. To turn off, turn each control knob clockwise until it locks in the "OFF" position. This does not turn off the
gas flow from the source.
NOTE: If burner does not light or flame is too low, you may have spider or other insect blockage in burner. See
"Burner Assembly/Maintenance" under Proper Care and Maintenance.
MATCH LIGHTING THE MAIN BURNERS:
1. Open lid before lighting.
2. Turn the burner control knobs to OFF.
3. Place a paper match in the end of the matchlighter. Strike the match and
place through lighting hole in the right hand side of the grill to
approximately 1/2" (1 to 2 cm) from the burner.
4. Turn on the FAR RIGHT burner control knob to the HIGH position. The
burner should light within 5 seconds.
5. If the burner does not light, turn the control knob to OFF and wait 5 minutes
for gas to evacuate the grill. Repeat Steps 1 through 5 until the burner
ignites.
6. Once lit, light adjacent burners in sequence by pressing in and rotating the control knob to the
HIGH position.
7. If the burner does not light within the first few attempts of match lighting, there is a problem with the gas
supply. Turn off the gas at the burner and cylinder. DO NOT attempt to operate the grill until the problem is
found and corrected. See “Trouble Shooting” section of this manual.
WARNING
19
Lighting Hole
Matchlighter
WARNING
Read, understand and follow all warnings and instructions contained in this manual. DO NOT skip
any of the warnings and instructions contained in the preceding sections of this manual.