Brinkmann ZONE User manual

OWNER’S MANUAL / MANUAL DEL PROPIETARIO
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.
SE PUEDE PRODUCIR UNA EXPLOSIÓN PELIGROSA SI SE HACE CASO OMISO
A ESTAS ADVERTENCIAS E INSTRUCCIONES. LEA Y SIGA TODAS LAS
ADVERTENCIAS E INSTRUCCIONES EN ESTE MANUAL PARA EVITAR
LESIONES PERSONALES, INCLUSO LA MUERTE, O LOS DAÑOS MATERIALES.
SAVE THIS MANUAL FOR FUTURE REFERENCE
GUARDE ESTE MANUAL PARA REFERENCIA FUTURA
ASSEMBLY AND OPERATING INSTRUCTIONS
INSTRUCCIONES DE ARMADO Y OPERACIÓN
NOTICE TO INSTALLER:
LEAVE THESE INSTRUCTIONS WITH THE
GRILL OWNER FOR FUTURE REFERENCE.
AVISO PARA EL INSTALADOR:
ENTREGUE ESTAS INSTRUCCIONES AL
PROPIETARIO DE LA PARRILLA PARA
REFERENCIA FUTURA.
WARNING/ADVERTENCIA
ROTISSERIE
5-IN-1 COOKING
SYSTEM GAS GRILL
5 EN 1 PARRILLA DEL GAS
QUE COCINA EL SISTEMA

a) DO NOT store a spare LP gas cylinder under or near this appliance.
b) Never fill the cylinder beyond 80% full.
c) If the information in (a) and (b) are not followed exactly, a fire causing death or
serious injury may occur.
1
WE WANT YOU TO ASSEMBLE AND USE YOUR GRILL AS SAFELY AS POSSIBLE.
THE PURPOSE OF THIS SAFETY ALERT SYMBOL IS TO ATTRACT YOUR ATTENTION TO
POSSIBLE HAZARDS AS YOU ASSEMBLE AND USE YOUR GRILL.
WHEN YOU SEE THE SAFETY ALERT SYMBOL
PAY CLOSE ATTENTION TO THE INFORMATION WHICH FOLLOWS!
READ ALL SAFETY WARNINGS AND INSTRUCTIONS CAREFULLY
BEFORE ASSEMBLING AND OPERATING YOUR GRILL.
IMPORTANT SAFETY
WARNINGS
IF YOU SMELL GAS:
1. Shut off gas to the appliance.
2. Extinguish any open flame.
3. Open Lid.
4. If odor continues, keep away from the appliance and immediately call your gas supplier or your fire
department.
1. DO NOT store or use gasoline or other flammable liquids or 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.
DANGER
DANGER
WARNING

2
General Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation and LP Cylinder Specifications and Safe Use . . . . . . . . . . . . . 4–6
Connecting LP Cylinder and Hose / Regulator to Grill . . . . . . . . . . . . . . . . 6–7
Leak Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–9
Pre-start Check List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Lighting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–11
Operating Grill and Helpful Hints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–14
Proper Care and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14–16
Transporting and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Frequently Asked Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18–19
Parts List and Assembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–30
Rotisserie Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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.
FOR COVERS & ACCESSORIES AND OTHER PRODUCTS, PLEASE VISIT US ONLINE AT:
WARNING
This product contains chemicals, including lead in the brass of certain component parts, that are
known to the State of California to cause cancer, and birth defects or other reproductive harm.
Wash hands after handling. When used, this product emits fuel combustion chemicals that are
known to the State of California to cause cancer, and birth defects or other reproductive harm.
Follow all instructions in this manual and use only in well ventilated, outdoor area.

3
GENERAL WARNINGS
• Never use natural gas in a unit designed for liquid propane gas.
• Never use charcoal or wood briquets in a gas grill. Flavoring chips must be contained in a metal
smoking box to contain ash and prevent fires.
• Leak test all connections before first use, even if grill was purchased fully assembled and after each
tank refill.
• Never check for leaks using a match or open flame.
CAUTION: Strong odors, colds, sinus congestion, etc. may prevent the detection of propane.
Use caution and common sense when testing for leaks.
• Always keep your gas grill free and clear of gasoline, lighter fluid, 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 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.
DO NOT lift the grill using side tables.
• 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 or valve regulator assembly.
• 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.
WARNING

4
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)
• Propane Installation Code: CAN/CGA B149.2 (Canada)
To check your local codes, see your local LP gas dealer or natural gas company. This grill was not intended to be
connected to a natural gas supply line. If an external electrical source is utilized, it must be electrically grounded in
accordance with local codes, or in the absence of local codes, with the National Electrical Code, ANSI/NFPA 70, or
the Canadian Electrical Code, CSA 22.1.
LP GAS CYLINDER (NOT SUPPLIED WITH THIS GRILL)
The LP cylinder is available for purchase at the same location the grill was purchased.
The LP (Liquid Propane) gas cylinder specifically designed to be used with this grill must have a 20
lb. (9.1 kg) capacity incorporating a Type 1 cylinder valve and an over-filling protection device (OPD).
• This grill is designed to fit Worthington, Manchester or SMPC brand 20 lb. (9.1 kg) cylinders. Other
brand DOT cylinders may fit this grill if the cylinder has similar dimensions of the top and bottom
rings.
• DO NOT connect this grill to an existing #510 POL cylinder valve with Left Hand threads. The Type 1
valve can be identified with the large external threads on the valve outlet.
• DO NOT connect to a propane cylinder exceeding this capacity.
• DO NOT connect to a cylinder that uses any other type of valve connection device.
• 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. Although minimum clearance
is 36 inches (91 cm), we strongly recommend that you do not operate this appliance within 10 ft.
(3.0 m) of any structure, combustible material or extra LP gas cylinders not attached to the
appliance. Not adhering to these clearances will prevent proper ventilation and may increase the
risk of a fire and/or property damage, which could also result in personal injury.
• Maintain a minimum clearance of 36 inches (91 cm) between all sides of grill, deck railings, 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.
WARNING
WARNING

5
CYLINDER SPECIFICATIONS:
When purchasing or exchanging a cylinder for your gas grill, it must be constructed and marked in accordance with
the specifications for LP gas cylinders of the U.S. Department of Transportation (DOT) or the National Standard of
Canada, CAN/CSA-B339 Cylinders, Spheres and Tubes for Transportation of Dangerous Goods; and Commission,
as applicable; and provided with a listed over-filling prevention device (OPD), and provided with a cylinder
connection device compatible with the connection for outdoor cooking appliances.
The cylinder must also be equipped with:
• A shut-off valve terminating in a Type 1 gas cylinder valve outlet.
• A Type 1 valve that prevents gas flow until a positive seal is obtained.
• An arrangement for vapor withdrawal.
• A collar to protect the cylinder shut-off valve.
• A safety relief device having direct communication with the vapor space of the cylinder.
• A listed over-filling prevention device (OPD).
• Turn off the cylinder valve when your grill is not in use.
• Handle the tank with care.
• Always secure the cylinder in an upright position.
• Never connect an unregulated LP gas cylinder to your grill.
• DO NOT expose LP gas cylinders to excessive heat or ignition sources.
• DO NOT store a spare LP gas cylinder under or near your grill.
• Allow only qualified LP gas dealers to fill or repair your LP gas cylinder.
• DO NOT allow the cylinder to be filled beyond 80% capacity.
• Read and follow all warnings and instructions that are on the cylinder and that accompany this
product.
• Never store a spare LP gas cylinder under or near your grill. This could cause excess pressure to be
expelled through the vapor relief valve resulting in fire, explosion, or severe personal injury including
death.
Note: PROPANE GAS IS HEAVIER THAN AIR AND WILL COLLECT IN LOW AREAS.
PROPER VENTILATION IS EXTREMELY IMPORTANT.
• Keep the ventilation opening(s) of the LP gas cylinder enclosure free and clear from obstructions
and debris.
• DO NOT insert any foreign objects into the valve outlet. Damage to the back-check could result. A
damaged back-check can cause a leak, possibly resulting in explosion, fire, severe bodily harm, or
death.
WARNING
DANGER

INSTALLING THE LP GAS CYLINDER ONTO THE GRILL:
1. Check that the cylinder valve is closed by turning the knob clockwise.
2. Place the cylinder into the tank holder in the bottom of cabinet.
3. Orient the cylinder such that the valve opening faces the side burner, and so
that the hose is not kinked or damaged.
4. Fully tighten the tank retention screw on the side of tank holder to secure
tank.
5. Attach or detach regulator to the LP gas cylinder only when cylinder is at rest
in tank holder.
HOSE AND REGULATOR:
Your grill is equipped with a Type 1 connection device with
the following features:
1. The system will not allow gas flow from the cylinder until a positive connection
to the valve has been made.
Note: The cylinder valve must be turned off before any connection is made
or removed.
2. A thermal device that will shut off the gas flow if the device is subject to
temperatures above 240°F to 300°F (115°C to 150°C). If this should happen,
remove the entire regulator assembly and dispose of properly. A replacement
regulator assembly can be purchased by contacting customer service at 800-
527-0717. The cause of the excessive heat should be determined and
corrected before using your grill again.
3. A regulator flow limiting device, when activated, restricts the flow of gas to 10
cubic feet per hour. If the flow limiting device is activated, perform Regulator
Resetting Procedure.
REGULATOR RESETTING PROCEDURE
1. Turn burner control knobs to "OFF", turn off the cylinder valve and disconnect regulator from LP gas tank. Wait
approximately two minutes.
2. Reattach regulator and slowly turn cylinder valve back on. The flow limiting device will now be reset.
6
Tank Holder
FILLING THE LP GAS CYLINDER:
• Allow only qualified LP gas dealers to properly fill or repair your LP gas cylinder.
• New tanks should be purged prior to filling; inform LP gas dealer if you are using a new tank.
• DO NOT allow the cylinder to be filled beyond 80% capacity. Over-filled tanks can create a
dangerous condition. Over-filled tanks can build-up pressure and cause the relief valve to expel
propane gas vapors. The vapor is combustible and if it comes in contact with a spark source or
flame an explosion causing severe burns, bodily harm, or death could occur.
• Always use a protective cylinder cap when grill is not connected to cylinder.
• If you exchange a cylinder with a qualified exchange program, be sure the cylinder has a Type 1
valve and an over-filling prevention device (OPD).
WARNING
Tank Retention Screw

7
• Never use your grill without leak testing all gas connections and hoses. See the section on "Leak
Testing" in this manual for proper procedures.
The pressure regulator and hose assembly supplied with your gas grill must be used.
• DO NOT attempt to connect grill, as purchased for LP (propane) gas, to any other fuel supply source
such as a natural gas line. A Brinkmann conversion kit must be purchased and installed for use with
natural gas.
• DO NOT use any other pressure regulator/hose assembly other than the one supplied with your grill.
Replacement pressure regulator/hose assembly must be part No 155-2390-0, which can be obtained
by contacting customer service at 800-527-0717.
• DO NOT attempt to adjust or repair the regulator. The regulator is designed to operate at a
maximum output pressure of 11 inches of water column (2.74 kPa).
CONNECTING HOSE AND REGULATOR TO AN LP GAS CYLINDER
• Ensure the tank valve is CLOSED prior to connecting the LP gas cylinder to your grill. Turn the valve
knob clockwise to properly close the valve. Read and follow all instructions and warnings on the
supply hose safety tags. Read and follow all warnings in this manual concerning the safe use of LP
gas cylinders and the hose and regulator before connecting cylinder to grill. Read and follow all
warnings on the LP cylinder.
During assembly and/or replacement of the gas cylinder, keep the gas supply hose 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.
CONNECTING HOSE AND REGULATOR
1. Check that the cylinder valve is closed by turning the knob clockwise.
2. Check that the grill’s burner control knobs are in the "OFF" positions.
3. Remove the protective plastic cap from the cylinder valve and the connection device.
4. Hold regulator and insert the nipple of connection device into the LP cylinder valve outlet. Ensure that the device is
centered properly.
5. Turn the large coupling nut clockwise by hand and tighten to a full stop. Take care not to cross thread the coupling
nut onto the cylinder valve. Do not over-tighten the knob onto the valve. Do not use tools to tighten connection.
Note: If you are unable to make the connection, repeat Steps 4 and 5.
6. Check that the hose does not contain kinks, does not contact sharp edges, and does not contact surfaces that may
become hot during use.
7. Leak check all fittings before lighting your grill. See section on "Leak Testing" in this manual.
WARNING
WARNING
WARNING

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. Turn on the fuel supply at the cylinder valve.
Turn the cylinder valve knob one turn counter-clockwise.
5. Apply the soap water mixture to the following:
Supply tank (cylinder) weld.
Connection nut to tank valve.
Back side of connection nut to brass nipple.
Brass nipple connection into regulator.
Regulator connections to gas supply hoses.
Side burner valve stem cap.
Side burner connection to hose.
Hose connections to gas manifold.
The full length of gas supply hose.
Tank valve to cylinder.
6. Check each place listed (A–J) for growing bubbles which indicates a leak.
7. Turn off gas supply at cylinder valve.
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 cylinder valve 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.
IMPORTANTSAFEGUARD
TURNGASONANDOFF
USINGVALVEONL.P.GAS
TANK.USETHISRED
CONTROLVALVEFOR
FLAMEADJUSTMENTONLY.
8
A
B
C
D
E
F
G
H
I
J
Watch For Bubbles
B
A
C
D
E
H
I
J
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.
WHEN TO PERFORM A LEAK TEST:
• After assembling your grill and before lighting for the first time, even if purchased fully assembled.
• Every time the LP gas cylinder is refilled or if any of 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.
F
G
DANGER
WARNING

9
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.
•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. Replace with hose and
regulator, Model No. 155-2390-0, which can be obtained by contacting customer service at 800-527-0717.
•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.
CAUTION: DO NOT use the grill if leaks cannot be stopped. Contact a qualified gas appliance
repair service.
Note: The leak test must be performed in an area that has adequate lighting in order to see if bubbles are
developing.
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.
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. Turn on the fuel supply by rotating the cylinder valve knob counter-clockwise to full open.
4. DO NOT stand with head, body, or arms over the grill when lighting.
WARNING
WARNING
WARNING