- The Coleman Company Natural Gas Conversion Kit Product Manual

ManualsBrandsColeman ManualsGrill8100 Series

Natural Gas Conversion Kit

IMPORTANT

Read this document carefully before attempting installation

of this conversion kit. These instructions should be left with

the consumer for future reference.

For the following Coleman® Gas Barbecue Grills:

8100 Series (M/N 9992-643)

8200 Series (M/N 9992-644)

WARNING

• This Natural Gas conversion Kit must be installed only by a qualified

service technician.

• Gas supply system must be installed in accordance with the U.S.

National Fuel Gas Code.

• This appliance and its individual shut off valve must be disconnected

from the gas supply piping system during any system pressure test in

excess of 1/2 PSI (3.5 KPA).

• Use a system manual shut off valve to shut off the gas supply to this

gas appliance before continuing with installation procedures.

WARNING

• If the information in this document is not followed exactly, a fire or

explosion may result causing property damage, personal injury or loss

of life. Read the Coleman®

Gas Barbecue Use, Care & Assembly

Manual With Grill Lighting Instructions,

before attempting installation

of this conversion kit.

WARNING

• TURN OFF THE GAS SUPPLY!

DO NOT attempt to install this Natural Gas Conversion Kit

while the barbecue is in operation or is hot.

Installation and provision for combustion and ventilation air

must conform with the

National Fuel Gas Code, ANSI Z223.1

CAN/CGA-B149.1, Natural Gas Installation Code

, or

CAN/CGA-B149.2, Propane Installation Code

WARNING

A liquid propane tank, not connected for use with this gas barbecue,

shall not be stored in the vicinity of this or any other appliance.

Note: These instructions apply to

more than one model grill. The

parts included are designed for

your specific grill. The

illustrations may differ slightly

from model to model.

Turn off LP tank and disconnect

regulator from tank prior to servicing grill.

Connections must comply with local requirements and are the sole responsibility of the person performing

the work. A certified plumber must make connection to gas source. All codes must be followed.

Summary of content (16 pages)

PAGE 1
Natural Gas Conversion Kit For the following Coleman® Gas Barbecue Grills: 8100 Series (M/N 9992-643) 8200 Series (M/N 9992-644) Connections must comply with local requirements and are the sole responsibility of the person performing the work. A certified plumber must make connection to gas source. All codes must be followed. Note: These instructions apply to more than one model grill. The parts included are designed for your specific grill. The illustrations may differ slightly from model to model.
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Natural Gas Conversion Instructions 1* 4 6 5 3 2 8 7 11 10 9 Part No. 1 Qty Description 1 Main Burner Valve & Manifold Assembly (NG) 8100 1 Main Burner Valve & Manifold Assembly (NG) 8200 2 1 Hose 19" - 3/8" Flare Both Ends for Side Burner (NG) 3 1 Side Burner Valve Assembly - 12K BTU (NG) 4 1 Regulator 3/8" FNPT Threads (NG) 5 1 Nipple Pipe 3/8" NPT x 1.
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Natural Gas Conversion Instructions Tools Needed: Phillips head screwdriver 1/4" nut driver * 9/16" wrench Adjustable wrench Fig 1 Heat Tents * 1/4” socket set with extension can also be used. Rear Heat Shield Be sure gas supply is off, the knobs are in the off position and the grill is cool. Fig 2 1. Remove cooking grates and heat tents (Fig. 1). 2. Remove the screws holding the rear heat shield in place. Lift out rear heat shield and set aside (Fig. 2). Screws 3.
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Natural Gas Conversion Instructions 5. Remove the screws from the bottom of the heat shield, holding the front heat shield in place. The screws are located under the bottom lip of the shield (Fig. 5). 6. Remove the two side heat shield screws located under the bottom lip of the heat shield. There is one screw on each side (Fig. 6). Fig 5 Screws under lip 7. Remove the front heat shield (Fig. 7). 8. Grasp and push the burner(s) towards the rear of the grill to detach the burner from the valves (Fig. 8).
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Natural Gas Conversion Instructions Flex Line 10. Disconnect the right side flexline from the manifold using the adjustable wrench. This will free up the right side of the manifold (Fig. 9). 11. Disconnect the left side flexline from the back infrared valve using an adjustable wrench. This will free up the left side of the manifold (Fig. 10). 12. Remove the control knobs from the front of the grill (Fig. 11). Fig 9 Gas Inlet Flex Line Manifold 13.
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Natural Gas Conversion Instructions 16. Start by placing the new manifold into the grill body with the control knob stems going outward through control panel front (Fig. 15). Control Knob Stems Fig 15 17. Reattach the bezels to the manifold with the two screws. Make sure that "off" is facing up on the bezel. (Fig. 12 & 13). 18. Reattach the flexline on the right of the grill to the new manifold using the adjustable wrench (See Fig. 9 on previous page). Manifold 19.
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Natural Gas Conversion Instructions Installing the NG regulator 1. Remove the hose from the brass flare fitting using an adjustable wrench. Located inside the cart on bottom of grill head (Fig. 20). Brass Flare Fitting Fig 20 Remaining hose end still connected will be removed later. 2. Remove the brass flare fitting from the gas pipe (Fig. 21). Note: For the following steps, the supplied pipe sealant needs to be applied to all pipe threads before the fittings are attached.
PAGE 8
Natural Gas Conversion Instructions 6. Attach the 3/8" street elbow to the bottom of the bottom of the tee connector. Make sure to apply pipe sealant before attaching. Tighten with wrench (Fig. 25). Fig 25 7. Reinsert the grommet in the side of the cart (Fig. 22). 8. Attach one end of the supplied hose to the flared fitting on the side of the tee connector (Fig. 26 and 27). 9. Assemble the 3/8" pipe nipple to the NG regulator. Assemble the 3/8" FNPT to flared fitting to the regulator.
PAGE 9
Natural Gas Conversion Instructions Converting the Rear Infrared Burner to NG 1. Remove the four screws on the inside of the grill that hold the rear infrared cover in place (Fig. 30). 2. Close the grill hood slowly. Fig 30 Rear Screws 3. Remove the two screws from the back infrared cover, located on the back of the grill (Fig. 31). 4. Grasp rear infrared cover and remove it from the grill. 5. Disconnect flex line and twist orifice elbow to remove LP orifice (Fig. 32 & 33). Fig 31 6.
PAGE 10
Natural Gas Conversion Instructions Converting the Side Burner to NG 1. Remove side burner grate, porcelain cap and burner head (Fig. 35). Fig 35 2. Remove and discard the LP regulator hose attached to the side burner LP valve assembly (Fig. 36). (Located on the under side of the side burner). 3. Remove the control knob from the front of the side burner (Fig. 37). (It should pull off by hand).
PAGE 11
Natural Gas Conversion Instructions 4. Remove the two screws holding the bezel and valve in place. Remove bezel from the front of the side burner (Fig. 38). Fig 38 5. Remove the two screws holding the side burner LP valve assembly in place. This will free up the assembly (Fig. 39 & 40). 6. Disconnect the igniter wire from the side burner electrode (Fig. 40). Screws 7. Holding the assembly securely, remove side burner valve assembly from casting. Replace with new side NG side burner valve assembly (Fig.
PAGE 12
Natural Gas Conversion Instructions 8. Install the NG valve assembly to the underside of the side burner with the two screws previously removed (Fig. 43). Screw Fig 43 Note: Make sure the NG valve is facing towards the front of the side burner and the valve stem is inserted into the hole. 9. Reattach the bezel to the front of the side burner and the NG valve with the two screws previously removed (Fig. 44). Bezel “H” Note: Make sure the bezel is installed in the correct position.
PAGE 13
Natural Gas Conversion Instructions Label the Grill 1. Apply conversion label 9992-461 on the grill, next to the lighting instruction label. Fig 46 Note: At the completion of the conversion, a leak test should be performed on all fittings. See Use and Care manual for leak testing procedure. Installation is now complete. Enjoy your grill safely.
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Natural Gas Conversion Instructions NOTES __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ _______________________________________
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Natural Gas Conversion Instructions NOTES __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ _______________________________________
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The Coleman Company, Inc. • 3600 North Hydraulic Wichita, KS 67219 U.S.A. 1-800-356-3612 • TDD: 316-832-8707 www.coleman.com ©2006 The Coleman Company, Inc. All rights reserved. Coleman® and are registered trademarks of The Coleman Company, Inc.