Coleman G52204, G52202 Assembly Manual

DURABILITY • POWER • PERFORMANCE
Manual Revision #: 22122009 PD
www.colemanbbqs.com
EVEN HEAT™
BARBECUE
WITH 3 BURNERS
ASSEMBLY MANUAL
85-3027-8 (G52202) Natural Gas
LIMITED 5-YEAR WARRANTY
Read and save manual for future reference.
Assemble your grill immediately. Missing or damaged parts
should be claimed within 30 days of purchase.
For product inquiries, parts, warranty and troubleshooting support,
please call 1-800-275-4617.
1
WARNING
Failure to follow all of the Manufacturer’s instructions could result in hazardous fires, explosions, property damage, or serious personal injury or even death.
Follow all leak check procedures carefully prior to operation of barbecue, even if grill was dealer assembled. Do not try to light this barbecue without reading the Lighting Instructions section of this manual.
THIS MANUAL MUST REMAIN WITH THE PRODUCT AT ALL TIMES
CAUTION
Rea d and foll ow all safe ty statement s, ass embly inst ruc tio ns, and use an d care directions before attempting to assemble and cook.
CAUTION
Sharp edges. Wear gloves when assembling your grill.
THIS BARBECUE IS FOR OUTDOOR USE ONLY
CONTACT CALL CENTRE IF ANY PARTS ARE MISSING
1-800-275-4617
INSTALLER OR ASSEMBLER/ CONSUMER
This manual should be kept with the BBQ at all times.
HEAVY ARTICLE NEEDS 2 TO LIFT
TOOLS NEEDED FOR ASSEMBLY
• #2 Phillips screwdriver (long and short)
• ¼” Slotted screwdriver (long and short)
• Adjustable wrench
• Pliers
Before assembling the barbecue, read these instructions carefully.
Assemble the barbecue on a at, clean surface. Grill is heavy. You should have at least two people assemble the barbecue together.
Caution: Sheet metal can cause injury. Wear gloves when installing the grill.
HARDWARE PACK
1/4”-20UNCx38 Screw
X 8
φ7 Washer
X 28
ST4.2x10 Tapping Screw
X 4
1/4”-20UNCx16 Screw
X 20
1/4”-20UNC Nut
X 10
φ5 Lock Washer
X 10
φ7 Lock Washer
X 28
NO.10-24UNCX13 Screw
X 10
ø5 Washer
X 10
NO.8-32UNC x10 Screw
X 4
φ4 Lock Washer
X 4
1
2
3
4 5
6
7
8 9
10
11 12
13 14 15
Control Knob
X 1
M4 Wing Nut
X 1
Wrench
X 1
φ4Washer
X4
No. Description Part Number Qty.
1 ¼"-20UNCX38 Screw 20120-13038-250 8
2 ¼"-20UNCX16 Screw 20120-13016-250 20
3 ø7 Lock Washer 41400-07000-250 28
4 ø7 Washer 40300-07000-250 28
5 1/4"-20UNC Nut 30220-13000-250 10
6 NO.10-24UNCx13 Screw 20124-10013-250 10
7 ø5 Lock Washer 41400-05000-250 10
8 ø5 Washer 40300-05000-250 10
9 ST4.2x10 Tapping Screw 22500-42010-137 4
10 NO.8-32UNCx10 Screw 20132-08010-250 4
11 ø4 Lock Washer 41400-04000-250 4
12 ø4 Washer 40300-04000-250 4
13 Control Knob G522-2800-9000 1
14 Wing Nut 33301-04000-032 1
15 Wrench G413-0032-9082 1
To ORDER non-warranty replacement parts or accessories,
or to register your warranty, please visit us on the web at
www.colemanbbqs.com
DANGER
1. If you smell Gas: a. Shut o gas to the appliance b. Extinguish any open flame c. Open lid d. If odor continues, keep away from the appliance and immediately call your gas supplier or your fire department
2. Requires two people to complete
the assembly process.
3. Beware of sharp edges.
WARNING
1. Do not store or use gasoline
or other flammable liquids or vapours 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.
2 3
Parts List (propane) for 85-3026-0 (G52201) EXPLODED DIAGRAM (PROPANE) FOR 85-3026-0 (G52201)
BH
BA
CH
CPCG
CE3
ED
EE
DG
CK
CJ
AA
AB
CL
CI
CE2
EB
EI
EF
BI
CB
CD
EG
EH
CE1
EL
CM
EC
EE
DH
CC
DB
DA
DC
DE
DF
DD
EK3
EK2
EK1
CC
CB
CD
CA
EA
CO
CN
EJ
BG
BE
BD
BF
Assembly
Manual
Safety & Care Manual
Hardware
Pack
F2
F3
F1
AC
AD
BC
BC
BB
CF
Extras
Item No. Qty. Description Part No.
AA 1 Top lid assembly G522-2000-01
AB 1 Thermometer G522-0005-01
AC 2 Screw for top lid G433-0002-01
AD 2 Lid bumper G508-0063-01
BA 1 Burner box assembly G522-3100-01
BB 3 Even Heat™ burners G522-2900-01
BC 1 Carryover assembly G522-0009-01
BD 1 Even Heat™ heat distribution
plate - left
G522-0050-01
BE 1 Even Heat™ heat distribution
plate - middle
G522-0022-01
BF 1 Even Heat™ heat distribution
plate - right
G522-0064-01
BG 3 Coleman® signature cooking
grate
G522-0023-01
BH 1 Warming rack G515-0058-01
BI 1 Match holder G608-0019-01
CA 1 Manifold assembly-LP G522-3300-01
CB 1 Regulator G606-0008-01
CC 1 Side burner valve with T
bracket - LP
G522-0016-01
CD 1 Metal hose, side burner G508-0024-01
CE1 1 Electronic ignition assembly G511-0055-01
CE2 1 Ignition battery cover G515-0030-01
CE3 1 Instastart™ ignition button G522-0017-01
CF 3 Electrode set, main burner G522-0020-01
CG 3 Control knob G522-2700-01
CH 1 Control panel G522-0011-01
CI 1 Front brace G522-0025-01
CJ 1 Quick Clean™ grease tray G522-0800-01
CK 1 Quick Clean™ grease cup G416-0015-01
CL 1 Upper back panel G522-0026-01
CM 1 Heat shield G522-0041-01
CN 1 Right track G522-0043-01
CO 1 Left track G522-0027-01
CP 1 Door support rail G522-5000-01
Item No. Qty. Description Part No.
DA 1 Left side burner side shelf G522-0700-01
DB 1 Side burner drip pan G522-0031-01
DC 1 Side burner G515-1000-01
DD 1 Electrode wire, side burner G515-0039-01
DE 1 Side burner lid G522-0032-01
DF 1 Side burner cooking grate G501-0077-01
DG 1 R ight side shelf G522-0600-01
DH 1 Side burner control knob G522-2800-01
EA 1 Left side panel G522-0300-01
EB 1 Right side panel G522-0400-01
EC 1 Left door assembly G522-8000-01
ED 1 Right door assembly G522-9000-01
EE 2 Door handle G522-0036-01
EF 1 Bottom shelf-LP G522-4000-01
EG 2 Locking castor G401-0061-01
EH 2 Castor G606-0027-01
EI 2 Door magnet assembly G501-00F2-01
EJ 2 Tank stopper G522-0042-01
EK 1 Quick Check™ fuel gauge
assembly
G522-3400-01
EK1 1 Quick Check™ fuel gauge
EK2 1 Quick Check™ hydraulic tube
EK3 1 Quick Check™ tank support
bracket
EL 1 Wire shelf G502-0069-01
F1 1 Hardware pack G522-B001-01
F2 1 Assembly manual G522-M001-01
F3 1 Safe use and care manual G522-M001-02
4 5
PARTS LIST (NATURAL GAS) FOR 85-3027-8 (G52202)
Item No. Qty. Description Part No.
AA 1 Top lid assembly G522-2000-01
AB 1 Thermometer G522-0005-01
AC 2 Screw for top lid G433-0002-01
AD 2 Lid bumper G508-0063-01
BA 1 Burner box assembly G522-3100-01
BB 3 Even Heat™ burners G522-2600-01
BC 1 Carryover assembly G522-0009-02
BD 1 Even Heat™ heat distribution
plate - left
G522-0050-01
BE 1 Even Heat™ heat distribution
plate - middle
G522-0022-01
BF 1 Even Heat™ heat distribution
plate - right
G522-0064-01
BG 3 Coleman signature cooking
grate
G522-0023-01
BH 1 Warming rack G515-0058-01
BI 1 Match holder G608-0019-01
CA 1 Manifold assembly- NG G522-4200-01
CB 1 Natural Gas hose G501-0099-01
CC 1 Side burner valve with T
bracket - NG
G522-0045-01
CD 1 Metal hose, side burner G508-0024-01
CE1 1 Electronic ignition assembly G511-0055-01
CE2 1 Ignition battery cover G515-0030-01
CE3 1 Instastart™ ignition button G522-0017-01
CF 3 Electrode set, main burner G522-0020-01
CG 3 Control knob G522-2700-01
CH 1 Control panel G522-0048-01
CI 1 Front brace G522-0025-01
CJ 1 Quick Clean™ grease tray G522-0800-01
CK 1 Quick Clean™ grease cup G416-0015-01
CL 1 Upper back panel G522-0026-01
CM 1 Heat shield G522-0041-01
CN 1 Right track G522-0043-01
CO 1 Left track G522-0027-01
CP 1 Door support rail G522-5000-01
Item No. Qty. Description Part No.
DA 1 Left side burner side shelf G522-0700-01
DB 1 Side burner drip pan G522-0031-01
DC 1 Side burner G515-1000-01
DD 1 Electrode wire, side burner G515-0039-01
DE 1 Side burner lid G522-0032-01
DF 1 Side burner cooking grate G501-0077-01
DG 1 Right side shelf G522-0600-01
DH 1 Side burner control knob G522-2800-01
EA 1 Left side panel G522-0300-01
EB 1 Right side panel G522-0400-01
EC 1 Left door assembly G522-8000-01
ED 1 Right door assembly G522-9000-01
EE 2 Door handle G522-0036-01
EF 1 Bottom shelf-NG G522-4600-01
EG 2 Locking castor G401-0061-01
EH 2 Castor G606-0027-01
EI 2 Door magnet assembly G501-00F2-01
EJ 2 Timer G430-0049-01
F1 1 Hardware pack G522-B001-01
F2 1 Assembly manual G522-M001-01
F3 1 Safe use and care manual G522-M001-02
EXPLODED DIAGRAM (natural gas) FOR 85-3027-8 (G52202)
BH
BA
CH
CPCG
CE3
EJ
ED
EE
DG
CK
CJ
AA
AB
CL
CI
CE2
EB
EI
EF
BI
EG
EH
CE1
CM
EC
EE
DH
CC
DB
DA
DC
DE
DF
CB
DD
CC
CD
CA
EA
CO
CN
BG
BE
BD
BF
Assembly
Manual
Safety & Care Manual
Hardware
Pack
F2
F3
F1
Extras
AC
AD
BC
BC
BB
CF
6 7
Front view
Front view
Separate the 2 dierent types of castors: 2 locking castors (EG) and 2 regular castors (EH).
Attach the locking castors (EG) to the back of the bottom shelf (EF), and the regular castors (EH) to the front of the bottom shelf (EF), as shown.
To secure the 4 castors, hand tighten first and then tighten further using the wrench provided in the hardware pack.
Ensure that the locking castors (EG) are
rmly locked in the “ON” position before
continuing.
Assemble the left side panel (EA) and the right side panel (EB), to the bottom shelf (EF).
Attach the front brace (CI) to the left and right cart side panels (EA and EB). The top of the front brace (CI) can be identified by two clips located on the top left, and right side of this part.
TIP: One person should align the left
side, while the second person assem­bles the right side.
ASSEMBLY INSTRUCTIONS ASSEMBLY INSTRUCTIONS
876
YOU WILL NEED:
YOU WILL NEED:
6 7 8
Upside down view
Close up
Back view
X 4 X 4 X 4
6
15
X 1
YOU WILL NEED:
THIS STEP REQUIRES 3 PEOPLE. DO NOT ATTEMPT ALONE. EXTREMELY HEAVY.
Position the top lid assembly and burner box assembly (A & B) onto the cart assembly (C), as shown.
1 3
42
876
2 3 4
X 6 X 6 X 6
EG
EF
EH
EG
EF
Close up
EB
EF
EA
EK
EA
EF
CI
EA
EB
Close up
A
B
C
8 9
Attach the upper back panel (CL) to both the left and right side panels (EA & EB).
DO NOT tighten screws until all hardware has been positioned.
YOU WILL NEED:
ASSEMBLY INSTRUCTIONS ASSEMBLY INSTRUCTIONS
PROPANE MODEL ONLY
b. Locate the Quick Check
TM
hydraulic tube support bracket (A) on the left side panel (EA). Unscrew the hardware and position the hydraulic tube (EK2) behind the bracket (A) and reconnect to the left side panel (EA) (Figure C).
1 3 4
X 4 X 4 X 4
Front view
Close up
Back view
5
6
6
PROPANE MODEL ONLY
a. Remove the Quick CheckTM tank
support bracket (EK3) from the carton located under the control panel (CH).
ATTENTION: Open the carton with care to avoid damaging or cutting the Quick Check
TM
hydraulic tube (EK2).
DO NOT bend the QUICK CHECK™ hydraulic tube (EK2).
DO NOT pull or place unnecessary force on to the QUICK CHECK™ hydraulic tube (EK2) connection points at the fuel gauge (EK1) or tank support bracket (EK3), as this may cause a leak in the hydraulic tube, resulting in unreliable fuel gauge readouts.
Left side, outside view
YOU WILL NEED:
c. Assemble the Quick Check
TM
tank support bracket (EK3) to the left side panel(EA), as shown in Figure E and F.
2 3 4 5
X 4 X 4 X 4 X 4
Quick CheckTM Fuel Gauge (EK)
Left side panel, Inside View
C
D
E
E
F
F
Left side panel, Inside view
CL
EA
EB
EK3
CH
A
B
EK1
EK2
EK3
EA
A
EK2
EK1
EK3
EK2
EK3
EA
CL
EA
EK2
10 11
ASSEMBLY INSTRUCTIONS
YOU WILL NEED:
6 7 8
d. Final image reects the proper
assembly of the Quick Check TM fuel gauge assembly (EK).
X 2 X 2 X 2
a. Assemble the left and right tracks
(CO and CN) for the Quick Clean™ grease tray (CJ), as shown in figure A.
b. Both the left and right tracks (CO and
CN) should be inserted into the two clips located on the front brace (CI), as shown in figure B.
c. Assemble the back of the left and right
tracks (CO and CN) to the upper back panel (CL), as shown in figure C.
Back view
Close up, front view
Close up, back view
6
7
C
B
A
Front view
Front, right side view
View inside burner box
Back, right side view
YOU WILL NEED:
ASSEMBLY INSTRUCTIONS
2 3 4
X 2 X 2 X 2
TIP: Do not tighten until all hardware is
in place.
a. Mount the right side shelf (DG) onto
the two hooks, located on the right, upper side panel of the burner box (BA).
b. Assemble the front of the right side
shelf (DG) to the control panel (CH), as shown in figure B.
c. Assemble the right side shelf (DG)
to the upper side panel of the burner box (BA), by positioning hardware through the interior of the burner box, as shown in figure C.
d. Complete the right side shelf assembly
(DG) by connecting the right side shelf (DG) to the rear of the burner box side panel (BA) as shown in figure D.
8
YOU WILL NEED:
2 3 4
X 2 X 2 X 2
5
X 2
A
B
A
A
B
B
A
B
YOU WILL NEED:
2 3 4
X 1 X 1 X 1
5
X 1
A
B
G A
B
C
D
EK1
EK3
CO
CN
CI
CN
CL
CO
BA
DG
DG
CH
BA
DG
BA
DG
12 13
ASSEMBLY INSTRUCTIONS
Front view
ASSEMBLY INSTRUCTIONS
a. Remove the hardware that is
pre-assembled to the side burner valve (CC). Feed the side burner valve (CC) through the bottom of the left side burner side shelf (DA), and re-attach the hardware, as shown.
b. Assemble the side burner control knob
(#13) to the side burner valve (CC).
c. Position the side burner (DC) through
the opening in the side burner drip pan (DB).
d. Make sure that the side burner (DC)
engages the side burner valve(CC), as shown in figure D.
A
B
C
D
9 10
A
A
B
B
A
B
YOU WILL NEED:
2 3 4
X 2 X 2 X 2
TIP: Do not tighten until all hardware is
in place.
a. Mount the left side burner side shelf
(DA) onto the two hooks, located on the right, upper side panel of the burner box (BA).
c. Assemble the left side burner side
shelf (DA) to the upper side panel of the burner box (BA), by positioning hardware through the interior of the burner box (BA), as shown in figure C.
d. Complete the left side burner side
shelf assembly (DA) by connecting the side shelf to the rear of the burner box side panel (BA), as shown in figure D.
YOU WILL NEED:
2 3 4
X 2 X 2 X 2
5
X 2
A
B
YOU WILL NEED:
2 3 4
X 1 X 1 X 1
5
X 1
A
B
A
B
C
D
YOU WILL NEED:
13
X 1
BA
DG
DA
DA
CH
DA
BA
BA
DA
CC
DA
CC
DC
DB
DC CC
13
b. Assemble the front of the left
side burner side shelf assembly (DA) to the control panel (CH), as shown in figure B.
14 15
ASSEMBLY INSTRUCTIONS
e. Using the wing nut (#14), assemble the
side burner (DC) to the side burner drip pan (DB), as shown.
f. Locate the side burner electrode wire
(DD) and insert into the base of the side burner electrode (DC), as shown in figure E.
g. Position the side burner cooking grate
(DF) onto the side burner drip pan (DB).
b. Position the electronic ignition box
(CE1) into the heat shield (CE1) and feed the assembly through the opening in the right side panel (EB) and secure using the nut.
c. Insert a “AA” battery into the battery
compartment, as shown. Secure using
the ignition button cover (CE2).
YOU WILL NEED:
14
X 1
a. Remove the ignition battery cover
(CE2) and the plastic nut from the electronic ignition box (CE1)
10
11
E
F
A
B
14
DB
DC
DD
DF
DB
CE2
CE1
EB
CE2
ASSEMBLY INSTRUCTIONS
f. Insert the Instastart™ ignition button
(CE3) wires into the Electronic ignition assembly (CE1), as shown in figure F.
e. Insert the Electrode wire, side burner
(DD) into the Electronic ignition assembly (CE1), as shown in figure E.
11
TIP: The Electrode Set, main burner
(CF) and the Electrode wire, side burner (DD), can be found attached to the control panel (CH) heat shield, as shown in gure C.
d. Insert the three Electrode set, main
burner (CF) wires into the Electronic ignition assembly (CE1) as shown in figure D.
C
D
E
F
CF
DD
CH
CF
CF
DD
EB
CE1
CE1
CE1
CE3
16
ASSEMBLY INSTRUCTIONS
a. Assemble the heat shield (CM) to
the bottom of the front brace (CI) as
shown in figure A.
b. Aseemble the back of the heatshield
(CM) to the upper back panel (CL), as
shown in figure B.
b. Assemble the wire shelf (EL) to the
right cart side panel (EB), as shown in
figure C.
Y
OU
WILL
NEED
:
9
X 2
PROPANE MODEL ONLY
a. Assemble the wire shelf (EL) to the
bottom shelf (EF), as shown in figure
12
13
Y
OU
WILL
NEED
:
9
X 2
A
B
C
A
B
OU
WILL
10 11 12
X 2
X 2
X 2
OU
WILL
10 11 12
CI
CM
CM
CL
EL
EF
EL
EB
Assemble the door support rail (CP) to
the left and right upper side panels (EA
and EB), as shown.
WARNING: This part may have sharp
edges. Wear protective gloves when
assembling.
Front, left side view
OU
WILL
1 3 4
Close up, front view
14
ASSEMBLY INSTRUCTIONS
15
Assemble the door handle (EE) to the
left and right door assembly (EC and ED)
as shown in figure A and B.
6 7 8
Y
OU
WILL
NEED
:
A
B
EA
CP
EB
EE
EC
EE
EC
18 19
ASSEMBLY INSTRUCTIONS
Position the Even HeatTM heat distribution plates (BD,BE and BF) into the burner box (BA) as shown.
Note: For optimal heat distribution, position the heat distribution plates as indicated in figure A. Each heat distribution plate will have a letter embossed to indicate L-left, M-Middle, and R- Right.
A
B
C
16
L
R
M
BD
BF
BE
PROPANE MODEL SHOWN
a. Assemble the right door assembly
(ED), to the bottom shelf (EF) by inserting the fixed pin (bottom of door) into the hole provided (figure B).
b. Assemble the top of the door
assembly (ED) to the door support rail (CP), by pressing in the door support pin and aligning with the hole located on the top right corner of the door.
TIP: Use a paint scraper to press-in the
support pin, while the second person aligns the door. The support pin will lock into position when the door is assembled correctly.
c. Repeat steps a, and b for the left door
assembly (EC).
Top of door
Bottom of door
B
C
A
16
ASSEMBLY INSTRUCTIONS
ED
EF
ED
EF
ED
CP
20 21
ASSEMBLY INSTRUCTIONS
FOR NATURAL GAS MODEL ONLY.
Attach the natural gas hose (CB) to the side burner valve (CC), as shown.
ATTENTION
: In order to complete
installation of your Natural Gas BBQ a
½” or 3/8” adapter may be required to
connect your BBQ’s Natural gas hose to your home gas supply. Contact your natural gas supplier to purchase the necessary part.
NOTE: EXTRA HARDWARE WILL BE
LEFT OVER FOR NATURAL GAS MODEL.
FOR PROPANE MODEL ONLY.
For natural gas model, follow step 21.
a. Feed the regulator (CB) through the
opening on the left side panel (EA).
b. Mount the 20lb propane cylinder
onto the Quick Check
TM
tank support bracket (EK3), located on the inside of the left side panel (EA).
c. Attach the regulator (CB) coupling nut
to the propane cylinder valve.
ATTENTION: DO NOT STORE EXTRA PROPANE TANKS WITHIN BBQ CART.
www.colemanbbqs.com
19
20
CC
EK3
CB
CB
ASSEMBLY INSTRUCTIONS
b. Place the cooking grates (BG) into the
burner box (BA), as shown in figure A.
a. Assemble the warming rack (BH) by
inserting the three fixed pins into the three holes provided on the burner box back panel (BA), as shown in Figure A and B
B
A
18
a. Position the QUICK CLEAN
TM
grease tray (CJ) onto the right and left tracks (CN and CO), as shown.
b. Position the QUICK CLEAN™ grease
cup (CK) in position under the under the QUICK CLEAN™ grease tray (CJ).
17
CJ
CK
BH
BG
BH
BA
WWW.COLEMANBBQS.COM
ADDITIONAL WARNINGS
POSITION YOUR BARBECUE
WARNING HOT SURFACES:
You have now completed the Assembly of your COLEMAN® EVEN HEAT™ BARBECUE.
NEXT STEPS:
Position your BARBECUE
1.
Read SAFETY & CARE MANUAL2. Perform Grill Safety Check-list3.
WARNING:
FOR YOUR FAMILIES SAFETY,
DO NOT ATTEMPT TO LIGHT
THIS BBQ UNTIL YOU HAVE REVIEWED PAGES 4-7 OF THE COLEMAN SAFEY AND CARE MANUAL. ALL SAFETY AND LEAK TESTS MUST BE PERFORMED BY THE END USER, PRIOR TO LIGHTING THIS BBQ.
Always confirm that this Barbecue is not positioned under a combustible object (e.g., an awning or umbrella) or in a covered area (e.g., porch or gazebo) before lighting it, to prevent a possible fire.
Always confirm that this Barbecue is not positioned under the overhang of a house, a garage or other structure before lighting it. An overhang will serve to deect are-ups and radiate heat into the structure itself, which could result in a fire.
Always confirm that this Barbecue is positioned more than 36” (91.4cm) away from
any combustible materials or surfaces before lighting it, and that no gasoline or other volatile substances are store in the vicinity of this Barbecue. The temperature of a grease fire or of the radiated heat might otherwise be sucient to ignite nearby combustibles or volatile substances. Do not position near windows, siding, or fencing.
Always locate the Barbecue where there will be ample combustion and ventilation air, but never position it in the direct path of a strong wind.
!
!
!
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