Coleman 9903 Series Manual

For Outdoor Use Only

Technical Characteristics

Input Rating: 6,500 BTU/H for left and right burners, 7,000 BTU/H for center burner.

Category: Pressure regulated propane

Fuel: 16.4 oz. disposable propane cylinders

Regulator: Cavagna-TYPE 798 regulator must be used

General Safety Information

This manual contains important information about the assembly, operation and maintenance of this outdoor propane appliance. General safety information is presented on this page and is also located throughout these instructions. Particular attention should be paid to information accompanied by the safety alert symbol: " DANGER", " WARNING", " CAUTION".

Keep this manual for future reference and to educate new users of this product. This manual should be read in conjunction with the labeling on the product.

Safety precautions are essential when any mechanical or propane fueled equipment is involved. These precautions are necessary when using, storing, and servicing. Using this equipment with the respect and caution demanded will reduce the possibilities of personal injury or property damage.

The following symbols shown below are used extensively throughout these instructions. Always heed these precautions, as they are essential when using any mechanical or propane fueled equipment.

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate personal injury, or property damage.
If you smell gas: Shut off gas to the appliance. Extinguish any open flame. Open lid. 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.

CALIFORNIA PROPOSITION 65:

This fuel, and by products of combustion of this fuel, contain chemicals known to the state of California to cause cancer, birth defects, or other reproductive harm.

FOR OUTDOOR USE ONLY. NEVER operate grill in enclosed areas, as this could lead to gas accumulating from a leak, causing an explosion or a carbon monoxide buildup which could result in injury or death. DO NOT use in garages, breezeways, sheds or any enclosed area. NOT FOR USE BY CHILDREN. If these instructions are ignored, a hazardous fire or explosion could result in physical injury, death or property damage!

DO NOT move grill while it is lit. Keep outdoor cooking gas appliance area clear and free from combustible materials, gasoline and other flammable vapors and liquids.

NEVER place more than 20 pounds on a side table. DO NOT lean on grill. NEVER use charcoal briquettes or lighter fluid in a gas grill. Grill is hot when in use; to avoid burns, DO NOT touch any hot grill surface. Keep children and pets away from hot grill. NEVER leave the grill unattended while it is in use. It is your responsibility to assemble, install, operate and care for your gas grill properly. DO NOT use gas grill indoors. Under some circumstances, propane may lose the distinctive odor that was added. Other strong odors may hide or mask the odor of propane. Colds, allergies, sinus congestion, and the use of tobacco, alcohol or drugs may impair your ability to detect the odor of propane.

If the outdoor cooking gas appliance is not in use, the gas must be turned off at the supply cylinder(s). Storage of an outdoor cooking gas appliance indoors is permissible only if the cylinder(s) is (are) disconnected and removed from the outdoor cooking gas appliance. Cylinders must be stored outdoors out of the reach of children and must not be stored in a building, garage or any other enclosed area.

General Installation

• Installation must conform with local codes or, in the absence of local codes, with either theNational Fuel Gas Code, ANSI Z223.1/NFPA 54, Natural Gas and Propane Installation Code, CSA B149.1, or Propane Storage and Handling Code, CSA B149.2, as applicable.
• To check local codes, see your local L.P. gas dealer or natural gas company listed in the Yellow Pages for recommended installation procedures and regulations.

This appliance is not to be installed in or on a recreational vehicle and/or boat. Follow these safety rules before each use: A minimum clearance of 24 inches from the left, right and back sides of the grill must be maintained between the grill and any combustible construction such as wood siding of a building. Never locate the grill under an unprotected combustible material or overhang. Do not obstruct the flow of combustion and ventilation air. The grill should be level and not facing directly into the wind.

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.

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

DO NOT attempt to adjust the regulator as this could create a situation causing personal injury or property damage.

Portable L.P. Gas Barbecue Cylinders

Liquefied Petroleum gas (abbreviated L.P. gas or propane), is highly flammable. It becomes liquid when stored under high pressure inside a cylinder and vaporizes when released. L.P. gas is heavier than air and tends to collect in low areas. It is important that there are no leaking connections on your gas grill that could cause a fire or explosion (see the section titled "LEAK TESTING"). Portable LP gas grills require a fuel delivery system which is comprised of a valve [A], a regulator [C] with vent hole [B], an L.P. gas supply cylinder [E], (Fig. 1) Illustration in Fig. 1 is for description purposes only.

Cylinder Specifications

• All L.P. gas cylinders used with this appliance shall be constructed and marked in accordance with the Specifications for L.P. 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 a cylinder connection device compatible with the connection for outdoor cooking appliances.
• Read labels on the L.P. Gas Supply Cylinder.

2. Check and clean the burner/venturi tubes for insects and insect nests. A clogged tube can lead to a fire beneath the appliance. Refer to the section titled "Cleaning the Venturi").

Leak Testing - Disposable LP Gas Cylinders

To Prevent Fire or Explosion Hazard:

• NO SMOKING. DO NOT use or permit sources of ignition in the area while doing a leak test.
• Perform leak tests outdoors only.
• NEVER perform a leak test with fire or flame.

How to Check for Leaks

1. Make a soapy solution of equal parts mild liquid dishwashing detergent and water.
2. Turn off the burner control knobs.
3. Apply a soap solution to the connections indicated with the arrow. (Fig. 24) If bubbles appear at these areas, a leak is indicated.
   

Keep the grill area clean and free from combustible materials, gasoline and other flammable vapors, liquids, and spare L.P. cylinders. To avoid the possibility of tipping over the grill, NEVER place more than 20 pounds on the side table. A filled 4-quart aluminum pot weighs approximately 10 pounds. DO NOT obstruct the flow of combustion and ventilation air. Keep the ventilation opening(s) of the L.P. cylinder enclosure free and clear of debris. A barbecue grill becomes hot during use. DO NOT touch grates, or cooking surfaces. Be sure to tighten all hardware (screws, nuts, bolts, etc.) at least once a year or before each grilling season.

Condition The Grill

• Before using the grill for the first time, or after storage, operate the grill 5 minutes on the high setting with the lid closed, to burn away oil.
• Once the oil has burned away, check the burner flame per the next step.

The Burner Flame

• Open the grill lid. The cooking grates should be in place.
• Keep your arms and face away from being directly above the cooking area. Look through the cooking grates and observe the burner's flame below.
• Flames should appear similar to the good flame shown in Fig. 35 and as follows:
  
  • A good flame should be blue with a yellow tip.
  • Some yellow tips on flames up to 1 inch in length are acceptable as long as no carbon or soot deposits appear.
  • If flames are excessively yellow and irregular, the oil residue may not be completely burned off, or the venturi may be clogged or may not be properly positioned over the orifices. Allow the grill to cool before repositioning the venturi over the valve and orifices.
  • Grills that have been in use for a while sometimes begin to show more yellow flame. A build-up of food deposits, fats or cooking seasonings can cause yellowing flames. Clean the burner to remove residue and check for clogged burner holes or a blocked venturi. Refer to the section titled "Cleaning the Venturi".
  • Regular use of your grill will actually help keep it operating more smoothly.
  • Each grill may heat differently. Some units will heat somewhat more to the center and back of the grill. The flavor of grilled food will improve the more you use the grill and as you become familiar with it.

Grilling Tips and Hints

Burner Control Setting Tips

• The high flame setting is too hot for direct cooking. The high flame setting is good for quick searing of meat, then finish cooking on medium or low flame settings.
• Use the high flame setting with the lid closed to preheat the grill for 5 minutes before cooking.
• Use a medium flame setting for direct cooking of steaks, pork chops, chicken and hamburgers.
• Use a low flame setting for roasts.
• Thick steaks will finish with a better texture and more juice if first seared on high flame setting and then cooked on a low flame setting.

Safe Grill Operation

• NEVER leave cooking food unattended. Continually observing the food will help in maintaining an even temperature, conserve fuel, improve the food's flavor and lessen flare-ups.
• To open the grill lid, slowly lift the handle to avoid burning in case of a grease fire flare-up.
• DO NOT expose any part of your body directly above the cooking area.

Food Preparation Hints

Your grill can cook a variety of foods. For best results, follow these instructions:

• Trim excess fat from meat and poultry. Slash any remaining fat to stop curling, but take care not to cut the meat.
• Frozen meat and poultry should be thawed prior to cooking.
• Frozen fish and vegetables will cook without thawing.
• Salt food after cooking to help prevent drying out the food.
• Brush naturally lean meats with cooking oil or margarine.
• Cook small pieces of tender foods in foil or on special delicate-food cooking grates (see the section titled "Cooking Methods").
• Apply barbecue, tomato or sugar-based sauces no sooner than the last 10 m inutes of cooking.
• Turn food with tongs or a spatula; piercing food (especially meat), tends to dry it out.

In Case of Grease Fire

Follow These Steps

1. Shut off the gas at the control knob(s) and stay away!
2. Allow the fire to burn itself out.
3. Once the fire is out and the appliance has cooled, remove the disposable cylinder.
4. Clean all parts and inspect for damage. Parts to check for damage are the L.P. cylinder, regulator, burner valve(s) and burner(s).
5. If any of the above mentioned components are damaged, please call phone numbers listed in warranty.

Note:

• Some flare-up adds a smoky flavor and sears food. Excessive grease fires can cause a potentially hazardous situation and damage the grill.
• Avoid excessive flare-ups by preheating the grill with the lid closed for 5 minutes on the high setting to burn off grease from previous cooking.
• Cook with the lid down and continually monitor cooking food to avoid grease fires and flare-ups.
• Trimming excess fat from meat will reduce grease fires and flare-ups. Cook fatty meat in smaller amounts over indirect heat on a low setting.
• Be sure to follow the instructions in the section titled "Care, Maintenance, and Cleaning".

Cooking Methods

Direct method:

• The heat source is directly below the food.
• Use for browning meat or cooking hot dogs and hamburgers, but check food frequently.
• Use for skillet and stir-fry cooking, but limit the amount of oil and heat to be used.
• Cook roasts, turkey or duck on low heat. Place meat with water in a foil pan with a corrugated bottom. Replenish water as needed.

Indirect method:

• Light only one side of the burner and place food on the opposite side for cooking.
• Allow food to cook at a lower temperature which increases tenderness and reduces grease flare-ups.
• It is a good method for cooking foods that burn easily (vegetables, fish, etc.).
• Cook casseroles in ovenware or foil pans much like cooking in a conventional oven.
• Also try placing a pan of water above the lit burner side to help meat retain its juices. Replenish the water as needed.

Care, Maintenance and Cleaning

NOTE TO PREVENT DAMAGE WHICH WILL VOID THE WARRANTY:

• Do not use pots, pans, ovens, ect., on this cooking grate or griddle surface.
• Do not stack a cooking grate and griddle together on the same burner.
• Do not use this cooking grate or griddle on a campfire or other open fire.
• Never leave the cooking grate or griddle over a lit burner without foodstuffs longer than one minute (except for the initial pre-heating period). Otherwise, the special coating will be damaged.
• Use this cooking grate or griddle only on the Coleman® grill for which it was designed.

COOKING GRATE AND GRIDDLE

The cooking grates and griddles can be cleaned immediately after cooking is completed and after turning off the grill. Wear a barbecue mitt and scrub the cooking grates and griddles with a damp cloth. If the grill is allowed to cool down, cleaning the grates and griddles will be easier if removed from the grill and cleaned with a mild detergent.

All cleaning and maintenance should be done only when the grill is cool & with the fuel supply turned off at the cylinder. Disposable propane cylinders should be detached from the grill during cleaning.

Suggested Cleaning Materials:

• Mild dishwashing liquid detergent
• Hot water
• Wire brush
• Paper clip
• Nylon cleaning pad
• Soft brass-bristled brush
• Putty knife
• Scraper

Component Cleaning:

• BURNER: Wire-brush loose corrosion from the burner exterior. Clean clogged gas port holes with an opened paper clip. Replace corroded or damaged burner that would emit excess gas.
• COOKING GRATE: Clean cooking grates with mild soap and hot water. Remove stubborn residue with a mild cleanser or scrub brush. DO NOT use a commercial oven cleaner.
• GRILL INTERIOR: Remove grates. Scrape side with tools and remove excess grease and cooking residue.

Cleaning the Venturi

Spider's nests or wasp's mud inside the venturi may cause fire at the valve. If a fire occurs, immediately turn off the gas supply at the control valve (see representative illustration in Fig. 36).

A collision with the grill, as with any metal object, could cause injury. Use care when moving a portable gas grill.

Note: Spiders and small insects can spin webs and build nests inside the venturi tubes. This especially occurs in late summer and fall before frost when spiders are most active. These nests can obstruct gas flow and cause a fire in and around the burner knob. Such a fire can cause operator injury and serious damage to the grill. To help prevent a blockage and ensure full heat output, clean and inspect the venturi tubes often (once or twice a month).

NOTE: Water or air pressure will not normally clear a spider web.

Steps For Cleaning Venturi:

1. To remove the above obstructions, use an accessory flexible venturi brush or bend a small hook on one end of a 20-inch long flexible wire such as the one shown in Fig. 37.
   

2. Remove the cooking grates and the water pan and set aside and remove the burner. (Fig. 38 and Fig. 39)
   

3. Look inside lower end of venturi tube for nests, webs or mud. If present, clean as noted in Step 1, Fig. 37.
4. Inspect and clean the burner if needed.
5. Replace the burner and burner clamps, and position the burner in the operating position.
6. Make sure the orifice fittings are inside the venturi tube, then tighten all self tapping screws. (Fig. 40 and Fig. 41)
   

Moving and Storage

A collision with the grill, as with any metal object, could cause injury. Use care when moving a portable gas grill.

Moving the grill:

• DO NOT move the grill or remove cylinder while it is lit or hot, or with objects on the cooking surface or side tables.
• Clean the grease tray before moving the grill to prevent spills.
• Collapse the grill before moving.
• Move the grill slowly. DO NOT run with the grill behind you; it could hit you from behind causing injury.

After moving the grill:

• Check all gas connections for leaks that could occur from the movement.
• Check the venturi tubes to be sure they are still over the orifices.

Steps to follow before storing grill:

• Clean the grill, including the grease tray.
• Coat the burner lightly with cooking oil to retard rusting.
• For outdoor use only. If the grill is stored indoors, detach the cylinder outdoors. If left outdoors, remove the cylinder and cover the grill for protection from the weather. Grill covers may be purchased from a grill dealer or manufacturer.

Troubleshooting

Problem: Grill will not light when the igniter button is pushed or has incomplete burner flame.
Possible Causes and Solutions:

1. Lack of fuel. Check to see that the cylinder has fuel.
2. Make sure the burner is turned on. Allow up to four seconds for gas flow to ignite.
3. If burner lights with match but not igniter, check the ceramic electrode position near the burner, the condition of the igniter wire and its connections. Perform igniter test and replace any damaged parts.
4. Check for spider webs or insect nest in venturi and clean venturi.
5. Check for misalignment of venturi on orifices. Position venturi over orifices.
6. Burner ports, orifices or knob have blockage. Clean the components.
7. Regulator failure; grill needs to be replaced.
8. Make sure the regulator and cylinder are properly assembled. See the section titled "Installing 1 lb. Propane Cylinders".

Problem: Yellow flame.
Possible Causes and Solutions:

1. Check for spider webs or insect nest in the venturi and clean the venturi.
2. New burner may have residual oil which will burn off.
3. Clean off any food residue, grease or seasoning salts on the burner.
4. The venturi may be misaligned and needs to be lined up over the orifice.

Problem: Flame blows out on low setting or has uneven heat distribution.
Possible Causes and Solutions:

1. Check for spider webs or insect nests in the venturi and clean the venturi.
2. Cold grill needs to be preheated for 5 minutes on high setting.
3. The venturi may be misaligned and needs to be lined up over the orifices.
4. Cold and windy weather will require you to move the grill away from the wind.
5. Lack of fuel. Check to see that the cylinder has fuel.

Problem: Grill too hot.
Possible Causes and Solutions:

1. Excessive flareups which require the maintenance described in the section titled "IN CASE OF GREASE FIRE".
2. A damaged orifice or regulator which requires replacement with factory authorized parts.
3. Buildup of grease inside the grill will require cleaning and emptying the grease tray.
4. Choose a lower cooking temperature if using excessively high settings.

Problem: Fire at any connection.
Possible Causes and Solutions:
IMMEDIATELY shut off control knob and allow grill to cool.

1. Gas is leaking from a faulty connection. Tighten connections with an adjustable wrench and replace damaged parts. Perform a leak test on all connections before cooking on the grill again.

Problem: Flame behind control panel or control knob area.
Possible Causes and Solutions:
IMMEDIATELY shut off control knob and allow grill to cool.

1. Check for spider webs or insect nest in the venturi and clean the venturi.
2. Gas is leaking from a faulty connection. Hand tighten connections and replace damaged parts. Perform a leak test on all connections before cooking on the grill again.
3. The venturi may be misaligned and needs to be lined up over the orifices.

Replacement Parts List — 9903 Series

1. Lid Assy
2. Water pan
3. Side Table Assy
4. Wheel w/ Hardware

Additional Accessories

5. Grate
6. Griddle
7. Pan/Pot Support

Please visit www.Coleman.com for a complete list of Replacement Parts and Accessories.

How to Obtain Warranty Service
Your product must be under warranty in order to obtain warranty service. If your product is defective and is within your warranty period, contact us at 1-800-835-3278 (TDD 1-316-832-8707)

Carefully package the product and send insured by UPS, FedEx Ground or Parcel Post with shipping and insurance prepaid to:
For products purchased in the United States:
The Coleman Company, Inc. 3600 North Hydraulic
Wichita, KS 67219 U.S.A.

For products purchased in Canada:
Newell Brands Canada ULC
20B Hereford Street
Brampton, ON L6Y 0M1

The cost of transporting the product to Coleman for warranty service is the responsibility of the purchaser.

Do not mail products with fuel in tanks, or with disposable propane cylinders.

DO NOT RETURN THIS PRODUCT TO THE PLACE OF PURCHASE.

If you have any questions regarding this warranty please call 1-800-835-3278 or TDD 1-316-832-8707 in the United States or 1-800-387-6161 in Canada.