LTR20071038, Rev. B
1/4/07
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Table of Contents
Read all instructions before
you operate your grill
WARNING
If the information in this manual is not
followed exactly, a fire or explosion may
result causing property damage, personal
injury or loss of life.
Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
Do not store an LP cylinder not connected
for use in the vicintiy of this or any other
appliance. A fire resulting in serious injury
or death may occur.
If you are installing a natural gas grill,
you are responsible for ensuring that the
natural gas line installed is safe to use.
California Acrylics Industries (C.A.I.) will
not be held responsible for an improperly
installed gas line.
DANGER
What To Do 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.
Save these instructions!
2007 Barbecue Grill and Cart Owner’s Manual
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Safety Instructions
Safety Instructions
WARNING: Improper installation, adjustment, alteration, service or maintenance can
cause injury or property damage. Read the installation, operating and maintenance
instructions thoroughly before installing or servicing this equipment.
dedicated 15A GFCI breaker in accordance with
local codes or the National Electrical Code, ANSI
/ NFPA 70, or the Canadian Electrical Code, CSA
C22.1.
Placement and Location
•
Cal Flame™ grills and carts are designed for
outdoor use only
•
Never locate this appliance in an enclosed room,
under a sealed overhead structure, or in any
type of enclosed area such as a garage, shed, or
breezeway. Keep clear of trees and shrubs.
•
Do not use an extension cord to supply power to
your Cal Flame™ grill or cart. Such use may result
in fire, electrical shock or other personal injury. Do
not install a fuse in the neutral or ground circuit.
A fuse in the neutral or ground circuit may result
in an electrical shock hazard. Do not ground this
appliance to a gas supply pipe or hot water pipe.
Keep any electrical supply cords and the fuel
supply hose away from any heated surfaces.
•
•
•
Do not place this grill under or near windows or
vents that can be opened into your home.
Cal Flame™ grills are not intended for installation
in or on recreational vehicles or boats.
Maintain sufficient distance as to not overheat any
overhead combustible material such as a patio
cover.
•
•
To prevent fire and smoke damage, remove all
packaging material before operating grill.
Before you start cooking, clean the entire grill
thoroughly with hot, soapy water. This is necessary
to remove residual solvents, oil and grease used in
the manufacturing process. The grates should also
be thoroughly cleaned in the same manner.
•
•
The area surrounding your new grill should be
kept clean and free from flammable liquids and
other combustible materials such as mops, rags or
brooms, as well as solvents, cleaning fluids, and
gasoline.
Do not use the grill, grill cabinet, or area
Operation
•
surrounding the grill as a storage area for
flammable or plastic items. Do not store the liquid
propane (LP) cylinder in the vicinity of this or any
other appliance when it is not being used.
Do not use grill for other than intended use.
•
In the event that a burner goes out, turn burner
knobs to the full OFF position, fully open the grill
hood and let it air out. Do not attempt to use the
grill until the gas has had time to dissipate.
Set-Up
•
Never use the grill if the drip pan is not properly
installed. Drip pan should be pushed all the way
to the rack located just under the grill. Fire or
explosion can result from an improperly installed
drip pan.
•
Before installing built in grills in enclosures, copy
all product information such as model number,
serial number and type of grill (e.g. natural gas or
LP) and store information in a safe place. This
information is located on a plate located behind the
grill and is visible when the hood is lowered or on
the right side of the chassis. There is an area on
the back cover of this manual where you can write
down this information.
•
•
Keep all electrical supply cords and the rotisserie
motor cord away from the heated areas of the grill.
Never use the grill or side burner in windy
conditions. If used in a consistently windy area a
windbreak will be required. Always adhere to the
specified clearances listed in this manual.
•
•
We recommend that a licensed contractor install
your Cal Flame™ grill. Installation must conform to
local codes, or in the absence of local codes, with
either the National Fuel Gas Code, ANSI Z223.1
/ NFPA54, Natural Gas and Propane Installation
Code, CSA B149.1, or Propane Storage and
Handling Code, B149.2), as applicable.
•
•
•
Never line the grill or side burners with aluminum
foil.
When the unit is not in use, be sure to turn off the
gas at the LP tank.
Your Cal Flame™ grill or cart must be plugged
into a permanent, grounded 110V outlet with a
Do not install or operate your grill unit in such a
manner that the cross ventilation openings are
Page 2
2007 Barbecue Grill and Cart Owner’s Manual
LTR20071038, Rev. B
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Safety Instructions
blocked. Fresh air must be able to pass though
installed vents to safeguard against residual gas
accumulation. Failure to allow proper ventilation
may cause fire or explosion.
•
•
Do not heat any unopened glass or metal container
of food on the grill. Pressure may build up and
cause the container to burst, possibly resulting in
serious personal injury or damage to the grill.
•
When handling LP gas line and connectors, do
not allow them to come in contact with any metal
surfaces of the cart or cabinet. Do not drop LP
connectors.
Do not reach over your grill or any other surfaces
when hot or in use.
Maintenance and Repair
•
Spiders and other insects can nest in the burners of
the grill and block the gas and airflow to the burner
ports. This creates a dangerous condition that
can result in a fire behind the valve panel. Inspect
and clean the burners periodically and follow
the guidelines in the Cleaning and Maintenance
section of this manual.
•
•
Do not use fuel such as charcoal briquettes in
electric or gas grills
Gas sources to the grill and side burners must be
regulated. Do not operate grill or side burners if
regulators have been removed, fire or explosion
can occur.
•
•
Never leave the grill and side burners unattended
when in use. When using pots and pans, boil-
overs will cause smoking and greasy boil-overs
may ignite.
•
Unless specifically recommended in this manual,
do not repair or replace any part of the grill. A
qualified technician should perform all service. Any
repairs made by a non- C.A.I. approved dealer
technician will void your warranty.
Always use the proper size pan. Select utensils
with flat bottoms large enough to cover the burner.
The use of under-sized utensils exposes the sides
of the utensils to direct contact with a portion of
the flame. This can scorch utensils and hamper
cleanup. Excessive flames on large stainless steel
pots can result in permanent discoloration. For
best results, we recommend commercial quality
aluminum pans and utensils.
Storage
•
When your gas grill is not in use, turn off the gas at
the supply cylinder.
•
Storage of a grill or cart indoors is permissible only
if the supply cylinder is disconnected and removed.
Precautions Regarding Children
•
•
Always position handles of utensils so they do
not extend over adjacent work areas or cooking
areas. This reduces the risk of burns, ignition of
flammable materials, and spillage due to accidental
contact with the utensils.
•
Never leave children unattended in the area where
the grill is being used. Close supervision of children
is necessary when any appliance is use near
children.
Do not use water on grease fires. Never pick up a
flaming pan. Turn the appliance off and smother the
flaming pan with a tight-fitting lid, a cookie sheet or
a flat tray. For flaming grease outside of the pan,
smother it with baking soda or use a dry chemical
or foam-type fire extinguisher.
•
•
Do not store items of interest to children around or
below the grill or cart.
Never allow children to sit or stand on any part of
the grill or cart.
Carts
•
Never allow clothing, pot holders or other
flammable materials come in contact with or be
close to any grate, burner or hot surface until it has
fully cooled. Never wear loose fitting or hanging
garments while using your grill. Fabric may ignite
and result in personal injury.
•
•
•
•
Do not attempt to move the stainless steel cart
while it is hot or in use.
It is extremely important to lock all caster wheels
even on flat surfaces.
Do not lean, sit or stand on the stainless steel cart,
including the foldout work surfaces.
•
•
When using the grill, do not touch the grill rack,
burner grate, or immediate surroundings as these
areas become extremely hot and can cause burns.
Use handles or knobs.
Do not exceed 50 pounds of weight on the foldout
work surfaces.
Only use dry pot holders and do not use a towel or
other bulky cloth in place of pot holders. Moist or
damp pot holders used on hot surfaces can cause
burns.
2007 Barbecue Grill and Cart Owner’s Manual
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LTR20071038, Rev. B
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Installation / Assembly
Installation / Assembly
Most cities and counties require permits for exterior
construction and electrical circuits. In addition, some
communities have codes requiring residential barriers
such as fencing and/or self-closing gates on property
to prevent unsupervised access to the property by
children under the age of five. Your dealer can provide
information on which permits may be required and how
to obtain them prior to the delivery of your equipment.
When determining a suitable location, consider factors
such as exposure to wind, proximity to traffic paths,
and windows that open into the home.
Locate barbecue grills and stainless steel carts only in
well-ventilated areas and only on solid, flat foundations
(e.g. deck or cement slab). Do NOT place stainless
steel carts on dirt or grass.
We recommend the installation, adjustment and service
of your new grill be performed by C.A.I. qualified
installers and service technicians to ensure proper
operation and prevent accidents.
Cabinet Cut-out Dimensions
Your Cal Flame™ grill is designed for easy installation
into a non-combustible enclosure. The supporting deck
or counter must be flat and level. When determining the
final location of your grill, adequate cross ventilation
must be present to prevent gas from being trapped in
the event of a leak.
When planning your Cal Flame™ grill or cart location,
access to gas lines and 110V power supplies should
be considered. The location with the shortest gas
line run is recommended. A grounded, dedicated,
15A, 110V, GFCI power source is required for use of
your appliances (e.g. lights, rotisserie, refrigerator,
receptacles, etc.).
The drawings below show the different types of cabinet
cut-out dimensions for gas grills and accessories.
Cut-out for barbecues, side burners and
slide-in accessories
Model Number Description
Width Depth Height
BBQ07870P / CP Charcoal Grill
30 ¾”
23 ¼”
23 ¼”
30 ¾”
38 ¼”
38 ¼”
22 ¼”
22 ¼”
22 ¼”
22 ¼”
22 ¼”
22 ¼”
9 ¼”
9 ¼”
9 ¼”
9 ¼”
9 ¼”
BBQ07872-1P
BBQ873
2 Burner Grill
3 Burner Grill
BBQ07874-1P
BBQ07875-1P
BBQ07875SP
4 Burner Grill
5 Burner Grill
5 Burner SmartControl Grill
Center
open
BBQ07898P
BBQ07899P
BBQ07954
Deluxe Single Side Burner
12 1/8” 21 ¾”
7 ¼”
7 ¼”
7 ¼”
8 ¾”
7”
Deluxe Double Side Burner 12 3/8” 21 ¾”
Deluxe Side by Side Burner 25 ¼”
13 ¼”
22 ½”
20 ½”
21 ¾”
BBQ07864P
BBQ07888P
BBQ07842P-12
BBQ07842P-18
BBQ07902
Ice Chest
31”
Food Warmer
12 ½”
12 ¼”
12” Cocktail Center
18” Cocktail Center
30” Drop-in Bar Center
Standard Blender
Pizza Oven
7”
17 ½” 24 3/8”
28 ¾” 22 ¾”
10”
12”
BBQ07903
16 ½” 24 3/4”
17 1/2” 23 ¼”
11 ¼”
9 1/2”
BBQ07877P
Page 4
2007 Barbecue Grill and Cart Owner’s Manual
LTR20071038, Rev. B
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Installation / Assembly
Model Number
BBQ07852P
BBQ07845P
BBQ07953P
Description
Width
11 ½”
14 ½”
24 ¼”
Depth
17 ¾”
14 ½”
19 ¾”
Height Cut-out for drop in accessories
Drop In Standard Side Burner
2 ¾”
Drop In Sink
Standard Side by Side Burner
4 ¼”
Model Number
Description
Width Depth
Height Cut-out for flat drop-in grill and drip tray
BBQ07874-F1
4 Burner Flat Drop In Grill
37 ¾” 22 ¾”
8 ¾”
A
B
C
D
BBQ0704103031
Drip tray cut-out
21 ¾”
1 ¾”
5”
6 ½”
Model Number
BBQ07868P
BBQ07869P
BBQ07862P
BBQ07889P
BBQ07891P
Description
Width Depth Height Cut-out for drawers
2 Drawer Storage
10 ¾”
10 ¾”
13 ½”
28 ¾”
13 ½”
19 ¾”
20”
17 ¼”
17 ¼”
2 ½”
10”
3 Drawer Storage
Griddle and Griddle Storage
30” Warming Drawer
Cutting Board and Drawer
19”
20 ½”
19 ½”
3”
2007 Barbecue Grill and Cart Owner’s Manual
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LTR20071038, Rev. B
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Installation / Assembly
Cut-out for refrigerators, cocktail centers
Width Depth Height and access doors
Model Number
BBQ07863P
Description
3 Pull Out Drawer, SS Refr.
25”
22 7/8”
16 ¼”
2 ¾”
32 ¼”
20 ½”
19”
BBQ07857P
Propane Tank Compartment 14 ¾”
BBQ07839P-18
BBQ07839P-30
BBQ07840P-18
BBQ07840P-30
BBQ07909
Single Access Door
16 ½”
28 ¾”
17”
Double Access Door
2 ¾”
19”
18” Door and Drawer Combo
30” Door and Drawer Combo
20 ¼”
20 ¼”
20 ½”
6 ½”
19 ¼”
19 ½”
19 ½”
14 ¾”
28 ¾”
51 ½”
8 ¾”
Complete Utility Storage Kit
Paper Towel Storage
BBQ07910
Cut-out dimensions for the following products are measured to include the
frame.
BBQ07843P
BBQ07847P
BBQ07848P
BBQ07908
Beer Tap Refrigerator
Stainless Refrigertor
21 ¼”
21 ¼”
25 ¼”
15 ¼”
22”
22”
34 ¼”
34 ¼”
34 ¼”
34 ¼
Deluxe Refrigerator, Glass door
22”
Ice Maker
23 ¾”
Page 6
2007 Barbecue Grill and Cart Owner’s Manual
LTR20071038, Rev. B
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Installation / Assembly
Gas Requirements and Connection
IMPORTANT: Cal Flame™ grills are manufactured to operate on either liquid propane (LP) or natural gas
(NG) and cannot be converted. To verify the grill’s operating fuel, check the serial number label in the back of
the chassis as you are looking at the grill from the front. Either LP or NG will be marked on the operating tab,
indicating the proper operating fuel. Attempting to convert Cal Flame™ grills from one fuel to another may
result in serious injury and will void the warranty coverage.
Always check the rating plate to make sure the gas supply you are hooking up to is the gas type the grill is
manufactured for.
If you do not have an updated filler valve on your existing propane tank, you will need to purchase one at your
local hardware store. Without it you will not be able to attach your tank to your Cal Flame™ grill or refill the
tank at your local propane refill station.
4. Apply the leak-testing solution by spraying it
Leak Testing Procedure
on joints of the gas delivery system. Blowing
bubbles in the soap solution indicates that a leak
Perform a leak test at least once a year whether the
is present.
gas supply cylinder has been disconnected or not. In
5. Stop a leak by tightening the loose joint or by
replacing the faulty part with a replacement
part recommended by the manufacturer. Do
not attempt to repair the cylinder valve if it is
damaged. The cylinder must be replaced.
addition, whenever the gas cylinder is connected to
the regulator or whenever any part of the gas system
is disconnected or replaced, perform a leak test.
As a safety precaution, remember to always leak test
your grill outdoors in a well-ventilated area. Never
smoke or permit sources of ignition in the area while
doing a leak test. Do not use a flame, such as a
lighted match to test for leaks. Use a solution of soapy
water.
6. Turn all control knobs back to the full OFF
position.
If you are unable to stop a leak:
1. Turn all control knobs back to the full OFF
position.
1. Prepare a leak testing solution of soapy water by
mixing in a spray bottle one part liquid soap to
one part water.
2. Shut off the gas supply to the grill and release
pressure in the hose and manifold by pushing in
and turning any of the control valves one quarter
turn counter-clockwise.
2. Make sure all the control knobs are in the OFF
position.
3. Turn on the gas.
3. On LP systems, remove the cylinder from the
grill.
a. On natural gas systems, turn the main feed
valve to the grill.
4. Call an authorized gas appliance service
technician or an LP gas dealer.
b. On LP systems, turn the cylinder valve knob
counter clockwise one turn to open.
Do not use the appliance until the leak is corrected.
2007 Barbecue Grill and Cart Owner’s Manual
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Installation / Assembly
LP Gas
Tank Requirements
For plumbed-in LP installation, use a
convertible regulator and set it for LP
gas.
Maximum line pressure for plumbed-
in propane is 14” WC (3.5 kPa).
Minimum line pressure for propane is
11” WC.
The grill unit must be used with the
gas pressure regulator. The regulator
will control and maintain a uniform
gas pressure in the manifold. The burner orifices
have been sized for the gas pressure delivered by the
regulator.
1. One side of the enclosure shall be completely
open.
2. Enclosures that have four sides, complete with a
top and bottom:
WARNING: Attempting to operate the grill unit without
the gas regulator installed could cause an explosion
and possible death.
a. At least two ventilation openings at cylinder
valve level shall be provided in the sidewall,
equally sized, spaced at 180º (3.14 rad), and
unobstructed. Each opening shall have a total
free area of not less than one square inch per
pound (7.1 cm²/kg) of stored fuel capacity, and
not less than a total free area of 10 square
inches (64.5 cm²).
Cylinder Specification
Any LP gas supply cylinder used with this grill must be:
•
Constructed and marked in accordance with the
Specifications for LP-Gas Cylinders of the U.S.
Department of Transportation or the National
Standard of Canada, CAN/CSA-B339, Cylinders,
Spheres and Tubes for Transportation of
b. Ventilation openings shall be provided at floor
level and shall have a total free area of not less
than one square inch per pound (7.1 cm²/kg)
of stored fuel capacity and not less than a
total free area of 10 square inches (64.5cm²).
If ventilation openings at floor level are in a
sidewall, there shall be at least two openings.
The bottom of the openings shall be at floor
level and the upper edge no more than 5
inches (127 mm) above the floor. The openings
shall be equally sized, spaced at 180º (3.14
rad) and unobstructed.
Dangerous Goods; and Commission, as applicable.
•
Approximately 12 inches in diameter and 18 inches
high.
The maximum fuel capacity is 20 lbs. of propane, or 5
gallons. Full cylinder weight should be approximately
38 lbs. (43.7 lbs. nominal water capacity.) Never fill the
cylinder beyond 80% full.
Place the dust cap on the cylinder valve outlet
whenever the cylinder is not in use. Only install the type
of dust cap on the cylinder valve outlet that is provided
with the cylinder valve. Other types of caps or plugs
may result in leakage of propane.
c. Every opening shall have minimum dimensions
so as to permit the entrance of a 1/8 inch (3.2
mm) diameter rod.
Transporting and Storing LP Gas
LP Gas Hook Up
Transport only one cylinder at a time. Ensure the
cylinder is secured in an upright position with the
control valve turned off and the dust cap in place. Store
cylinders outdoors and out of reach of children. Do
not store cylinders in a building, garage, or any other
enclosed area.
An enclosure for an LP gas cylinder shall be vented by
openings at the level of the cylinder valve and at floor
level. The effectiveness of the openings for purposes of
ventilation shall be determined with the LP-gas supply
cylinder in place. This shall be accomplished in one of
the following manners:
Page 8
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LTR20071038, Rev. B
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Installation / Assembly
Natural Gas
Requirements
Always check the rating plate to make sure the gas
supply you are hooking up to is the gas type the grill is
manufactured for.
Your Cal Flame™ grill for use with natural gas comes
equipped with its own regulator that MUST NOT
be removed. If, this regulator needs to be replaced
use only the type specified by Cal Flame™ for this
appliance.
IMPORTANT: Never connect the grill to an unregulated
gas supply.
Connection
The installation of this appliance must conform with
local codes or, in the absence of local codes, to the
national fuel gas code, ANSI Z223.1a-1998. Installation
in Canada must be in accordance with the standard
CAN/CGA-B149.2, Propane Installation Code.
1. Remove the rear panel from the barbecue to gain
access to the regulator and gas connection point.
2. Connect a suitable flex connector to the grill
regulator.
A licensed contractor or local gas company
representative must perform all natural gas
connections.
3. Check the grill controls to ensure all control valves
are in the full OFF position.
4. Turn on the main gas supply and check all
connections for leaks using soapy water as
described in the leak testing procedure section.
Ensure that the service supplying the grill is fitted with a
shut off valve conveniently positioned near the grill and
giving ease of access.
Warning: If you see bubbles in the soapy solution at
any of the connections, turn off the gas supply and
tighten the connection. If tightening the connection
does not seal the leak, it may be necessary to replace
the flex hose.
The grill must be isolated from the gas supply piping
system by closing its individual manual shutoff valve
during any pressure testing of the gas supply piping
system at test pressures equal to or less than 0.5 psi
(3.5 kPa).
The grill and its individual shutoff valve must be
disconnected from the gas supply piping system during
any pressure testing of that system at test pressure in
excess of 0.5 psi (3.5 kPa).
2007 Barbecue Grill and Cart Owner’s Manual
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Installation / Assembly
Installing and Replacing
Infrared Burners
3. Through the access door underneath the grill, find
the round stud and locking pin that locks the burner
you want to replace.
4. Carefully remove the locking pin with your fingers.
1. Disconnect or shut off the liquid propane or natural
gas line connect to the grill. Wait until the burners
cool down.
5. Raise the stud from the locking hole and move
the burner forward carefully to release it from the
ignition and gas supply valve.
2. Open the hood and remove the grate and flame
tamer on top of the burner you want to replace.
6. Take the burner out of the grill and store it in a safe
and dry place.
7. Install the infrared burner. Align the gas inlet on
the burner with the gas supply valve on the grill
and torch tube with ignition. Make sure they align
perfectly. Slide the stud at the other end into the
locking hole.
8. Adjust the infrared burner. Make sure the burner is
aligned and in position.
9. Install the locking pin. Through the access door
underneath the grill, find the stud to lock the burner
in place. Install the locking pin. Make sure the
locking pin is secured correctly.
10. Repeat steps 2 through 9 if you want to replace
other burners.
11. Put back the grate you just removed. (You don’t
need the flame tamer for infrared burners.)
12. Reconnect or turn on the gas line.
If you want to change back to regular burners, just
follow the procedure above in reverse order.
Page 10
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Installation / Assembly
Installing the Transformer
All grills with electrical components such as lights or a convection
fan will require the transformer to be installed and plugged in before
you can use it. This needs to be done before the grill is inserted in
the island or modular cart. When the transformer is attached to the
grill chassis, use care in placing the grill in the island cutout to avoid
hitting the transformer.
1. Remove the transformer and the metal screws from the plastic
bag.
2. Place the grill on a sturdy surface and tilt it back to show the
underside of the grill.
3. Using the metal screws, attach the transformer to
the left side of the grill near the internal electrical
connection. Attach the metal plate to the outside
surface of the grill as shown in the figure below.
4. When you have firmly tightened the screws and
nuts, connect the plug from the transformer to the
grill. Screw on the stainless steel retainer.
2007 Barbecue Grill and Cart Owner’s Manual
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Installation / Assembly
Installing Grills in Modular Carts Installing Grills in Barbecue
Islands
You will need a second person to help you to
avoid damaging the grill, the transformer, or your
barbecue island
You will need a second person to help you to
avoid damaging the grill, the transformer, or your
Keep fingers away from where the grill will be
supported on the cart. Your fingers could become
trapped and serious injury could occur
barbecue island
Before installing a grill or side burner in any island or
cut out, make sure that the opening is not bigger than
the outside frame of the grill unit. The grill should
rest on the lip of the frame. For drop-in accessories,
adequate cross ventilation must be designed into
enclosure to ensure the drop-in grill or side burner does
not become overheated.
1. Slowly lower grill unit onto the cart, making sure
that screws line up with slots on top of the cart.
Ensure that no electrical cords or gas lines become
trapped between any part of the cart and any part
of the grill.
2. The grill should sit flat on the cart all the way
around. Gently realign cart sides to allow them to
sit under outside lip of grill.
Pay careful attention to the location of gas lines. Gas
lines should be routed away from sources of heat and
should make as few bends as possible.
3. Check that all burner control knobs are in the OFF
position.
Check to see if gas line connections will be accessible
when grill is installed.
4. Attach the gas connector to the LP tank.
•
If gas line connections are not easily accessible
when the grill is installed, support the grill above
counter level and attach the gas lines to the grill.
When the gas connections are made, slide the grill
into the cut out.
When handling the LP gas line and connectors, do not
allow them to come in contact with any metal surfaces
of the cart or cabinet. Do not drop LP connectors.
•
If gas line connections are accessible when the grill
is installed, slide the grill into the cut out and then
attach the gas lines.
Be very careful not to kink gas lines when lowering the
grill or side burner into the cut out.
Keep your fingers away from where the grill will be
supported on counter. Your fingers could become
trapped and serious injury could occur.
Check to make sure the grill is level and is supported
around the entire outside edge. If the grill is not level
or is unstable, use non-combustible shims under the
outside lip to stabilize it.
Perform the leak test procedure as described earlier in
this manual.
Page 12
2007 Barbecue Grill and Cart Owner’s Manual
LTR20071038, Rev. B
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Installation / Assembly
Installing Barbecue Cart End
Shelves
6. Slides the shelf into the brackets from bottom.
1. Prepare the installation of handle: 2 hex screws, 2
washers
7. Make sure to slide into the brackets on both side
evenly.
2. Use finger to thread the hex screws and washers
into the threads on both ends of the handle.
8. Slide the shelf fully onto the mounting brackets.
3. Use ratchet to tighten the hex screws on both ends.
The handle has been installed onto the shelf.
9. Lift and rotate the shelf so it slide back into the
brackets.
4. Take the three screws off on both sides of the cart
to install the mounting bracket.
10. Keep the shelf in the normal open position.
11. Prepare to install stop brackets under the mounting
brackets on both sides.
5. Install the mounting brackets on both sides. Make
sure the mounting brackets are in the correct
orientation. Two mounting brackets have been
installed onto the cart.
12. Remove one screw and loose the other screw so
the stop bracket can be placed as shown. Tighten
both screw to hold the stop bracket.
Installing the Rotisserie
Remove the metal cap protecting the outlet that
provides power for the rotis motor. Plug in the
motor cord and screw on the retainer nut to keep
the plug in place.
Attach the two brackets to the sides of the grill, one on each
side, using two screws as shown below.
Slide the rotis motor on one of the brackets as shown below.
The rotis motor will work on either side of the grill.
2007 Barbecue Grill and Cart Owner’s Manual
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Installation / Assembly
3. Connect the flexible hose (male end) to the pipe
Installing Side Burners
tee.
1. Assemble a 3/8” pipe nipple to the 3/8” pipe tee
using Teflon tape or pipe sealant. Use only sealant
that is approved for use on LP gas.
4. Install and secure the side burner into the island by
simply setting it in place.
5. Connect the female end of the flexible hose to the
2. Install the pipe tee assembly to the grill intake pipe.
Tighten assembly and align the branch opening of
the tee with the hole of the cabinet.
side burner intake pipe.
6. Connect gas supply to the grill.
7. Check for gas leaks using soap water solution.
Open barbecue door. Install hose with regulator on propane
tank. Then connect other end to "T" adapter. Make sure to
use gas rated tape seal when installing adapter to insure
proper seal.
Items Included with Barbecue
A
1) "T" adapter (3/8")
2) 2 each Hose 3/8" Fittings
3) Regulatorw/ Hose
C
B
Grill
"T" Adapter (3/8" Threaded)
To grill, located
To side burner, located
underneath behind burner.
underneath and
behind grill
From Side Burner
To Propane Tank
From Grill
A
Then take other end of "T" adapter with hose attached
B
3/8" Fittings
and connect to end of male located underneath and at
the back of the grill. (Use gas rated tape seal on all
connections).
Connect the last open line to the side burner
(Use gas rated tape seal on all connections)
C
NOTE: You will need to use a gas rated
sealer on gas connectors that are not flared.
GAS LINE
Page 14
2007 Barbecue Grill and Cart Owner’s Manual
LTR20071038, Rev. B
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Operating Your Barbecue
Operating Your Barbecue
Read all instructions before you operate your grill
We recommend you wash your entire grill with soap
and water prior to lighting it for the first time. Oils are
used during the manufacturing process and some
residual oil may still be on the stainless steel parts
of your grill. Washing will reduce the possibility of
discoloration. We also recommend you keep your grill
covered when not in use. This will minimize the amount
of dust and dirt that accumulates on your grill and
extend the life of your grill.
•
Do not heat sealed containers such as cans or
jars on grills or side burners. Explosion may result
resulting in injury or death. Any sealed container,
such as a pressure cooker, must have a properly
operating pressure relieve valve to minimize
explosion hazard.
•
•
Never put combustible material such as paper,
cloth, or flammable liquids on your grill at any time.
Do not use grill, side shelves, cabinets, or any area
around grill to store flammable materials.
Remember to use your Cal Flame grill safely by
following these reminders:
Never operate main burners and rear infrared
convection burners at the same time. Excessive
grill temperatures will result. Never allow your grill
temperatures to exceed 500° F.
•
It is dangerous to use barbecue grills and side
burners in any manner other than for what it is
designed for.
•
Do not use charcoal in a gas grill or side burner or
electric grill.
Infrared Burner
Light Switch
Infrared Burner
Grill Controls
Light Switch
The controls shown at right are for
the Cal Flame™ drop-in grills and
stainless steel carts. Familiarize
yourself with these controls before
using your Cal Flame™ barbecue.
Grill
Grill
Right Side Burner
Left Side Burner
Grill
Grill
Grill
Grill
BBQ07873 - 3 Burner Grill
CR3000 - 3 Burner Cart
CR3000S - 3 Burner Cart with Sideburner
Infrared Burner
Infrared Burner
Off
Light Switch
Light Switch
High
Grill
Grill
Grill
Grill
Grill
Grill
Grill
Grill
Low
BBQ07874 - 4 Burner Grill
CR4000 - 4 Burner Cart
Grill Knob Operation
BBQ07874F - 4 Burner Flat Drop-in Grill
CR4000C - 4 Burner Cart with Convection
Infrared Burner
Infrared Burner
Infrared Burner
Infrared Burner
Light Switch
Light Switch
Grill
Right Side Burner
Left Side Burner
Grill
Grill
Grill
Grill
Grill
Grill
Grill
Grill
Grill
BBQ07875 - 5 Burner Grill
CR5000DS - 5 Burner Cart with Double Side Burners
Warning
NEVER cover the entire cooking or grill surface with griddles or pans. Overheating will occur and burners will
not perform properly when combustion heat is trapped below the cooking surface.
CAUTION: NEVER spray water on a hot gas unit. This may damage porcelain or cast iron components.
2007 Barbecue Grill and Cart Owner’s Manual
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Operating Your Barbecue
Lighting the Grill
Each time you light the grill, check the following:
•
•
If connected to a propane cylinder,
carefully inspect the rubber hose attached
to the regulator before each use
•
Inspect the hose before using the grill. If there is
excessive abrasion or wear, or if the hose is cut,
it must be replaced prior to using the grill. If you
need a replacement hose, contact your Cal Flame
dealer.
Ensure the propane cylinder, regulator,
and rubber hose are installed in a location
not subject to heating above 125º F (51º
C)
•
Ensure the area around the barbecue is clear of
flammable substances such as gasoline, yard
debris, wood, etc.
•
Ensure the burner flames burn evenly along both
sides of each burner with a steady flame (mostly
blue with yellow tipping). If burner flames are not
normal, check the orifice and burner for insects or
insect nests.
•
•
Ensure there is no blockage of the airflow through
the vent space located below the face of the unit.
When using propane gas:
•
•
Ensure the in-line gas valve or gas cylinder valve
is always shut OFF when the barbecue is not in
use.
•
Keep the special ventilation openings in
the enclosure free and clear of debris
Do not operate the side burner with its cover
closed or the back burner with its cover installed.
5. If the burner does not light after three attempts,
turn the control knobs to the OFF position. Wait five
minutes until the gas clears before attempting to
light it again.
Electronically Lighting the Grill and
Infrared Burners
1. Open the hood.
2. Keep your face as far away from the burners as
possible.
6. Repeat the procedure or try the manual lighting
procedure below.
3. Rapidly rotate the burner knob counter clockwise
past the light position to HIGH. You will hear a loud
click as the electronic lighter produces a spark.
7. Upon successful lighting, repeat the process on the
other burners you wish to light.
8. To shut off the burners, rotate the knob and turn to
OFF. It is normal to hear a popping sound when the
burners are turned off.
4. Listen for the sound of the gas igniting. If the burner
does not light on the first try, repeat immediately.
5. Light and insert a long stem match, holding it near
the burner ports.
Manually Lighting the Grill and Infrared
Burners
6. Push in and turn the control knob just past the
WARNING: Do not use standard matches or cigarette
lighters to perform match lighting procedures. Serious
burns can occur and lighters can explode.
LIGHT position to HIGH.
7. Listen for the sound of the gas igniting. If the
burner does not light after five seconds, turn
the control knobs to the OFF position. Wait five
minutes until the gas clears before attempting to
light it again.
1. Open the hood.
2. If you have just attempted to light the burner, allow
five minutes for any accumulated gas to dissipate.
3. Slide out the drip tray from the grill.
8. If the burner does not light after several attempts
see Troubleshooting Guide in the back of this
manual.
4. Keep your face as far away from the burners as
possible.
Page 16
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LTR20071038, Rev. B
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Operating Your Barbecue
Basic Grill Operation
3. Turn the control knob to HIGH and preheat the
grill for 15 minutes. Close the top cover during the
appliance preheat period.
Before lighting, make sure all burner controls are off.
Do not attempt to light the burners if the smell of gas is
present. Check the connection with a soap and water
solution after attaching the hose. For LP units, make
sure there is gas in the tank and it is sitting upright. For
natural gas units, make sure the shut off valve is on.
4. Place the food on the grill and cook to desired
completion. Adjust heat setting if necessary. You
may set the control knob to any position between
HIGH and LOW.
1. Make sure the drip tray is in place.
5. Allow the grill to cool and clean the drip tray after
each use.
2. Light the grill burners using the instructions on the
previous page.
Do not leave the grill unattended while cooking.
Cooking with the Rotisserie
The rotisserie burner is an infrared type, which provides
intense searing radiant heat. It is designed to cook
items from the back using infrared heat. The location
of the burner allows the placement of a rotisserie-
basting pan (NOT included) beneath the food to collect
juices and drippings for basting and gravy.
2. To use the rotisserie, first mount the motor on the
left side of the grill. Place securely onto support
bracket.
3. The rod of the rotisserie system is assembled into
the motor by placing the pointed end into the motor
and resting the threaded end on the support at the
side of the grill. Once the rod is pushed as far as
possible into the motor, the grooved end of the rod
should rest on the right side bracket.
The rotisserie does not require and additional outlet
as it is powered by a 12-volt input located on the side
of the grill connected with a sainless steel sheathed
power cable.
4. If necessary, to offset unbalanced loads, slide the
counter weight on to the rod. With the counter
weight loose, allow the loaded rod to rotate and
come to a stop. Now rotate the counter weight
above the rod in a vertical position and tighten
the thumbscrew. You can slide the counter weight
away from or closer to the rotisserie rod as needed
for balanced operation. Once lit, the rotisserie
burner will reach cooking temperature in about one
minute. The orange/red glow will even out in about
five minutes.
1. To load the rotisserie rod, hold the handle firmly
while sliding one of the fork assemblies (prongs
facing away from the handle) onto the rod. Push
the rod through the center of the food, then slide
the other holder (prongs toward the food) onto
the rod. Center the meat on the rod and push
the fork assemblies firmly together. Tighten the
thumbscrews. To secure any loose portions of
your meat, use butcher string (never use nylon or
plastic string). Place a basting pan under the food
to collect the drippings.
2007 Barbecue Grill and Cart Owner’s Manual
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Operating Your Barbecue
Cooking with a Convection Grill
A convection grill has an internal fan that circulates heated air evenly throughout the grilling area when the hood
is closed. Cooking in this way distributes heat more efficiently so you no longer have to be concerned with “hot
spots” on the grill where food tends to burn. The fan switch is located at the far left of the front panel of the grill.
INTAKE VENTS
INTAKE VENTS
EXHAUST VENTS HEAT
THAT IS DRAWN IN
FROM THE BAC K. IT
IS THEN REDISTRIBUTED
INTAKE FAN MOUNTED ON INSIDE
OF G RILL AREA TO PULL HEAT INWARD
A
FRONT VIEW OF GRILL
Inta ke/Rec irc ula tion Fa n
Hea t C ha mber
Motor mounted on ba c k of grill
Inta ke/Rec irc ula tion Fa n
TOP VIEW OF GRILL
Exha ust Vents- Hea t tha t is dra wn in
from Inta ke opening is then redistributed
out these vents
FRONT VIEW OF GRILL
(RECIRCULATION SHOWN)
Hot Air Fa n Inta ke Rec irc ula tion
SIDE VIEW OF GRILL
(EXHAUST/INTAKE SHOWN)
Hot Air
Hot Air
Hot Air
REAR VIEW OF GRILL
(INTAKE DESIGN SHOW)
REAR VIEW OF GRILL
(EXHAUST DESIGN SHOW)
Page 18
2007 Barbecue Grill and Cart Owner’s Manual
LTR20071038, Rev. B
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Operating Your Barbecue
Charcoal Grill
Leave about a one-half inch space between each piece
of charcoal. This helps to avoid flare-ups from the
meat juices and provides the even heat best suited for
grilling.
Lighting Instructions
NEVER use flammable materials and fluids such as
gasoline, kerosene, butane or propane, diesel fuel, or
alcohol to light or re-light fires. Keep the grill away from
such substances when lit.
Grilling
NEVER allow children or pets unattended in an area
where a grill is being used. Never allow children to sit,
stand or play on or around the grill at any time. When in
use, certain areas of the grill get hot enough to cause
severe burns.
Use high quality hardwood charcoal to ensure a good
flame. Charcoal briquettes made from maple, oak,
birch, or elm woods will burn cleanly, minimizing smoke
and unpleasant odors.
Leave the hood open for “Texas Style” open air grilling.
Close the hood for “Smoker” cooking.
1. Open the hood and remove cooking grates.
2. Place charcoal on the ashtray at the bottom of grill
and arrange charcoal in a pyramid shaped stack.
For the greatest concentration of heat, leave the hood
open. Adjust the crank handle to lift the charcoal tray
up so the burning charcoal will be close to the grilling
meat. Lower the charcoal tray to slow the grilling
temperature.
3. Add charcoal lighting fluid according to
manufacturer’s instructions. Let it stand for about a
minute to let fluid penetrate charcoal.
4. Carefully light charcoal, allowing it to burn
approximately 15 to 20 minutes or until a light gray
ash develops.
Storage
Never store the grill with ashes or combustible
materials inside. Do not store the grill until the fire is
completely extinguished and the grill body has cooled.
Turning on and off the Lights
and Fan
The ON / OFF switch controlling your halogen light is
located at the control panel on the front lower left side.
Certain models of the Cal Flame grill are equipped with
either one or two halogen light.
Your grill is equipped with a grounded (3 prong) 120
VAC plug located in the lower left rear corner of your
cart and must be plugged into a permanent grounded
120 VAC outlet with a dedicated 15amp GFI breaker.
DO NOT cut or remove the ground prong as this may
result in fire, electrical shock or other personal injury.
This electrical source provides power to the lights.
2007 Barbecue Grill and Cart Owner’s Manual
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LTR20071038, Rev. B
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Operating Your Barbecue
Griddle
30” Warming Drawer
When sliding the griddle out of the enclosure, always
do it slowly as the heavy weight may cause you to
suddenly drop the griddle. Lift the griddle out of the
enclosure instead of sliding it all the way out.
Preheating Instructions
The warming drawer is designed to keep foods at a
safe temperature (above 140ºF) when used according
to the operating instructions. The drawer must be
pre-heated for at least 1 hour on the highest setting.
If the warming drawer isn’t pre-heated, the internal
temperature of the food being warmed could fall below
the minimum safe level and bacteria could develop.
Always pre-heat the drawer according to instructions
described in this manual.
Remove two cooking grates for the griddle space.
Leave grease in the front drain when cooking. Wait
until the griddle cools down when done cooking. Use
both hands when removing the griddle and draining the
grease.
Before storing the griddle, make sure it is clean and
dry. Slide the griddle into the enclosure for safe and
easy storage.
Be certain to use only dry potholders. Moist or damp
potholders on a hot surface may cause burns from
steam. Do not use a towel or other bulky cloth in place
of potholders.
Drop-In Food Warmer
1. Never store anything in the warming drawer.
Flammable materials can catch fire, plastic items
may melt or ignite and other types of items could
be ruined.
Attach this three-pan food warmer to your favorite
bartending center or grill and serve a variety of hot,
fresh hors d’ oeuvres and side dishes. The food warmer
has three steamer pans and a built-in fuel drawer.
2. Do not hang articles from any part of the appliance
or place anything against the drawer. Some fabrics
are quite flammable and could catch on fire.
1. Remove one steamer pan and fill the container pan
with approximately 2”-3” warm water. Gently place
the steamer pan back on to the container pan.
3. For safety reasons and to avoid damage to the
appliance, never sit, stand, or lean on the warming
drawer door.
2. Open the sterno fuel drawer. Remove the sterno
fuel can holder covers. Place two sterno fuel cans
into the can holder.
4. For personal safety reasons, wear proper apparel.
Loose fitting garments or hanging sleeves should
never be worn while using this appliance. Some
synthetic fabrics are highly flammable and should
not be worn while using this appliance.
3. Using a butane lighter or long stem match, light the
sterno fuel. For safety, the rear one first.
4. Close the drawer.
5. Place food to be warmed into the steamer pans
and cover with pan lids.
5. Do not use aluminum foil to line any part of the
warming drawer. Using a foil liner can be a fire
hazard and can obstruct of the flow of heat and
ventilation air. Foil is an excellent heat insulator
and heat will be trapped underneath it. This trapped
heat can upset the performance of the warming
drawer parts.
6. To extinguish the sterno fuel flame, open the
drawer and carefully replace the fuel holder covers.
Flames will go out.
IMPORTANT
•
The water in the container pan is a scald and burn
hazard as it gets hot. Do not attempt to empty it
until it is cooled.
Temperature Settings
The dial on the right of the unit is the on/off and
temperature control adjustment. When the dial is turned
clockwise from the off position to the low position, the
unit will maintain a temperature approximately 175ºF.
By rotating the dial clockwise to the high position,
the drawer will reach a temperature of approximately
230ºF.
•
•
Do not burn sterno fuel with the drawer open.
Do not leave sterno fuel burning unattended. Do
not leave children unattended around food warmer
during and immediately after use.
To use, turn the thermostat dial to a temperature
setting:
Page 20
2007 Barbecue Grill and Cart Owner’s Manual
LTR20071038, Rev. B
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Operating Your Barbecue
High
210ºF – 230ºF
190ºF – 210ºF
175ºF – 190ºF
•
•
Use care when opening a hot warming drawer.
To avoid severe burns, open slowly, allowing the
hot air or steam to escape before reaching in to
remove or replace any foods.
Medium
Low
•
•
•
•
If you use the tray, preheat it while preheating the
warming drawer.
Do not repair or replace any part of this appliance
unless it is specifically recommended in this
manual. All other servicing should be referred to
a qualified service technician. Service technicians
must disconnect the power supply before servicing
this appliance.
Preheat any empty serving dishes to be used while
preheating the drawer.
Add cooked, hot food in its cooking container or
heat a safe container.
•
•
When using the warming drawer: DO NOT TOUCH
THE INTERIOR SURFACES or the exterior area
immediately surrounding the door until it has had
sufficient time to cool to avoid burn injuries.
You may use aluminum foil to cover food
containers.
Safety Practice & Precautions
Clean the warming drawer with caution. Avoid
steam burns. Do not use a wet sponge or cloth
to clean the appliance while it is hot. Some
cleaners produce noxious fumes if applied to a hot
surface. Follow directions provided by the cleaner
manufacturer.
•
•
•
As with any cooking or heating appliance, never
leave the warming drawer unattended when
warming food.
Only certain types of glass, heat proof glass-
ceramic, ceramic, earthenware or glazes are
suitable for temperature changes.
•
Be sure all the controls are turned off and the
appliance is cool before using any type of aerosol
cleaner on or around the appliance. The chemical
that produces the spraying action could, in the
presence of heat, ignite or cause metal parts to
corrode.
Never heat unopened containers, as a build up of
pressure may cause the container to burst.
•
•
120V 5 amp minimum circuit required.
Grease is flammable. Avoid letting grease deposits
collect in the warming drawer. Clean up any
spillage.
•
•
Do not touch the heating element or interior
surfaces of the warming drawer. Even if they
appear dark in color. They may still be hot enough
to cause burn injury. Allow sufficient time to cool.
•
•
DO NOT use water on grease fires. Turn OFF
the warming drawer, then smother the fire with
baking soda or use a dry chemical or foam-type fire
extinguisher.
Do not allow flammable materials which may ignite
to come in contact with the hot heating element or
the interior surface of the warming drawer until the
unit has a sufficient time to cool.
When opening a drawer while warming liquids, the
drawer must be opened slowly to avoid spillage.
2007 Barbecue Grill and Cart Owner’s Manual
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Cleaning and Maintenance
Cleaning and Maintenance
and other flammable vapors and liquids. Do not
obstruct the flow of combustion and ventilation air.
To ensure safe and proper maintenance, we
recommend you follow these directions carefully.
If your LP-gas grill is placed in a stationary barbecue
island, keep the access door for the propane cylinder
clear of any obstruction. Ensure the ventilation
opening for cylinder enclosure is kept clear.
Clean internal parts of the grill regularly as determined
by the amount of use and foods cooked. The entire
grill should be cleaned at least once a year.
In addition, keep the area around your grill or cart
clear and free from combustible materials, gasoline,
DISCONNECT ELECTRICAL SUPPLY BEFORE
CLEANING ANY PART OF THE GRILL.
Burners
Care of Stainless Steel
Spiders and small insects occasionally inhabit or make
nests in the burner tubes, obstructing the gas flow.
Sometimes this results in a type of fire in and around
the gas tubes called “flashback”. To reduce the risk of
flashback, this procedure should be followed at least
once a month or when your grill has not been used for
an extended period of time.
Do NOT use wire wool pads, scrappers, harsh
abrasive, scoring materials, bleaches, or harsh
cleaners on your cart or grill, or allow salt and vinegar
mixtures to remain in contact for a long period of time.
This will cause scratching, scoring, rusting and pitting.
We recommend that you clean stainless steel
components with a cleaner that is approved for
stainless steel and only clean when the grill is cool and
in indirect light. Never use steel wool.
IMPORTANT: Prior to starting this procedure, turn OFF
all of the gas control knobs, shut off the fuel supply, and
disconnect the fuel line.
1. Remove burners from the grill by carefully lifting
each burner up and away from the gas valve
orifice.
Covering Your Cart or Grill
When not in use and after cooling, cover your cart or
grill with our full length, zippered side canvas cover.
(See your local Cal Flame dealer for details.) The
cover will help protect your cart or grill from detrimental
effects of weather and environmental pollutants. Never
put a cover on a hot grill. Allow the grill to cool before
covering.
2. Use a wire brush to clean the outer surface of each
burner to remove food residue and dirt. Clean any
clogged ports with a stiff wire such as an opened
paper clip.
3. Inspect each burner for damage (cracks and
holes). If any damage is found, replace the burner
and discontinue grill usage.
After Use Care
4. Upon reinstallation, inspect the gas valve orifices
for cleanliness and condition and the location of the
igniters.
The easiest way to clean the grill is immediately after
cooking is completed and after turning off the flame.
•
Scrub the grill rack with a brass bristle barbecue
brush and hot soapy water.
Drip Pan
•
Wipe the grill with a damp soapy cloth and rinse
with warm/hot, clean water. For more tenacious
deposits, including oil, grease and water-borne
deposits, use a multipurpose cream cleanser and
apply with a soft, damp cloth.
The full width drip pan will collect grease from the main
grill area. The pan should be cleaned after every use
to avoid the possibility of a grease fire. Be sure to allow
the drip pan to cool prior to cleaning. You may clean
the drip pan with a solution of warm soapy water. Make
sure to rinse thoroughly to avoid staining.
•
Dry with a soft, dry, clean towel if preferred.
Page 22
2007 Barbecue Grill and Cart Owner’s Manual
LTR20071038, Rev. B
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Cleaning and Maintenance
Hood and Body
Island Cabinets
Wipe the inside hood and body with detergent and hot
water. The external surfaces may be cleaned in the
same fashion. Wipe all area dry before storing.
Be sure to unplug the electrical supply before cleaning
any part of your Cal Flame barbecue. Spray cabinet
area with a soap and water solution. Rinse with a
gentle stream of fresh water.
Storage
For your safety, make sure unit is cool and wood and
charcoal embers completely extinguished before
storing.
Griddle
To prevent burns or injury, make sure the griddle is
completely cool before cleaning.
Drop-in Food Warmer
The griddle is made from non-magnetic, 304 grade
stainless steel. There are various stainless steel
cleaners available. Always use the mildest cleaning
procedure first, and always scrub in the direction of
the grain. Soapy water should be sufficient for most
cleaning. A sniff brush may also be helpful in removing
grime and food deposits. Wipe all area dry before
storing.
To prevent burns or injury, make sure the food warmer
is completely cool before cleaning. The drop in food
warmer is made from non-magnetic, 304 grade
stainless steel. There are various stainless steel
cleaners available. Always use the mildest cleaning
procedure first, and always scrub in the direction of
the grain. Soapy water should be sufficient for most
cleaning. All parts of the food warmer can be cleaned
with hot soapy water, rinsed, dried and buffed with a
heavy pile cloth.. Be sure to rinse thoroughly and to
wipe dry to avoid watermarks.
Charcoal Grill
To prevent burns or injury, make sure the grill is
completely cool before cleaning. After initial usage,
areas of the grill may discolor from the grill’s heat.
Note: DO NOT use oven cleaners or abrasive cleaners
on enameled surfaces. They may damage the finish,
causing accelerated wear.
There are various stainless steel cleaners available.
Always use the mildest cleaning procedure first, and
always scrub in the direction of the grain. Soapy water
should be sufficient for most cleaning.
30” Food Warmer
•
Be careful cleaning any part of this appliance,
particularly the drawer box and back of the drawer
face. All parts of the drawer can be cleaned with
hot soapy water, rinsed, dried and buffed with a
heavy pile cloth. Always try this first, as it is the
mildest cleaning procedure.
DO NOT use oven cleaners or abrasive cleaners on
enameled surfaces. They may damage the finish,
causing accelerated wear.
Ash Removal
Remove the ashes as soon as possible after each use.
Wait until the charcoal has cooled, slide out the drip
pan and pour out the ashes. You can save the larger
pieces of charcoal for the next time you cook. Use a
garden hose to wash out accumulated grease and
ashes. Allow the drip pan to dry before reinserting into
the grill.
•
Be sure the warming drawer is turned off and
the appliance is cooled before using any type of
aerosol cleaner on or around the appliance. The
chemical that produces the spraying action could,
in the presence of heat, ignite or cause metal parts
to corrode.
•
•
Use the mildest cleaning procedure first. Some
brands of cleaners are harsher than others, read
their directions. Try in a small area first.
Cooking Grates
Use a solution equal parts detergent and hot water
just as you would for any cooking equipment. A stiff
brush may also be helpful in removing grime and food
deposits.
To avoid marring the surface always rub the metal
finishes in the direction of the polish grain lines.
The cleaner will be more effective when used in the
direction of the polished lines.
2007 Barbecue Grill and Cart Owner’s Manual
Page 23
LTR20071038, Rev. B
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Cleaning and Maintenance
•
Use only clean sponges, soft cloths, paper towels,
plastic or non-metal soap pads for cleaning or
scouring, as recommended in this section.
•
Be sure to rinse thoroughly and to wipe dry to avoid
watermarks.
Drawer
Clean the drawer with warm soapy water.
Clean same as drawer.
Drawer Front
Gasket
Clean with warm soapy water.
Knobs
The ON/OFF temperature knob may be removed for cleaning.
Same as drawer above.
Drawer Cavity
Heating Element Care should be taken when cleaning the heating element. Only clean the element when the
unit is cool. Use warm soapy water on damp cloth.
Light Bulb Replacement
WARNING: Never attempt to replace a light bulb when
the grill is in use. Serious burns will result.
WARNING: Never touch halogen bulbs with your
bare fingers. Use a tissue or a small piece of paper
to handle bulbs. Oils from your hands will damage
halogen bulbs.
Light Removal
1. Open the grill hood and locate the glass light
covers at the back of the grill.
2. Using a small screwdriver, gently pry the light cover
away from the housing. Be extremely careful prying
off the light cover. You may damage the light cover
as a result.
3. Unscrew the two screws located at the side of the
white ceramic light fixture.
4. Pull the burnt bulb out of the socket.
Light Replacement
1. Using a tissue or small piece of paper, carefully
push a new bulb into the socket, making sure both
wires on the bulb go into the light socket evenly.
2. Tighten the two screws on the side white ceramic
light fixture.
3. Carefully replace the light cover by snapping it in
place.
Page 24
2007 Barbecue Grill and Cart Owner’s Manual
LTR20071038, Rev. B
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Appendix
Troubleshooting
Appendix
Problem: Smell of gas is present
Solution: Check for loose connections in the gas line. Perform a leak test following the procedure described in
this manual.
Problem Burner does not ignite
Solution Use the following procedure with the figure below.
Check the position of the sparker tip. It should be pointing forward towards the front of the burner.
•
•
•
•
•
Make sure there is a blue spark at the electrode tip to the burner.
Make sure the igniter wire is connected firmly to the valve ignition device and the electrode.
Make sure the valve orifice is free of any debris, dust or grease.
Make sure the valve orifice is aligned inside the front hole of the burner.
If there is no spark at all, replace the electrode or igniter wire.
Note: Turn off the gas at the source while troubleshooting.
Problem: Burner tube is misaligned over the orifice
Solution: Reposition the burner tube so that it is properly seated over the orifice.
Problem: Obstruction in the gas line
Solution: Remove the fuel line from grill. (Do not smoke or perform any maintenance in the vicinity of an
open flame.) Open the gas valve for one second to blow out any debris. Close off the gas valve and
reconnect the fuel line securely.
Problem: Yellow Flame
Solution: Once the entire burner is operating, check the flame color to be sure that it is mostly blue. Some
yellow at the tips may be present due to impurities in the fuel. If the flame is golden or yellow in
color, the reason could be seasoning salts, oil film, or other foreign matter on the burner.
2007 Barbecue Grill and Cart Owner’s Manual
Page 25
LTR20071038, Rev. B
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Appendix
Problem: Plugged orifice
Solution: Unplug the orifice as follows:
•
•
Remove cooking grills, flame tamer and grease tray.
Remove burners from the bottom of the firebox by pulling the cotter pin from beneath the burner
peg using a standard screwdriver or needle nose pliers.
•
•
•
•
Carefully lift each burner up and away from the gas orifice.
Remove the orifice from the control valve.
Gently clear any obstruction with a fine wire.
Reinstall the orifice, reinstall the burners over the orifices, and seat each burner peg into
position hole at the bottom ledge of the firebox.
•
•
Replace all cotter pins.
Replace cooking components and grease collectors.
If an obstruction is suspected in the control valve, contact your local Cal Flame dealer for
assistance.
Problem: Misalignment of Igniter on Burner
Solution: • Check for proper position of the electrode tip, which should be pointing forward towards the front
of the burner and free of grease to allow proper sparking.
•
•
The ignition wire should be connected firmly to the valve ignition device and electrode. Replace
the ignition wire if it is frayed or cracked.
With the gas supply closed and all control knobs set to the off position, check each position
igniter individually for the presence of a spark at the electrode. Push each knob in fully and
rotate it about 1/4 turn to the left (counter-clockwise) until you hear a loud click. The trigger
hitting the strike block should produce a blue spark at the electrode tip. Return control knob to
the off position before checking the next igniter.
•
While the grill is still hot, wait for a minimum of five minutes before commencing re-ignition. (This
allows accumulated gas fumes to clear.) If all checks / corrections have been made and the gas
grill still fails to operate properly, contact your local Cal Flame dealer.
Problem: Flashback
Solution: When fire occurs in and around the burner tubes, immediately turn off gas at its source and turn the
control knob(s) clockwise to the ‘OFF’ position. Wait until the grill has cooled off and then clean the
burner tubes and burners as described on page of this manual.
Page 26
2007 Barbecue Grill and Cart Owner’s Manual
LTR20071038, Rev. B
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Appendix
Replacement Covers
Cal Flame Drop-Ins
BBQ010
BBQ011
BBQ012
BBQ013
COVER, GRILL, SMALL, 3 BURNER
COVER, GRILL, MEDIUM, 4 BURNER
COVER, GRILL, LARGE, 5 BURNER
COVER, SIDE BURNER, SINGLE & DOUBLE
Cal Flame Carts
BBQ835CR4 BARBECUE CART COVER, 4 BURNER, BLACK
BBQ835CR5 BARBECUE CART COVER, 3 & 5 BURNER, BLACK
Location of Serial Number Plate
The serial number of your Cal Flame grill is located
on the back and is visible when the hood is down as
shown below.
2007 Barbecue Grill and Cart Owner’s Manual
Page 27
LTR20071038, Rev. B
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Page 28
2007 Barbecue Grill and Cart Owner’s Manual
LTR20071038, Rev. B
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Warranty Information
•
Damage caused by continued operation of the
barbecue with either known or unknown problems.
See your Cal Flame barbecue dealer for a copy of the
applicable warranty, details and any questions you
may have regarding the warranty coverage on your
barbecue.
•
•
Damage caused by direct sunlight.
Damage caused as a result of failure to follow the
operating instructions as defined in this Owner’s
Manual.
Warranty Limitations
This Limited Warranty applies only to barbecues
normally used for personal, family, or household
purposes.
The Limited Warranty is void if the barbecue has
been subject to negligence, alteration, misuse, abuse,
repairs by non- C.A.I. authorized representatives,
incorrect electrical installation, acts of God and any
other cases beyond the control of C.A.I. Examples of
common acts invalidating this warranty include but are
not limited to:
This Limited Warranty specifically excludes commercial
barbecues.
Warranty Exclusions
•
•
Scratches caused by normal use.
C.A.I. warranties the barbecues from defects in
material and workmanship for a period of one year from
the original date of purchase.
Damage caused by extreme weather conditions
(hot, cold, etc.)
•
Damage caused by dirt, sand, and/or water
damage.
Barbecue stereo systems are delivered with their own manufacturer’s warranty. For more information, see their
warranties in the owner’s information package that was delivered with your barbecue.
Don’t forget to register your new product at www calspas com
Locating the product serial number
The serial number of your Cal Flame grill is located on the back and is visible when the hood is down (see
page 24). You will need this number to properly register your grill or cart and activate coverage. Write this
information in the space provided below.
Grill or cart model: ____________________________________________________________________
Grill or cart serial number: ______________________________________________________________
Type of fuel (circle one):
Liquid propane
Natural gas
Charcoal
Date purchased: ______________________________________________________________________
Date installed: ________________________________________________________________________
Cal Flame dealer’s phone number: _______________________________________________________
Cal Flame dealer’s address: _____________________________________________________________
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