LTR50001038, Rev. C
12/26/11
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1
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.
on the right side of the chassis. There is an area
Placement and Location
on the back cover of this manual where you can
write down this information.
•
Cal Flame™ grills are designed for outdoor
use only
•
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 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 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.
•
•
Your Cal Flame™ grill must be plugged into a
permanent, grounded 110V outlet with a 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.
Maintain sufficient distance as to not overheat any
overhead combustible material such as a patio
cover.
•
•
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 an extension cord to supply power to
your Cal Flame™ grill. 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.
Donotusethegrill,grillcabinet,orareasurrounding
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.
•
•
To prevent fire and smoke damage, remove all
packaging material before operating grill.
Set-Up
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.
•
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
Operation
•
•
Do not use grill for other than intended use.
DANGER
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.
What To Do If You Smell Gas
• Shut off gas to the appliance.
•
•
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.
• Extinguish any open flame.
• Open lid.
• If odor continues, keep away from the
appliance and immediately call your
gas supplier or your fire department.
Keep all electrical supply cords and the rotisserie
motor cord away from the heated areas of the
grill.
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•
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.
•
•
•
•
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.
•
•
•
Never line the grill or side burners with aluminum
foil.
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.
When the unit is not in use, be sure to turn off the
gas at the LP tank.
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.
Do not install or operate your grill unit in such
a manner that the cross ventilation openings are
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 reach over your grill or any other surfaces
when hot or in use.
•
When handling LP gas line and connectors,
do not allow them to come in contact with any
metal surfaces of the cabinet. Do not drop LP
connectors.
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 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.
•
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-LMS approved dealer
technician will void your warranty.
•
•
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.
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 indoors is permissible only if the
supply cylinder is disconnected and removed.
•
•
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.
Precautions Regarding Children
•
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.
Never allow children to sit or stand on any part of
the grill.
•
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.
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3
Built-in Construction
Read these instruction before constructing your grill
enclosure. Failure to follow these instructions may result in
damage, injury, or death.
In this section:
•
•
•
•
•
•
Location of grill enclosure
Construction materials
Built-in dimensions
LMS Inc will not be held responsible for property damage,
injury, or death as a result of locating a grill enclosure in a
non-approved location or using non-approved construction
materials
Enclosure ventilation
Plumbing for side burners
Electrical supply requirements
We strongly recommend that grill owners hire a contractor to construct
the built-in enclosure.
Location of grill enclosure
Cal Flame grills are designed for outdoor use Do not locate your grill enclosure under a sealed
only
overhead structure.
Do not locate your grill enclosure in an enclosed area,
which is any covered area that is walled on two, three,
or four sides. This includes areas or rooms such as a
garage, shed, breezeway, patio, cabana, etc.
The sides, bottom and back of the grill enclosure
should not be any closer than 24” to combustible
construction.
When planning your Cal Flame grill location, access
to gas lines and 110V power supplies should be
considered. If you are using natural gas, the location
with the shortest gas line run is recommended. You
may need a grounded, dedicated, 15A 110V GFCI
power source for use of your appliances (e.g. lights,
rotisserie, refrigerator, receptacles, etc.).
Although some enclosed areas may have windows,
screens, or ventilation systems, they are nevertheless
considered to be hazardous and may cause damage,
injury, or death. Enclosed areas are NOT approved
for a grill enclosure.
Do not locate your grill enclosure in any vehicle,
including recreational vehicles, campers, trucks, or
boats.
When determining a suitable location, consider
factors such as exposure to wind, proximity to traffic
paths, and windows that open into the home.
To reduce the risk of personal injury caused by
reaching over a hot appliance, avoid locating cabinet
storage space directly above the outdoor grill.
Locate the grill enclosure any place where there is
adequate ventilation. The size and configuration of
your house and yard will determine how you should
locate your grill enclosure, but as a general rule,
do not place it under or near windows that can be
opened into your home.
Maintain sufficient distance as to not overheat any
overhead combustible material. We recommend a
minimum distance of six feet, measured from the top
of the grill hood. Check with local inspectors and your
homeowner’s association.
Construction materials
DO NOT use combustible materials for the built-in construction
Acceptable building materials: Brick, cinder block, steel frame, hardiboard, granite, tile, glass
brick, concrete, cement, stucco, stone.
Unacceptable building materials: Wood of any sort, laminate or synthetic materials, plastics,
linoleum, fiberglass.
In addition, we do not recommend using materials that are susceptible to damage or decomposition by
weather, such as dry wall or plaster.
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4
Built-in Dimensions
Plan the installation so that the electrical connection, The design of the outdoor cooking enclosure must
gas shut-off valve, and pressure regulator are allow the LP gas cylinder to be connected and
accessible inside the base enclosure. The gas valve disconnected and the connections inspected and
shall be readily accessible for hand operation. A door tested.
on the enclosure to gain access to the gas valve is
There must be a minimum clearance of 2 inches
acceptable, provided it is non-locking and can be
(51mm) between the floor of the LP-gas cylinder
opened without the use of tools.
enclosure and the ground.
DEPTH
HEIGHT
The dimensions shown below are for Cal Flame appliances only.
Model
Description
Width Depth Height
BBQ08873P
3 Burner Grill
23 3/8” 22¼”
9 ¼”
9 ¼”
9 ¼”
BBQ08874CP 4 Burner Grill
31”
22¼”
22¼”
BBQ08875CP 5 Burner Grill
38 ½”
Model
Description
Width
Depth Height
BBQ08954P
BBQ08899P
Deluxe Side by Side Burner 25 ¼”
Deluxe Double Side Burner 12 ¼”
12 ½” 7 ¼”
22”
7 ¼”
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Built-in Dimensions cont
The dimensions shown below are for Cal Flame appliances only.
Model
Description
Width
24 ¼”
11 ½”
Depth
19 ¾”
17 ¾”
BBQ08953P
BBQ08852P
Side By Side Flat Burner
Single Flat Side Burner
DEPTH
HEIGHT
DEPTH
WIDTH
Top view of enclosure
with back splash
Minimum
Clearance
Thebackedgeofthegrillmustmaintainaminimumclearance
of 8” from non-combustible back splash materials.
Side view of enclosure
with back splash
Top view of enclosure
with back splash
WIDTH
WIDTH
12” Minimum Distance
Between Grill and Side Burner
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6
Enclosure Ventilation
For proper ventilation, the base structure must be constructed using one of two designs:
An enclosure with one side open
1
An enclosure having four sides, a top, and bottom
2
At least two ventilation openings at cylinder valve be at least two openings. The bottom of the openings
level shall be provided in the side wall, equally sized,
spaced at 180 degrees and unobstructed.
shall be at floor level and the upper edge no more
than 5 inches (127mm) above the floor. The openings
shall be equally sized, spaced, and unobstructed.
Each opening shall have a total free area of not less
than 10 square inches (254 square mm).
LP-gas cylinders should be ventilated by openings
at the level of the cylinder valve and the floor level.
The effectiveness of the openings, for purposes of
ventilation, shall be determined with the LP-gas
Ventilation openings shall be provided at floor level
and shall have a total free area of not less than 10
square inches (254 square mm). If the ventilation
openings at floor level are in a side wall, there shall supply cylinder in place.
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7
Plumbing for Side Burners
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.
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.
Items Included with Barbecue
GAS LINE
1) "T" adapter, 3/8"
2) 2 hose fittings, 3/8”
3) Regulator with hose
3. Connect the flexible hose (male end)
to the pipe tee.
"T" adapter, 3/8" Threaded
4. Install the side burner into the island
by simply setting it in place.
To grill, located
underneath and
behind grill
To side burner, located
underneath behind burner.
5. Connect the female end of the flexible
hose to the side burner intake pipe.
6. Connect gas supply to the grill.
7. Check for gas leaks using soap water
solution.
From Side Burner
To Propane Tank
From Grill
3/8" Fittings
Electrical Supply Requirements
Your Cal Flame grill must be plugged into a Do not install a fuse in the neutral or ground circuit.
permanent, grounded 110V outlet with a dedicated A fuse in the neutral or ground circuit may result in
15A GFCI breaker in accordance with local codes or an electrical shock hazard.
the National Electrical Code, ANSI / NFPA 70,
Do not ground this appliance to a gas supply pipe or
or the Canadian Electrical Code, CSA C22.1.
hot water pipe.
It is the owner’s responsibility to ensure that the
Use copper wire only. The use of aluminum wire may
electrical connection to this appliance is properly
result in unsatisfactory connections.
installed. We recommend a contractor or licensed
electrician install a dedicated 110V electrical service Install 120VAC, 15 Amp duplex outlet in an accessible
for your grill.
location under the grill inside the base enclosure.
Do not use an extension cord to supply power to Locate the electrical supply box inside the built-in
your Cal Flame grill. Such use may result in fire, enclosure within reach of the power cord so the
electrical shock or other personal injury.
connection is accessible when the grill is completely
installed in the enclosure.
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Installation
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. 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 4. When you have firmly tightened the screws and
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.
nuts, connect the plug from the transformer to
the grill. Screw on the stainless steel retainer.
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Installing Grills in Barbecue
Islands
Installing the Rotisserie
Attach the two brackets to the sides of the grill, one
on each side, using two screws as shown below.
You will need a second person to help you to
avoid damaging the grill, the transformer, or
your barbecue island
Slide the rotis motor on one of the brackets as
shown below. The rotis motor will work on either
side of the grill.
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.
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.
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.
Check to see if gas line connections will be accessible
when grill is installed.
•
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.
•
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.
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Gas Connection
Gas Requirements and Connection
IMPORTANT: The Cal Flame grill is manufactured to operate on liquid propane (LP). However, it can be
converted to operate on natural gas (NG) by an authorized service technician. Consult your Cal Flame dealer
for information on converting your gas grill.
Owners must not convert their grills themselves Attempting to convert the grill from LP to NG
may result in serious injury and will void the warranty coverage
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
Perform a leak test at least once a year whether the
gas supply cylinder has been disconnected or not.
In 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.
bubbles in the soap solution indicates that a leak
is present.
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.
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
6. Turn all control knobs back to the full OFF
position.
lighted match to test for leaks. Use a solution of If you are unable to stop a leak:
soapy water.
1. Turn all control knobs back to the full OFF
1. Prepare a leak testing solution of soapy water by
mixing in a spray bottle one part liquid soap to
one part water.
position.
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.
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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
WARNING: Attempting to operate the grill unit
without the gas regulator installed could cause an
explosion and possible death.
top and bottom:
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 Dangerous Goods;
and Commission, as applicable.
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.
•
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
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.
LP Gas Hook Up
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:
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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.
Connection
1. Slide the grill forward to gain access to the
regulator and gas connection point in the rear.
2. Remove the rear panel from the barbecue to
gain access to the regulator and gas connection
point.
IMPORTANT: Never connect the grill to an unregulated
gas supply.
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.
3. Connect a suitable flex connector to the grill
regulator.
4. Check the grill controls to ensure all control valves
are in the full OFF position.
5. Turn on the main gas supply and check all
connections for leaks using soapy water as
described in the leak testing procedure section.
A licensed contractor or local gas company
representative must perform all natural gas
connections.
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.
Ensure that the service supplying the grill is fitted
with a shut off valve conveniently positioned near the
grill and giving ease of access.
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).
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.
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13
Using Your Grill
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:
•
It is dangerous to use barbecue grills and side
burners in any manner other than for what it is
designed for.
Never operate main burners and rear infrared
convection burners at the same time. Excessive
grill temperatures will result.
•
Do not use charcoal in a gas grill or side burner.
Basic Grill Operation
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.
3. Turn the control knob to HIGH and preheat the
grill for 15 minutes. Close the top cover during
the appliance preheat period.
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
2. Light the grill burners using the instructions on
after each use.
the previous page.
Do not leave the grill unattended while cooking.
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.
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Grill Controls
The controls shown below are for Cal Flame drop-in grills. Familiarize yourself with these controls before
lighting your grill.
The ON / OFF switch controlling the fan and halogen light is located on the control panel at the front lower
left side.
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Lighting the Burners
Each time you light the grill, check the following:
•
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.
before each use.
•
•
Ensure the propane cylinder, regulator, and rub-
ber hose are installed in a location not subject to
heating above 125º F (51º C).
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 in-
sects or insect nests.
•
•
•
•
Ensure the area around the barbecue is clear of
flammable substances such as gasoline, yard de-
bris, wood, etc.
Ensure there is no blockage of the airflow
through the vent space located below the face
of the unit.
•
•
Ensure the in-line gas valve or gas cylinder valve
is always shut OFF when the barbecue is not in
use.
When using propane gas, keep the special ven-
tilation 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 in-
stalled.
If connected to a propane cylinder, carefully in-
spect the rubber hose attached to the regulator
Electronically Lighting the Burners
Manually Lighting the Burners
1. Open the hood.
WARNING: Do not use standard matches or
cigarette lighters to perform match lighting
procedures. Serious burns can occur and lighters
can explode.
2. Keep your face as far away from the burners
as possible.
3. Press and 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.
1. Open the hood.
2. If you have just attempted to light the burner,
allow five minutes for any accumulated gas
to dissipate.
4. Listen for the sound of the gas igniting. If the
burner does not light on the first try, repeat
immediately.
3. Slide out the drip tray from the grill.
4. Keep your face as far away from the burners
as possible.
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.
5. Light and insert a long stem match, holding it
near the burner ports.
6. Push in and turn the control knob just past
6. Repeat the procedure or try the manual
the LIGHT position to HIGH.
lighting procedure below.
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.
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.
8. If the burner does not light after several
attempts see Troubleshooting Guide in the
back of this manual.
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Heat Distribution on the Cooking Grates
When you place food your Cal Flame grill,
remember that the back of the grill tends to
be hotter than the front.
As your food cooks, you should periodically
shift it to different spots on the cooking
grates to ensure everything cooks evenly
without burning.
Convection Fan
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.
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Cooking with the Rotisserie
The rotisserie cooks with the infrared back burner,
which provides intense searing radiant heat. The
location of the rotisserie and burner allows the
placement of a rotisserie-basting pan (NOT included)
beneath the food to collect juices and drippings for
basting and gravy.
Before you can use the rotisserie, you need to
mount the brackets and motor to the grill. See
page 9 for instructions.
The rotisserie does not require an additional outlet as it is powered by a 12-volt input located on the side of
the grill connected with a stainless steel sheathed power cable. See page 9 for more information.
Loading food on the rotisserie rod
Cooking with the rotisserie
1. Hold the handle firmly while sliding one of the
fork assemblies (prongs facing away from the
handle) onto the rod.
1. Remove the warming rack.
2. Place the pointed end of the rotis rod into the
motor and rest the threaded end on the support
at the side of the grill. When the rod is pushed
as far as possible into the motor, the grooved end
of the rod should rest on the right side bracket.
2. Push the rod through the center of the food, then
slide the other holder (prongs toward the food)
onto the rod.
3. Center the meat on the rod and push the fork
3. 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.
assemblies firmly together.
4. Tighten the thumbscrews.
5. To secure any loose portions of your meat,
use butcher string (never use nylon or plastic
string).
6. Place a basting pan under the food to collect the
drippings.
4. Light the infrared back burner. It will reach
cooking temperature in about one minute. The
orange/red glow will even out in about five
minutes. The back burner flame can be adjusted
to the level of intensity you prefer.
The rotisserie motor has an
ON / OFF switch that controls
the single-speed motor. The
rotisserie rotates in both
directions. You can change the
direction by turning it off and
turning it back on again.
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Optional Grill Accessories
These grill accessories are optional and may be ordered directly from Cal Flame customer service. See page 21
for ordering information.
Sear Zone Infrared Burner
The Sear Zone infrared burner can be use in place of any regular burner.
Producing intense infrared heat, it cooks quickly with searing heat to seal
in juices. (Note: The Sear Zone infrared burner is NOT the same as the
infrared back burner used with the rotisserie.)
Instructions for installing the optional Sear Zone burner are on page 32.
BBQ07890P
Pizza Brick Tray
You can use your grill as a pizza oven using the pizza brick tray. Made of
stone and stainless steel, it fits on any Cal Flame grill and is large enough
to cook a large sized pizza.
Set the tray on the grates, set the burners to medium heat, and heat up
your grill for about 10 minutes. Place the pizza on the tray and close the
hood. Depending on the size of the pizza, it will need between 10 to 20
minutes to cook.
BBQ07900
Any burner can be switched to accommodate the Smoke Tray.
Smoke Tray
1. Remove a grate and a flame tamer (the angular metal piece covering
the burner). Do not remove the burner.
2. Set the smoke tray in the grilling area so that the notches in the end
rest on the round metal posts attached to the inside of the grill area.
The smoke tray will resting over, but not ON, the burners.
3. Place wood chips or charcoal in the Smoke Tray.
4. Replace the grate.
5. Ignite the burner under the Smoke Tray and turn it up to HIGH.
BBQ08854P
6. Let it burn until the wood chips start to smoke. This should take 7 to
10 minutes. Then lower the heat to low.
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Use Turn part of your Cal Flame grill into a charcoal and gas grill.
Charcoal Tray
Turn off the gas and wait for the grill to cool before setting the
Charcoal Tray in place.
Placement
1. Remove two grates (left or right side) and the flame tamers (the
angular metal pieces covering the burners). Do not remove the
burners.
2. Set the charcoal tray in the grilling area so that the notches in
the side rest on the round metal posts attached to the inside of
the grill area. The charcoal tray will resting over, but not ON, the
burners.
BBQ11859
3. Place the ash screen in the Charcoal Tray.
Using the Charcoal Tray
Removal and Clean-up
The Charcoal Tray is designed and intended to When the grill has cooled and the charcoals are
be used with plain charcoal Quick-light char- dead, clean the grill as described in the grill owner’s
coal can produce excessive heat and may be manual.
dangerous
Remove ash from the Charcoal Tray immediately
Make sure the drip tray is in the grill before after use. Do not let it accumulate. Do not use the
you begin
grill again until charcoal ash has been removed from
the Charcoal Tray and the drip tray.
Keep the hood up until you are ready to cook.
1. Arrange charcoal in the tray.
2. Replace the grates.
Never use the Charcoal Tray over a Sear
Zone infrared burner
3. Ignite both burners under the Charcoal Tray and
turn them up to HIGH.
4. Let them burn until the charcoal remains lit
without help from the burners. This should take
7 to 10 minutes.
NEVER use charcoal in a gas grill
without the charcoal tray Doing so will
void your warranty
5. When the charcoal is ready, turn off the
burners.
6. Lower the hood if you wish to use the grill as a
smoker.
Perfect for roasting vegetables or cooking fish, this rotisserie
basket makes preparing these foods and others easy!
Rotisserie Basket
Open the rotisserie basket and set your food inside. Close and
clamp it shut, then slide the rotisserie rod lengthwise through it.
You can use it with either the standard burners or the infrared
back burner.
BBQ08892
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Deep Fryer Helper Set
The Deep Fryer Helper can turn part of your grill into
a deep frying station. It is designed to fit in any Cal
Flame grill.
The Deep Fryer Helper Set is shipped with its
own instructions for placement and use Read
them carefully before use
The Deep Fryer Helper Set comes with two commercial-
sized fryer baskets, a built-in thermometer, and storage
hangers allow baskets to be stored within unit. The lid
closes and seals for easy storage–wet (with oil) or dry
(drained). The lid can be removed for easy cleaning.
BBQ09902
The griddle tray is an optional feature installed in Cal Flame
barbecue islands. Included with the griddle tray is an enclosure for
storage.
Griddle Tray
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.
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.
BBQ07862P
Before storing the griddle, make sure it is clean and dry. Slide the
griddle into the enclosure for safe and easy storage.
Pull-Out Cutting Board
The pull-out cutting board is an optional feature installed in
Cal Flame barbecue islands.
The cutting board has an extra large cutting surface with a
bacteria resistant surface. It is on a gliding mechanism that
locks in full open position. A switch in the slider allows the
cutting board to be removed for cleaning.
BBQ07891P
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Cleaning and Maintenance
To ensure safe and proper maintenance, we recommend you follow these directions carefully.
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 clear and free from combustible materials, gasoline, and other
flammable vapors and liquids. Do not obstruct the flow of combustion and ventilation air.
DISCONNECT ELECTRICAL SUPPLY BEFORE CLEANING ANY PART OF THE GRILL.
These instructions describe the best way to care for
your stainless steel. They apply to grills and barbecue
Cleaning Products and Materials
DO NOT USE these common cleaning products
and materials – they will damage the surface of
your stainless steel.
islands with stainless steel fixtures.
Although stainless steel grills will discolor and
accumulate grime with regular use, they can keep
their original shine with periodic cleaning. We strongly
recommend using a surface protectant to prevent
smudging and surface rust from accumulating.
•
•
•
•
•
•
•
•
•
•
•
CLR
Lime-Away
Oven cleaner
Cleansers such as Ajax or Comet
Ammonia
Bleach
Chlorine
Steel wool pads
Wire brushes
Scrapers
The easiest way to clean the grill is immediately after
cooking is completed. Doing so will extend the life of
your grill, prevent grease fires, and present a pleasant
appearance while you grill.
Stainless Steel Care and Cleaning
All exposed stainless steel surfaces require special
attention if you want to keep them looking clean and
bright. Following these simple instructions will help
avoid scratching or damaging the finish and keep your
stainless steel attractive.
Pumice
We recommend these products for cleaning your
stainless steel:
•
•
•
•
•
•
Mild dish detergent such as Dawn
Formula 409
Fantastik
Instant Rust Out (exterior ONLY)
WD-40 (exterior ONLY)
Sheila Shine (exterior ONLY)
Cleaning instructions for grill interiors, including racks
and burners, are described after this section.
1 Clean
Thoroughly clean stains, food, and grime using
a sponge or damp cloth with warm water and a
mild dish soap. Use Fantastik or Formula 409 to
remove heavier soil.
We have had best success with Instant Rust Out,
but WD-40 works very well too. Instant Rust Out is
available in some hardware stores. WD-40 is widely
available.
2 Rinse
Thoroughly rinse all surfaces and dry them
completely with a clean towel. Do not allow
stainless steel to air dry.
Baking soda, lemon oil, olive oil, vinegar, or club
soda can also be effective for cleaning light soil on
all stainless steel surfaces.
3 Polish
Do not use steel wool or wire brushes to
scrub your grill.
We strongly recommend that you apply a surface
protectant to all exposed stainless steel surfaces.
For light soil, use a damp sponge or cloth.
Spray a small amount of WD-40 or Sheila Shine on a
piece of paper towel and rub with the grain over the
surface of the appliance. Using a clean terry cloth or
paper towel, polish the appliance by rubbing with the
For heavier stains, use a Scotch-Brite scrubber or
similar product.
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grain until excess liquid is removed and the surface 2 Rust removal with WD-40 or Sheila Shine:
shines. It should not be oily to the touch, however
Spray exterior stainless steel surfaces with WD-40 or
some residue is acceptable.
Sheila Shine and wipe down with a dry cloth or paper
Furniture polish, such as Old English, can be effective towel until surface is free of rust. If there is significant
for polishing stainless steel and protecting the rust or corrosion, use a Scotch-Brite scrubber.
surface.
Both of these products will act as a surface protectant
and help resist smudges, stains, and rust.
Do not use Instant Rust Out, WD-40,
or Sheila Shine near food or on food
preparation surfaces as it is a health
hazard. This includes the interior of the
grill, grill racks, stainless steel sinks, the
inside of cabinets, warming drawers, and
ovens.
Although nitric acid (also called aqua
fortis) can be effective for rust removal, it
is a highly corrosive chemical. Because of
the potential for injury or damage to your
stainless steel, we do not recommend
using nitric acid.
Caution
Caution
NEVER spray WD-40 or Sheila Shine
near an open flame! These products
are extremely flammable while in their Cleaning the Interior of Your Grill
Fire
Hazard
aerosol forms.
1. Thoroughly clean stains, food, and grime using
a sponge or damp cloth with warm water and a
mild dish soap. Use Fantastik or Formula 409 to
remove heavier soil.
Rust Removal
It is a common misconception that stainless steel does
not rust. It does not stain, corrode, or rust as easily
as ordinary steel (it stains less), but it is not stain-
proof. If not properly protected and maintained, it can
corrode, pit, and discolor.
2. Thoroughly rinse all surfaces and dry them
completely with a clean towel. Do not allow water
to accumulate and puddle on stainless steel.
Water from various sources such as garden hoses
contains iron which will give the appearance of
rusting on stainless steel. If allowed to stand for
long periods of time on stainless steel, it will cause
pitting.
Because salt will accelerate rust and
corrosion, grill or barbecue island
owners who live near the beach need to
Important
be diligent in maintaining their stainless
3. The racks, flame tamers, and flavor bars can all be
steel hardware. You need to clean and
polish your stainless steel frequently,
apply a protectant, and ensure water
does not collect and puddle.
removed for cleaning and are dishwasher safe.
Burners
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.
There are two methods of rust removal we
recommend:
1 Rust removal with Instant Rust Out:
Spray exterior stainless steel surfaces with Instant
Rust Out. Let it stand for about 30 seconds, then wipe
with a clean cloth. Apply a second time if necessary.
IMPORTANT: Prior to starting this procedure, turn OFF
all of the gas control knobs, shut off the fuel supply,
and disconnect the fuel line.
Instant Rust Out will leave a white residue which can
be rinsed off with water. Wipe the grill dry with a clean
cloth and apply Sheila Shine or WD-40 as a surface
protectant.
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The burners can be removed by removing the locking
pins and lifting them out. The locking pins are located
under the grill toward the back. They are used to
keep the burners in place during shipping and are not
necessary to operate your grill. Remove burners from
the grill by carefully lifting each burner up and away
from the gas valve orifice.
Steam Cleaning Your Grill
Steam cleaning the interior of your grill is very effective
and will not void your warranty. Portable hand-held
steam cleaners are inexpensive and do not require
chemicals. You can steam clean all parts of your
Cal Flame grill, including the burners. When you are
finished, make sure you wipe all surfaces down.
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.
If you spray the burners, ignite them and let them
burn for about 10 minutes to prevent any water from
accumulating inside them.
Inspect each burner for damage (cracks and holes). If
any damage is found, discontinue grill usage until you
replace the burner.
Covering Your Grill
When not in use and after cooling, cover your grill with
our full length, zippered side canvas cover. (See your
local Cal Flame dealer for details.) The cover will help
protect your grill from detrimental effects of weather
and environmental pollutants. Never put a cover on a
hot grill. Allow the grill to cool before covering.
Upon reinstallation, inspect the gas valve orifices
for cleanliness and condition and the location of the
igniters. When you replace the burners, you do not
need to replace the locking pins.
Cooking Grates
Use a solution equal parts detergent and hot water just
as you would for any cooking equipment. A stiff wire
brush or steel wool may also be helpful in removing
grime and food deposits.
Do not use a wire brush or stainless steel
on any other part of your grill or any
other stainless steel surface except the
Note
cooking grates or the griddle!
Drip Pan
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.
Griddle
To prevent burns or injury, make sure the griddle is
completely cool before cleaning.
The griddle is made from non-magnetic, 304 grade
stainlesssteel.Therearevariousstainlesssteelcleaners
available. Always use the mildest cleaning procedure
first, and always scrub in the direction of the grain.
Use soapy water for most cleaning. A non-abrasive
scrubber may also be helpful in removing grime and
food deposits. Steel wool may be used for especially
difficult spots. Wipe all areas dry before storing.
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Seasonal Cleaning
If you haven’t used your grill in a few months, we recommend that you clean the burners and the interior
of your grill. Cleaning the burners periodically will keep them burning evenly and cleanly and help prevent
“flashback”, a type of fire in and around the gas tubes. This happens when spiders and small insects inhabit or
make nests in the burner tubes, obstructing the gas flow.
IMPORTANT: Before removing the burners, turn OFF all of the gas control knobs, shut off the fuel
supply, and disconnect the fuel line
1 Remove the components
Remove the racks, the flavor bars, and the flame
tamers from the grill and set them aside. They don’t
need to be in the grill in order to clean them. In fact,
all of the items can be cleaned in a dishwasher if you
wish.
Leave the drip pan in place for now.
2 Remove the burners
The burners can be removed by taking out the locking pins and
carefully lifting them up and away from the valve orifice. The
locking pins are located under the grill toward the back. They are
used to keep the burners in place during shipping and are not
necessary to operate your grill.
3 Clean the burners
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.
Make sure the flow channel is clear.
The flow channel is the narrow slot
on the bottom of the burner near the
anchor post.
Inspect each burner for damage, such as cracks and
holes. If any damage is found, don’t use the grill until
you replace the burner.
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4 Clean the grill interior
While the burners are out of the grill, you can use this opportunity to clean the interior of your grill
thoroughly. You should still have the drip pan in place to catch water and grime as you clean the grill
interior.
When the grill interior is clean, remove the drip pan. Dump out any water and grime residue and spray it
off with a garden hose.
Dry both the grill interior and the drip pan thoroughly to prevent water damage.
5 Clean the components
You can clean the racks by first soaking them in warm water and dish detergent and scrubbing them with
a wire brush.
Clean the flavor bars and the flame tamers with dish detergent. You can use any kind of scrubber you wish:
a non-abrasive pad, steel wool, or a wire brush, depending on your needs.
Dry all of the components thoroughly to prevent water damage.
6 Replace the burners
Before you replace the burners, inspect the gas
valve orifices for cleanliness and condition and
the location of the igniters.
Set the flame tamers in place before you replace
the burners.
Carefully insert the burner into the opening for
the valve orifice and gently slide it in. Then set
the other end of the burner down so the anchor
post rests in the hole.
When you replace the burners, you don’t need
to replace the locking pins.
7 Replace the
components
Putallofthecomponents
back as they were, as
shown in step 1.
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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.
Cal Flame grills use two different types of light housings. These instructions describe how to change the bulb
in both types.
Light Lens with Screw Clip
1. Remove the screw at the left or right of the
lens.
2. Carefully pull the lens away and out of the
light fixture. Set the lens, screw clip, and
screw aside.
3. Unscrew the two screws located at the side of
the white ceramic light fixture.
4. Using a tissue or small piece of paper, pull the
burnt bulb out of the socket.
5. 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.
6. Tighten the two screws on the side white
ceramic light fixture.
7. Replace the light lens by replacing the screw
and screw clip.
Snap-in Light Lens
1. Using a small standard screwdriver, carefully
pop out the light lens and set it aside.
2. Using a tissue or small piece of paper, pull the
burnt bulb out of the socket.
3. 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.
4. Replace the light lens by carefully snapping it
back in place
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Appendix
Troubleshooting
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: Note: Turn off the gas at the source while troubleshooting.
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.
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. Let the area ventilate for a few seconds
before reconnecting the fuel line.
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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.
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 locking 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 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 knobs 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.
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Converting from LP to NG
WARNING! You must have an authorized service technician perform this
procedure. If these instructions are not followed exactly, a fire or explosion may
result causing property damage, personal injury or loss of life Lloyd’s Material Supply
(LMS) will not be held responsible for an improperly converted gas grill
All Cal Flame grills are manufactured as standard
liquid propane (LP) grills and can be converted to
burn natural gas (NG). There are two steps required
to convert a grill from LP to NG.
You must perform both steps.
Step 1: Switching the regulator behind the
grill
Step 2: Changing the burner orifices
The conversion kit provided with your grill may
include some or all of the parts shown at right,
depending on the size and model of your grill.
The kit contains orifices to convert main burners,
rear infrared burners, and the large infrared burner.
Your kit will have only the parts you need to convert
NOTE: A flared fitting is NOT included
with your grill
your grill.
If you are attaching a flex hose to the regulator,
Before you begin, make certain the LP gas source
you will need a fitting. The fitting requires a male
has been disconnected from the grill.
flare on the input end with a 1/2” MPT on the
To gain access to the NG regulator, tilt the grill
forward.
output end. The flared male input end needs to be
the size of your flex tubing. You can also connect
the regulator directly to your NG gas service, which
will not require a flared fitting.
Step 1: Switching the regulator
behind the grill
You will need:
The manifold in the image below has been removed from a grill to illustrate
this procedure.
•
•
13mm open end wrench
Male flared fitting
1. Remove the LP gas line.
(not provided)
Pipe compound suitable
for natural gas
2. Remove the cap fitting from the end of the NG gas regulator.
3. Place the cap fitting over the LP gas inlet.
•
4. Insert a male flared fitting (not provided) in the NG gas regulator.
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Gas Conversion (continued)
Step 2: Changing the burner orifices
You will need:
•
•
6mm socket or nut driver
Two to five 1.9mm orifices (depending on
your grill
1 Replace the main burner orifices
a. Remove the grates, flame tamers, and drip tray
•
Pipe compound suitable for natural gas
from the grill. See figure below.
Orifice
b. Remove the locking pins from the end of the
burners.
The locking pins are accessible by removing the
drip tray and tilting the grill back. They can be
seen underneath the grill in the back. See figures
below.
c. Remove all burners by carefully lifting them up
and away from the valve orifice.
d. Using a 6mm socket or nut driver, remove the
orifice for the burner.
e. Apply a small amount of pipe compound to the
Burner
orifice threads.
f. Screw in the orifice until it is finger tight.
Locking Pin
g. Tighten the orifice with the 6mm wrench.
h. Repeat the above steps for the remaining
burners.
i. Replace the burners, flame tamers, drip tray, and
grates.
You do not need to replace the locking pins. They
are used to keep the burners in place during
shipping and are not necessary to operate your
grill.
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Gas Conversion (continued)
2 Replace the infrared burner orifices
3 Replace the side burner orifices
You will need:
You will need:
•
•
Either a 13mm or 10mm open end wrench
One #50 orifice (for single infrared burner)
OR
Two #54 orifices (for dual infrared burners)
OR
•
•
7mm wrench, socket, or nut driver
One or two 1.75mm orifices (depending on
your side burner)
•
•
Pipe compound suitable for natural gas
•
•
One #52 orifice (for single infrared burner)
a. Remove the grate, burner cap and burner
Pipe compound suitable for natural gas
diffuser from the side burner.
a. Unscrew the back cover from the grill and lift it
up and under the grill hood.
b. Using a wrench, remove the orifice for the infrared
burner.
b. Using a 7mm wrench, remove the orifice for
the burner.
c. Apply a small amount of pipe compound to
the orifice threads.
d. Screw in the orifice until it is finger tight.
e. Tighten the orifice with the 7mm wrench.
f. If you have dual side burners, repeat the
previous steps for the second burner.
4 Mark the rating plate
After conversion has been completed, mark the rating
plate as NG with an indelible marker.
c. Apply pipe compound to the fitting threads where
you will place the new orifice.
d. Screw on the correct orifice for your grill until it is
finger tight.
e. Tighten the orifice with the wrench.
f. If you have dual infrared burners, repeat the
previous steps for the second burner.
g. Replace the back cover.
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32
Installing Sear Zone Burners
1. Disconnect or shut off the LP or natural gas line
connected to the grill. Wait until the burners cool
down.
2. Open the hood and remove the grate and flame
tamer on top of the stainless steel burner you
want to replace.
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.
5. Raise the stud from the locking hole and carefully
move the burner forward to release it from the
igniter and gas supply valve.
6. Take the burner out of the grill and store it in a
safe and dry place.
7. Install the Sear Zone burner. Align the gas inlet
on the burner with the gas supply valve on the
grill and torch tube with the igniter. Make sure
they align perfectly. Slide the stud at the other
end into the locking hole.
11. Reconnect or turn on the gas line.
8. Adjust the Sear Zone burner, make sure the
burner is aligned and in position.
If you want to change Sear Zone burners to regular
burners, just follow the above procedure above in a
similar way.
9. Repeat steps 2 through 9 if you want to replace
other burners.
10. Put back the grate you just removed. (You don’t
need flame tamers for Sear Zone burners.)
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33
Wiring Diagram
LIGHT AND
CONVECTION
FAN SWITCH
ROTISSERIE
PLUG
TRANSFORMER
PLUG
ROTISSERIE
PLUG
2
1
1
2
1
2
WHITE
RED
-
+
WHITE
WHITE
WHITE
WIRE NUT
WIRE
NUT
HALOGEN
LIGHT
HALOGEN
LIGHT
CONVECTION
FAN
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Replacement Parts
See following page for part numbers and ordering
information.
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All parts can be used on all three grill sizes except where described below.
Item
No
Item
No
Part
Grill Size
3 burner
4 burner
5 burner
3 burner
4 burner
5 burner
3 burner
4 burner
5 burner
3 burner
4 burner
5 burner
Part #
Part
Grill Size
Part #
BBQ08856P3
BBQ08856P4
BBQ08856P5
BBQ07100781
BBQ04101016
BBQ04101015
BBQ04101014
BBQ04101013
BBQ08000420
BBQ07100781
BBQ04101809
BBQ04101257
BBQ10104049-CC
BBQ07104050
3 burner
1
2
3
Control panel
24
Spit rod assembly
4 burner
BBQ10104051-CC
BBQ07104053
5 burner
All
25
26
Rotisserie motor
Back panel
Hood
BBQ07104054
Main burner valve (LP)
Main burner valve (NG)
Back burner valve (LP)
Back burner valve (NG)
Convection fan
All
BBQ07104055
All
BBQ07100587-CC
BBQ07100588-CC
BBQ07100589-CC
BBQ07100686
All
27
All
28
29
30
31
All
Transformer
All
4
5
Drip pan
BBQ07100687
Back burner electrode
Hood hinge
All
BBQ07100688-CC
All
3 and 4 burner BBQ07300440
Upper rack holder, left
32
33
All
All
BBQ04100706
Back burner
side
5 burner
All
BBQ07300430
BBQ10103070
BBQ04103059
LIT16300031
Upper rack holder, right
6
7
Light housing
Light lens
Halogen bulb
Thermometer
Flavor bar
Cal Flame logo
Bezel
BBQ07100707
side
All
3 burner
4 burner
5 burner
BBQ07220172
BBQ07220170
BBQ07220171
8
All
Convection panel heat
34
shield
9
All
BBQ07410350
BBQ04103000
BBQ04100972
BBQ08410351
BBQ04101028
BBQ04100659
BBQ07100683
BBQ07100639
BBQ07100641
BBQ08410354
BBQ08101028
BBQ08000513
BBQ08000514
BBQ08000515
BBQ04101043
BBQ04103040
BBQ08100656-CC
BBQ01000657-CC
BBQ08100658
BBQ04100786
BBQ04103010-CC
BBQ07100661
10
11
12
13
14
All
Grill cover (not shown in All -- one size BBQC2345GB
drawing) fits all
All
All
2” knob
All
Grates
All
Ordering replacement parts
3 burner
4 burner
5 burner
All
To order replacement parts, either contact an
authorized selling dealer or LMS Customer Service at
(800) 225-7727.
15
Handle
16
17
Light bezel
Light/fan knob
All
3 burner
4 burner
5 burner
All
18
19
20
Manifold
Regulator (LP)
Regulator (NG)
All
3 burner
4 burner
5 burner
All
Warming rack
21
22
23
Rotisserie bracket
Flame tamer
Burner
All
All
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36
Limited Warranty
All Cal Flame models are manufactured with the highest quality appliances and are warranted to be free from
defects in material and workmanship at time of delivery.
LMS warrants barbecue grills and associated hardware from deterioration, corrosion, and defects in material
and workmanship for a period of one year from the original date of delivery, with the exception of plastic items
and glass light covers, which are warranted for 90 days.
This warranty is void if the barbecue grill has been
subject to negligence, alteration, misuse, repairs,
dings, dents, scratches, or incorrect and / or prohibited
applications, as specified in the owner’s manual.
Extent of Warranty
This limited warranty is only valid on Cal Flame models
delivered in the United States or Canada and extends
through the selling dealer to the original purchaser at
Gas lines must be installed by a licensed plumber
only or local gas company agent. Incorrect electrical
installation by unlicensed electricians, service by non-
LMS authorized representatives, acts of God and other
cases beyond the control of LMS are not covered by
this warranty. Please refer to the owner’s manual for
examples of exclusions and common acts invalidating
this warranty.
the original site of installation. This warranty becomes
valid at time of delivery and ends either by specified
time-frame listed above or upon owner transfer or
relocation.
Warranty Performance
In the event of a malfunction or defect covered under
the terms of this warranty, contact either the selling
dealer or a local contractor or service technician.
Depending on your needs, this may be a contractor
qualified to repair stone and tile or a service agent
licensed to repair gas or electrical appliances.
This limited warranty applies only to barbecue grills
and associated hardware used for personal, family,
and outdoor household purposes. This warranty does
not apply to labor charges on grills, replacement parts
and hardware. This limitation is retroactive and applies
to all grills and hardware manufactured from 2000 and
hereafter.
In the event the consumer is unable to obtain
satisfactory customer service from the selling dealer
or service agent, written notification must be given
to the LMS Customer Relations Department within 30
days of the reported failure.
Examples of common acts invalidating this warranty
include but are not limited to:
There will be no charge for parts on a covered item.
Cost of labor is the responsibility of the owner. Shipping
and handling charges will apply to all warranted
replacement parts. The service agent may assess a
reasonable travel or mileage charge per service call.
If LMS determines that repair of a covered item is
not feasible, LMS reserves the right to replace the
defective merchandise with merchandise equal in value
to the original purchase price. Warranty repair and /
or replacement are the sole discretion of LMS and this
warranty does not cover costs therein, including but
not limited to: freight, removal, re-installation, etc.
•
•
Scratches caused by normal use.
Damage caused by extreme weather conditions
(hot, cold, etc.)
•
•
•
Damage caused by salty and humid conditions
(especially in beach or seaside communities)
Damage caused by dirt, sand, and/or water
damage.
Damage caused by continued operation of
the barbecue with either known or unknown
problems.
This warrant is non-transferable and may not
be extended beyond the above mentioned time
frames under any circumstances, by any of LMS’s
representatives.
•
•
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 and specifically excludes rental or commercial
applications.
The stainless steel grill hood, stainless steel grill racks,
and the optional fabric grill cover are not covered by
this warranty.
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Disclaimers
LMS shall not be liable for loss of use of the barbecue
grills, related hardware or other incidental or
consequential costs, expense or damages, which may
include, but are not limited to, removal of permanent
deck or other custom fixtures or the necessity for crane
removal. Any implied warranty shall have duration
equal of the applicable warranty stated above.
Legal Remedies
This limited warranty gives you specific legal rights.
You may have other rights, which may vary from state
to state.
Customer Service
For customer service, contact the authorized selling
dealer immediately. If you need additional information
or assistance, please contact the LMS Customer
Relations Department at 1462 E. Ninth St., Pomona
CA 91766 or call (800) 225-7727.
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.
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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. You will need this
number to properly register your grill and activate coverage.
Write this information in the space provided below.
Grill model: __________________________________________________________________________
Grill serial number: ____________________________________________________________________
Type of fuel (circle one):
Liquid propane
Natural gas
Date purchased: ______________________________________________________________________
Date installed: ________________________________________________________________________
Cal Flame dealer’s phone number: ________________________________________________________
Cal Flame dealer’s address: ______________________________________________________________
Don’t forget to register your new product at
California Proposition 65 Warning: Chemicals known to
the State of California to cause cancer, birth defects or
other reproductive harm are found in and/or created
by the combustion of natural gas, propane, butane and
other fuels. Always operate this unit as described in the
LTR50001038, Rev. C
12/26/11
owner’s manual and in well ventilated areas.
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