Installation / Assembly
Cabinet Cut-out Dimensions . . . . . . . . . . . . 5
LP Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Leak Testing Procedure . . . . . . . . . . . . . . . . 9
Installing the Grill in a Barbecue Island . . 10
Using Your Grill
Grill Controls . . . . . . . . . . . . . . . . . . . . . . . . 11
Basic Grill Operation . . . . . . . . . . . . . . . . . . 12
Electronically Lighting the Grill . . . . . . . . . 13
Manually Lighting the Grill . . . . . . . . . . . . . 14
Cleaning and Maintenance
Stainless Steel . . . . . . . . . . . . . . . . . . . . . . 15
Drip Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Covering Your Grill . . . . . . . . . . . . . . . . . . . 16
After Use Care . . . . . . . . . . . . . . . . . . . . . . . 16
Appendix
Troubleshooting . . . . . . . . . . . . . . . . . . . . . 17
Replacement Covers . . . . . . . . . . . . . . . . . . 20
Removing and Replacing Burners . . . . . . . 20
2009 Warranty . . . . . . . . . . . . . . . . . . . . . . 21
Save these instructions!
Copyright 2008-2009 LMS, Inc. All rights
reserved. Duplication without written
consent is strictly prohibited.
Cal Flame ® is a registered trademark.
Due to continuous improvement programs,
all models, operation, and/or specifications
are subject to change without prior notice.
LTR20091050, Rev. A
12/11/08
CONTACT INFORMATION
For customer service, please contact
your authorized dealer immediately. If
you need additional information and/or
assistance, please contact:
Customer Service Department
1462 East Ninth Street
Pomona, CA 91766
Toll Free: 1-800-CAL-SPAS
Fax: 1-909-629-3890
www.calspas.com
Safety Instructions
1
Placement and Location
Cal Flame grills 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 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.
•
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 or area 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.
Set-Up
•
Before installing built in grills in enclosures, copy all product
information such as model number, serial number and gas type
(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.
•
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.
•
To prevent fire and smoke damage, remove all packaging material
before operating grill.
2009 G3, G4, G5 Grills
LTR20091050, Rev. A
www.calspas.com
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.
Safety Instructions
2
•
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.
Operation
•
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.
•
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.
•
Keep all electrical supply cords away from the heated areas of the
grill.
•
Never use the grill 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.
•
Never line the grill with aluminum foil.
•
When the unit is not in use, be sure to turn off the gas at the LP
tank.
•
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 use fuel such as charcoal briquettes in gas grills.
•
Gas sources to the grill must be regulated. Do not operate grill if
regulators have been removed, fire or explosion can occur.
•
Never leave the grill burners unattended when in use.
•
Do not use water on grease fires. Never pick up a flaming pan.
Turn the appliance off and smother the flaming pan with a tightfitting 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.
•
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
2009 G3, G4, G5 Grills
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LTR20091050, Rev. A
3
•
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.
•
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.
•
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 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.
•
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.
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.
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 store items of interest to children around or below the
grill.
•
Never allow children to sit or stand on any part of the grill.
2009 G3, G4, G5 Grills
LTR20091050, Rev. A
www.calspas.com
Safety Instructions
garments while using your grill. Fabric may ignite and result in
personal injury.
Installation / Assembly
4
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.
We recommend the installation, adjustment and service of your new
grill be performed by LMS qualified installers and service technicians to
ensure proper operation and prevent accidents.
When planning your Cal Flame grill location, access to a gas line
should be considered. The location with the shortest gas line run is
recommended.
When determining a suitable location, consider factors such as exposure
to wind, proximity to traffic paths, and windows that open into the
home.
Locate the barbecue grill only in a well-ventilated area and only on a
solid, flat foundation (e.g. deck or cement slab).
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.
Converting Gas Grills
IMPORTANT: Cal Flame G3, G4, and G5 grills are manufactured to
operate on liquid propane (LP). However, they 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.
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LTR20091050, Rev. A
5
Your Cal Flame grill is designed for easy installation into a noncombustible 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.
The drawings below show the different types of cabinet cut-out
dimensions for gas grills and accessories.
Grill Model
Width Depth Height
G3 Three Burner
23 ¼”
22 ¼”
9 ¼”
G4 Four Burner
30 ¾”
22 ¼”
9 ¼”
G5 Five Burner
38 ¼”
22 ¼”
9 ¼”
WIDTH
DEPTH
HEIGHT
2009 G3, G4, G5 Grills
LTR20091050, Rev. A
www.calspas.com
Installation / Assembly
Cabinet Cut-out Dimensions
Installation / Assembly
6
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.
WARNING: Attempting to operate the grill unit without the gas
regulator installed could cause an explosion and possible death.
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.
•
Approximately 12 inches in diameter and 18 inches high.
2009 G3, G4, G5 Grills
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LTR20091050, Rev. A
7
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.
LP Gas Hook Up
An enclosure for an LP gas cylinder shall be vented by openings at
level of the cylinder valve and at floor level. The effectiveness of
openings for purposes of ventilation shall be determined with the
gas supply cylinder in place. This shall be accomplished in one of
following manners:
the
the
LPthe
1. One side of the enclosure shall be completely open.
2. Enclosures that have four sides, complete with a 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).
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.
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.
2009 G3, G4, G5 Grills
LTR20091050, Rev. A
www.calspas.com
Installation / Assembly
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.
Installation / Assembly
8
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.
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.
A licensed contractor or local gas company representative must perform
all natural gas connections.
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.
Connection
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.
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.
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.
2009 G3, G4, G5 Grills
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LTR20091050, Rev. A
9
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.
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.
1. Prepare a leak testing solution of soapy water by mixing in a spray
bottle one part liquid soap to one part water.
2. Make sure all the control knobs are in the OFF position.
3. Turn on the gas.
a. On natural gas systems, turn the main feed valve to the grill.
b. On LP systems, turn the cylinder valve knob counter clockwise
one turn to open.
4. Apply the leak-testing solution by spraying it on joints of the gas
delivery system. Blowing 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.
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.
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.
3. On LP systems, remove the cylinder from the grill.
4. Call an authorized gas appliance service technician or an LP gas
dealer.
Do not use the appliance until the leak is corrected.
2009 G3, G4, G5 Grills
LTR20091050, Rev. A
www.calspas.com
Installation / Assembly
Leak Testing Procedure
Installation / Assembly
10
Installing the Grill in a
Barbecue Island
You will need a second person to help you to avoid damaging
the grill or your barbecue island.
Before installing a grill 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.
Pay careful attention to the location of the gas line. It should be
routed away from sources of heat and should make as few bends
as possible.
Check to see if the gas line connection will be accessible when grill
is installed.
• If the gas line connection is not easily accessible when the grill
is installed, support the grill above counter level and attach the
gas line to the grill. When the gas connection is made, slide the
grill into the cut out.
• If the gas line connection is accessible when the grill is installed,
slide the grill into the cut out and then attach the gas line.
Be very careful not to kink the gas line when lowering the grill 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 noncombustible shims under the outside lip to stabilize it.
Perform the leak test procedure as described earlier in this manual.
2009 G3, G4, G5 Grills
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LTR20091050, Rev. A
Using Your Grill
11
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.
Remember to use your grill safely by following these reminders:
•
It is dangerous to use barbecue grills in any manner other than for
what it is designed for.
•
Do not use charcoal in a gas grill.
•
Do not heat sealed containers such as cans or jars on grills.
Explosion may result resulting in injury or death.
•
Never put combustible material such as paper, cloth, or flammable
liquids on your grill at any time. Do not use grill or any area around
grill to store flammable materials.
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.
Grill Controls
The controls shown below are for the G4 grill. Familiarize yourself
with these controls before using your Cal Flame barbecue.
Off
High
Low
Burners
1
2
3
4
Grill Knob Operation
2009 G3, G4, G5 Grills
LTR20091050, Rev. A
www.calspas.com
Using Your Grill
Read all instructions before you operate
your grill.
Using Your Grill
12
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.
1. Make sure the drip tray is in place.
2. Light the grill burners using the instructions on the previous page.
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.
5. Allow the grill to cool and clean the drip tray after each use.
Do not leave the grill unattended while cooking.
•
When using propane gas:
• Keep the special ventilation openings in the enclosure
free and clear of debris.
• If connected to a propane cylinder, carefully inspect
the rubber hose attached to the regulator before each
use.
• Ensure the propane cylinder, regulator, and rubber
hose are installed in a location not subject to heating
above 125º F (51º C).
2009 G3, G4, G5 Grills
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LTR20091050, Rev. A
13
•
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 area around the barbecue is clear of flammable
substances such as gasoline, yard debris, wood, etc.
•
Ensure there is no blockage of the airflow through the vent space
located below the face of the unit.
•
Ensure
burner
burner
insects
•
Ensure the in-line gas valve or gas cylinder valve is always shut
OFF when the barbecue is not in use.
the burner flames burn evenly along both sides of each
with a steady flame (mostly blue with yellow tipping). If
flames are not normal, check the orifice and burner for
or insect nests.
Electronically Lighting the Grill
1. Open the hood.
2. Keep your face as far away from the burners as possible.
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.
4. Listen for the sound of the gas igniting. If the burner does not
light on the first try, repeat immediately.
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.
6. Repeat the procedure or try the manual lighting procedure
below.
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.
2009 G3, G4, G5 Grills
LTR20091050, Rev. A
www.calspas.com
Using Your Grill
Each time you light the grill, check the following:
Using Your Grill
14
Manually Lighting the Grill
WARNING: Do not use standard matches or cigarette lighters to
perform match lighting procedures. Serious burns can occur and
lighters can explode.
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.
4. Keep your face as far away from the burners as possible.
5. Light and insert a long stem match, holding it near the burner
ports.
6. Push in and turn the control knob just past the 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.
8. If the burner does not light after several attempts see
Troubleshooting Guide in the back of this manual.
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.
2009 G3, G4, G5 Grills
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LTR20091050, Rev. A
Cleaning and Maintenance
15
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.
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.
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.
4. Upon reinstallation, inspect the gas valve orifices for cleanliness
and condition and the location of the igniters.
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.
2009 G3, G4, G5 Grills
LTR20091050, Rev. A
www.calspas.com
Cleaning and Maintenance
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. 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.
Cleaning and Maintenance
16
Stainless Steel
Do NOT use wire wool pads, scrappers, harsh abrasive, scoring
materials, bleaches, or harsh cleaners on your 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.
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.
After Use Care
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.
• 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.
• Dry with a soft, dry, clean towel if preferred.
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.
Hood and Body
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.
2009 G3, G4, G5 Grills
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LTR20091050, Rev. A
Appendix
17
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
troubleshooting.
the
gas
at
the
source
while
2009 G3, G4, G5 Grills
LTR20091050, Rev. A
www.calspas.com
Appendix
Troubleshooting
Appendix
18
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:
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.
2009 G3, G4, G5 Grills
www.calspas.com
LTR20091050, Rev. A
19
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:
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.
2009 G3, G4, G5 Grills
LTR20091050, Rev. A
www.calspas.com
Appendix
Problem:
Appendix
20
Replacement Covers
CVRBLT001
CVRBLT003
CVRBLT007
COVER, GRILL, MEDIUM, 3 BURNER
COVER, GRILL, MEDIUM, 4 BURNER
COVER, GRILL, MEDIUM, 3 BURNER
Removing and Replacing Burners
1. Disconnect or shut off the gas line connect to the grill. Wait until
the burners cool down.
2. Open the hood and remove the grate and flame tamer on top of
the 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 remove.
4. Carefully remove the locking pin with your fingers.
5. Raise the stud from the locking hole and move the burner forward
carefully to release it from the ignition and gas supply valve.
6. Take the burner out of the grill and store it in a safe and dry
place.
2009 G3, G4, G5 Grills
www.calspas.com
LTR20091050, Rev. A
21
LMS warrants the G3, G4, and G5 grill and associated hardware from
defects in material and workmanship for a period of one year from the
original date of purchase.
One Year Equipment and Component Warranty
LMS warrants against deterioration and corrosion
•
Flame Tamers
•
Burners
•
Grates
•
Mountings
•
Grill Lid and Body
Extent of Warranty
This 2009 Cal Flame 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 the original site of installation. This warranty
becomes valid at time of purchase and ends either by specified timeframe listed above or upon owner transfer or relocation.
Manufacturer 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. The appliance warranty is extended
through the manufacturer of the product.
Warranty Performance
In the event of a malfunction or defect covered under the terms of
this warranty, a factory authorized service agent of LMS will perform
the necessary repairs. To obtain service, contact the selling dealer.
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. There will be no charge for parts or
labor on a fuel delivery item. However, 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
2009 G3, G4, G5 Grills
LTR20091050, Rev. A
www.calspas.com
Appendix
2009 Warranty
Appendix
22
to the original purchase price. Warranty repair and / or replacement
is the sole discretion of LMS and this warranty does not cover costs
therein, including but not limited to: freight, removal, re-installation,
etc. 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.
Warranty Limitations
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. Gas lines
must be installed by a licensed plumber only or local gas company agent.
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. 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.
Examples of common acts invalidating this warranty include but are
not limited to:
•
Scratches caused by normal use.
•
Damage caused by extreme weather conditions (hot, cold, etc.)
•
Damage caused by dirt, sand, and/or water damage.
•
Damage caused by continued operation of the barbecue with either
known or unknown problems.
•
Damage caused by direct sunlight.
•
Damage caused as a result of failure to follow the operating
instructions as defined in the owner’s manual.
This Limited Warranty applies only to barbecue grills normally used
for personal, family, or household purposes and specifically excludes
commercial use of the barbecue grill.
2009 G3, G4, G5 Grills
www.calspas.com
LTR20091050, Rev. A
23
LMS shall not be liable for loss of use of the barbecue grills or
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.
2009 G3, G4, G5 Grills
LTR20091050, Rev. A
www.calspas.com
Appendix
Disclaimers
Appendix
24
2009 G3, G4, G5 Grills
www.calspas.com
LTR20091050, Rev. A
25
Appendix
2009 G3, G4, G5 Grills
LTR20091050, Rev. A
www.calspas.com
LMS Customer Service Department
1462 East Ninth Street
Pomona, CA 91766
Toll Free: 1-800-CAL-SPAS
Fax: 1-909-629-3890
www.calspas.com
LTR20091050, Rev. A
12/11/08