Calflame | G Series | Owner`s manual | Calflame G Series Owner`s manual

LTR50001050, Rev. E
12/22/14
WARNING
If the information in this manual is not followed
exactly, a fire or explosion may result causing
property damage, personal injury or loss of
life.
Safety Instructions
Placement and Location . . . . . . . . . . . . . . . .
Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and Repair . . . . . . . . . . . . . . .
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions Regarding Children . . . . . . . . . . . . . .
Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any
other appliance.
Proper Location of the Grill
Do not store an LP cylinder not connected for
use in the vicinity of this or any other appliance.
A fire resulting in serious injury or death may
occur.
Built-in Construction
If you are installing a natural gas grill, you are
responsible for ensuring that the natural gas
line installed is safe to use. LMS will not be held
responsible for an improperly installed gas line.
Read all instructions before you
operate your grill.
Save these instructions!
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
owner’s manual and in well ventilated areas.
CONTACT INFORMATION
For customer service, please contact your authorized
dealer immediately. If you need additional information
and/or assistance, please contact:
LMS Customer Service Department
1462 East Ninth Street
Pomona, CA 91766.
Toll Free: 1-800-225-7727
Fax: 1-909-629-3890
Copyright 2014 LMS. All rights reserved. Duplication without
written consent is strictly prohibited. Cal Flame™ is registered
trademark.
Due to continuous improvement programs, all models,
operation, and/or specifications are subject to change
without prior notice.
LTR50001050, Rev. E
12/22/14
250-464
1
1
1
2
2
2
Ensuring Proper Ventilation . . . . . . . . . . . . . 3
Construction materials . . . . . . . . . . . . . . . . . 4
Built-in Dimensions . . . . . . . . . . . . . . . . . . . 5
Enclosure Ventilation . . . . . . . . . . . . . . . . . . 7
Gas and Electrical Supply Requirements
Gas Requirements . . . . . . . . . . . . . . . . . . . . 8
Electrical Supply Requirements . . . . . . . . . 10
Installation and Connection
Connecting the Grill and Side Burner . . . . 11
Leak Testing Procedure . . . . . . . . . . . . . . . 14
Using Your Grill
Basic Grill Operation . . . . . . . . . . . . . . . . . .
Grill Controls . . . . . . . . . . . . . . . . . . . . . . . .
Lighting the Burners . . . . . . . . . . . . . . . . . .
Gas Cylinder Orientation . . . . . . . . . . . . . .
15
16
16
18
Optional Grill Accessories
Sear Zone Infrared Burner . . . . . . . . . . . . .
Pizza Brick Tray . . . . . . . . . . . . . . . . . . . . .
Smoke Tray . . . . . . . . . . . . . . . . . . . . . . . . .
Charcoal Tray . . . . . . . . . . . . . . . . . . . . . . .
Griddle Tray . . . . . . . . . . . . . . . . . . . . . . . .
Pull-Out Cutting Board . . . . . . . . . . . . . . . .
19
19
19
20
21
21
Cleaning and Maintenance
Stainless Steel Care and Cleaning . . . . . . .
Cleaning the Interior of Your Grill . . . . . . .
Covering Your Grill . . . . . . . . . . . . . . . . . . .
Seasonal Cleaning . . . . . . . . . . . . . . . . . . .
22
23
24
25
Appendix
Troubleshooting . . . . . . . . . . . . . . . . . . . . .
Converting from LP to NG . . . . . . . . . . . . .
Replacement Parts . . . . . . . . . . . . . . . . . . .
Installing Sear Zone Burners . . . . . . . . . . .
Limited Warranty . . . . . . . . . . . . . . . . . . . .
27
29
32
34
35
Safety Instructions
1
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.
Placement and Location
• 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.
•
•
Maintain sufficient distance as to not overheat any
overhead combustible material such as a patio
cover.
To prevent fire and smoke damage, remove all
packaging material before operating grill.
•
•
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.
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.
•
Do not use the grill, grill cabinet, 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 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
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.
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.
•
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.
•
Keep any electrical supply cords and the fuel
supply hose away from any heated surfaces.
•
Never line the grill or side burners with aluminum foil.
•
When the unit is not in use, be sure to turn off the
gas at the LP tank.
•
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.
G Series Gas Grills
LTR50001050, Rev. E
www.calflamebbq.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
•
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.
•
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.
•
Never leave the grill and side burners unattended
when in use. When using pots and pans, boilovers 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.
•
•
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.
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.
•
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.
•
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-L.M.S. 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.
G Series Gas Grills
www.calflamebbq.com
LTR50001050, Rev. E
Proper Location of the Grill
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.).
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 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. Ventilation is address in greater detail
in the next section.
The sides, bottom and back of the grill enclosure
should not be any closer than 24” to combustible
construction.
To reduce the risk of personal injury caused by
reaching over a hot appliance, avoid locating cabinet
storage space directly above the outdoor grill.
Cal Flame grills are designed for outdoor use
only.
Carbon Monoxide Hazard
This appliance can produce carbon
monoxide which has no odor.
Using it in an enclosed
space can kill you.
Never use this appliance in
an enclosed space such as a
camper, tent, car, or home.
Ensuring Proper Ventilation
Do not locate your barbecue island 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.
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 barbecue island.
Do not locate your barbecue island under a sealed
overhead structure. Acceptable overhead structures
allow for airflow, such as screen or lattice.
You can install an awning over your barbecue island,
provided you make sure it is high enough to prevent
damage or fire. We recommend a minimum overhead
distance of six feet from the top of the grill hood.
• Solid foundation
• Open on three sides
• Minimum distance of
six feet overhead from
combustible material
• Overhead is not sealed
• Not placed near windows
• No overhead storage
• No combustible materials
stored nearby
G Series Gas Grills
LTR50001050, Rev. E
www.calflamebbq.com
Safety Instructions
Here are some general considerations when
determining where to place your new barbecue island.
Be certain that your installation will meet all city and
local safety codes and requirements.
3
Built-in Construction
4
Built-in Construction
Note: The terms “built-in construction” and “grill
enclosure” as used in these instructions refer to any
method for installing a barbecue island for use. A
barbecue island is both built-in constructions and a grill
enclosure. Read these instruction before constructing
your grill enclosure.
The Cal Flame convection grill is expected to be used
with a Cal Flame barbecue island. If the convection
grill is not placed in a Cal Flame barbecue island, it
must be used in a safe manner that will not void your
warranty. If you plan to do this, use the information in
this section on the construction and materials required
for the grill enclosure and its proper location. Cal Flame
wishes our customers to enjoy our products safely. We
strongly recommend that grill owners hire a contractor
to construct the built-in enclosure.
Failure to follow these instructions may result in voiding
your warranty, property damage, injury, or death.
Construction materials
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.
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.
G Series Gas Grills
www.calflamebbq.com
LTR50001050, Rev. E
WIDTH
Minimum
Clearance
DEPTH
HEIGHT
WIDTH
WIDTH
DEPTH
Plan the
installation so that the electrical connection,
gas shut-off valve, and pressure regulator are
WIDTH accessible inside the base enclosure. The gas valve
shall be readily accessible for hand operation. A door
on the enclosure to gain access to the gas valve is
acceptable, provided it is non-locking and can be
opened without the use of tools.
The design of the outdoor cooking enclosure must allow
the LP gas cylinder to be connected and disconnected
and the connections inspected and tested.
There must be a minimum clearance of 2 inches
(51mm) between the floor of the LP-gas cylinder
enclosure and the ground.
DEPTH
HEIGHT
WIDTH
WIDTH
WIDTH
12” Minimum Distance
tween Grill and Side Burner
Minimum
Clearance
The dimensions shown below are for Cal Flame appliances only.
WIDTH
TH
Model
Description
WID
Width
BBQ09G03
BBQ08G04
BBQ09G05
G3 three burner grill
G4 four burner grill
G5 five burner grill
23 3/8”
22”
31”HEIGHT 22”
38 7/8”
22”
Model
Description
BBQ08954P
BBQ08899P
WIDTH
Depth
DEPTH
Height
9 ¼”
9 ¼”
9 ¼”
Width
Depth Height
Deluxe Side by Side Burner
25 ¼”
12 ½”
7 ¼”
Deluxe Double Side Burner
12 ¼”
22”
7 ¼”
Burner
Burner
Locking Pin
G Series Gas Grills
LTR50001050, Rev. E
Locking Pin
www.calflamebbq.com
Built-in Construction
Built-in Dimensions
5
HEIGHT
Minimum
Clearance
6
Built-in Construction
ner
DEPTH
WIDTH
WIDTH
The dimensions shown below are for Cal Flame appliances only.
Model
Description
Width
Depth
BBQ08953P
Side By Side Flat Burner
24 ¼”
19 ¾”
BBQ08852P
Single Flat Side Burner
11 ½”
17 ¾”
DEPTH
WIDTH
HEIGHT
WIDTH
DEPTH
WIDTH
Top view of enclosure
with back splash
DEPTH
WIDTH
DE
DEPTH
Minimum
Clearance
DEPTH
The back edge of the grill must maintain a minimum
HEIGHT splash
clearance of 8” from non-combustible back
materials.
Burner
WIDTH Burner
Locking Pin
WIDTH
WIDTH
WIDTH
Side view of enclosure
with back splash
DEPTH
WIDTH
WIDTH
WIDTH
WIDTH
Locking Pin
WIDTH
WIDTH
12” Minimum Distance
Between Grill and Side Burner
WIDTH
DEPTH
WIDTH
HEIGHT
WIDTH
12” Minimum Distance
H and Side Burner
Between
WIDTGrill
D
Top view of enclosure
with back splash
Minimum
Clearance
WIDTH
G Series Gas Grills
www.calflamebbq.com
LTR50001050, Rev. E
WIDTH
7
Built-in Construction
Enclosure Ventilation
For proper ventilation, the base structure must be constructed using one of two designs:
1
An enclosure with one side open
2
An enclosure having four sides, a top, and bottom
The second type of enclosure must be constructed
with the following specifications:
•
At least two ventilation openings at cylinder
valve level shall be provided in the side wall,
equally sized, spaced at 180 degrees and
unobstructed.
•
Each opening shall have a total free area of not
less than 10 square inches (254 square mm).
•
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 be at least two openings. The
bottom of the openings 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.
•
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 supply cylinder in place.
G Series Gas Grills
LTR50001050, Rev. E
www.calflamebbq.com
Gas and Electrical Supply Requirements
8
Gas and Electrical Supply Requirements
Gas Requirements
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.
This barbecue grill does not include the parts for converting to NG. The gas conversion kit can be ordered
separately. The part number for the conversion kit is BBQ07101045. Grill conversion instructions can be
found on page 29 and ordering information can be found in this manual on page 32.
Liquid Propane
Tank Requirements
For plumbed-in LP installation, use a convertible
regulator and set it for LP gas.
Any LP gas supply cylinder used with this grill must
be approximately 12 inches in diameter and 18 inches
high.
Maximum line pressure for plumbed-in propane
is 14” WC (3.5 kPa). Minimum line pressure for
propane is 11” WC.
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.
The grill 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
The LP cylinder 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/CSAB339, Cylinders, Spheres and Tubes for
Transportation of Dangerous Goods; and
Commission, as applicable.
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 grill or refill the
tank at your local propane refill station.
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.
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.
G Series Gas Grills
www.calflamebbq.com
LTR50001050, Rev. E
9
Gas and Electrical Supply Requirements
Natural Gas
NG Service Installation and Connection
Natural gas 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.
You do not need to hire a contractor to install your
natural gas service, but you need to make sure you
have all required permits and ensure the installation
complies with State and local code. We recommend
you hire a certified contractor if you do not wish to do
the installation yourself.
The natural gas pipe from your house to the
location of your barbecue island needs to be ¾” and
terminate with a shut-off valve with a ½” male fitting.
Check with a contractor or your local inspector for
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.
NG Regulator
The 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 for this appliance.
IMPORTANT: Never connect the grill to an
unregulated gas supply.
Shut-off Valve
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).
G Series Gas Grills
LTR50001050, Rev. E
www.calflamebbq.com
Gas and Electrical Supply Requirements
10
Electrical Supply Requirements
You will need a dedicated 120V 10 amp grounded
electrical service. The power supplied to your grill
enclosure must be on a dedicated circuit with no other
appliances or lights sharing the power.
You do not need to hire a contractor to install your
electrical service, but you must ensure you have
all required permits and the installation complies
with State and local code. We recommend you hire
a certified contractor if you do not wish to do the
installation yourself.
If your dealer is not a certified contractor, you will need
to hire a contractor for installation of your electrical
service.
When installed in the United States, the electrical
wiring must meet the requirements of National Electric
Code, ANSI/NFPA 70-1999 and any applicable state
or local codes. The electrical circuit must be installed
by an electrical contractor and approved by a local
building / electrical inspector.
To determine the current, voltage, and wire size
required for the island configuration to be connected,
refer to the following:
•
Wire size is determined by length of run from
breaker box to the barbecue island and maximum
current draw.
•
We recommend
insulation.
•
All wiring must be copper to ensure adequate
connections. Do not use aluminum wire.
•
When NEC requires the use of wires larger than #6
(10mm²), install a junction box near the barbecue
island and use #6 (10mm²) wire between the
junction box and the grill enclosure.
copper
wire
with
THHN
G Series Gas Grills
www.calflamebbq.com
LTR50001050, Rev. E
Installation and Connection
11
These instructions show you how to connect a grill only or a grill and side burner combination.
If you plan to convert to your grill from LP to NG, you need to do this before it is connected to a gas source.
Grill conversion instructions can be found on page 29 and ordering information can be found in this manual on
page 32. There are a few differences between connecting to LP and NG.
1.
Place the Grill and Side Burner in the Cut-outs
You will need a second
person to help you to avoid
damaging the grill or your
barbecue island.
Before installing a grill or side
burner in any island or cut out,
make sure that the opening is
not bigger than the outside
frame of the grill unit. The grill
should rest on the lip of the
frame. For drop-in accessories,
adequate cross ventilation must
be designed into enclosure
to ensure the drop-in grill or
side burner does not become
overheated.
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.
G Series Gas Grills
LTR50001050, Rev. E
www.calflamebbq.com
Installation and Connection
Connecting the Grill and Side Burner
Installation and Connection
12
2.
Connect the Gas Line to the Grill
Note: Make sure you have converted the grill for natural gas before connecting the gas line to the regulator.
See page 29 for instructions on converting the grill from LP to NG.
Connecting the grill only
If you have a grill and side burner combination, go
to step 2.2.
Slide the grill forward about six inches and connect the
gas line to the grill using the appropriate connection
for your gas type.
Liquid Propane
Natural Gas
G Series Gas Grills
www.calflamebbq.com
LTR50001050, Rev. E
13
Connect the Gas Line to the Grill and Side Burner
Two 3/8” flex lines
•
LP gas line with regulator OR
3/8” NG flex line
Connect two 3/8” flex lines to the
ends of the T connector that will
connect with the grill and side
burner. Connect either a third flex
line (if you are using NG) or a LP
gas line (if you are using LP) to
the third end of the T connector as
shown at left.
b. Connect to the grill
The gas manifold for the convection
grill can be configured for both LP
and NG. Make sure you connect
to the correct fitting depending on
your gas type. Connect to gas line
to the grill as shown in step 3.1
above.
I I I I I II
IIIII
IIIII
Connect to
side burner
3/8” flex line
Connect to
propane tank
Black LP gas line
with regulator
NG CONNECTION
1/2” to 3/8” reducer
3/8” tee adapter
Connect to grill
3/8” flex line
3/8” flex line
IIIII
3/8” flex line
IIIIIIIIIIIIIIII
•
III
IIIII
One or two 1/2” to 3/8” flare
reducers
IIIII
•
3/8” flex line
IIIII
IIIII
One 3/8” T adapter
1/2” to 3/8” reducer
3/8” tee adapter
III I I
•
Connect to grill
IIIII
a. Assemble the T Connection
Items required for connection (NOT
included with your grill):
LP CONNECTION
IIIII
Note: This is only necessary if you
have a side burner.
Connect to
side burner
Connect to
c. Connect to the side burner
NG gas source
Connect the flex line from the T
connector to the 1/2” to 3/8” flare
reducer fitting on the side burner gas line. No regulator is required for either LP or NG.
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Installation and Connection
3.
Installation and Connection
14
4.
Connect to a Gas Source
Liquid Propane Connection
Use the pressure regulator and hose assembly supplied
with the grill, or a regulator and hose assembly with
the same specifications. Replacement LP regulator and
hose must have a coupling nut that will connect to a
QCC-1 cylinder valve on one end and a female fitting
that will connect to a 3/8” tapered fitting on the grill
manifold. See the figures below.
Connect the brass fitting to the manifold behind the
grill. Do not use Teflon tape or plumber’s dope. Do NOT
remove the NG regulator from the manifold. Connect
the coupling nut to the LP cylinder valve.
When you are finished connecting to the gas source, perform a leak test.
Natural Gas Connection
Connect the gas line to the NG stub-up inside the barbecue island. When you are finished connecting to the
gas source, perform a leak test.
Leak Testing Procedure
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.
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
lighted match to test for leaks. Use a solution of
soapy water.
6. Turn all control knobs back to the full OFF
position.
1. Prepare a leak testing solution of soapy water by
mixing in a spray bottle one part liquid soap to
one part water.
2.
Shut off the gas supply to the grill and release
pressure in the hose and manifold by pushing in
and turning any of the control valves one quarter
turn counter-clockwise.
3.
On LP systems, remove the cylinder from the
grill.
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.
If you are unable to stop a leak:
1. Turn all control knobs back to the full OFF
position.
4. Call an authorized gas appliance service technician
or an LP gas dealer.
Do not use the appliance until the leak is corrected.
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.
G Series Gas Grills
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Using Your Grill
15
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 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.
•
Do not use charcoal in a gas grill or side burner.
•
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.
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.
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.
G Series Gas Grills
LTR50001050, Rev. E
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Using Your Grill
Read all instructions before you operate your grill.
Using Your Grill
16
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 Operaon
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. See
page 8 for LP connection instructions and specifications. 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.
•
When using propane gas, keep the special ventilation openings in the enclosure free and clear of
debris.
•
If connected to a propane cylinder, carefully in-
spect 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).
•
Ensure the burner flames burn evenly along both
sides of each burner with a steady flame (mostly
blue with yellow tipping). If burner flames are not
normal, check the orifice and burner for insects or
insect nests.
•
Ensure the in-line gas valve or gas cylinder valve
is always shut OFF when the barbecue is not in
use.
•
Do not operate the side burner with its cover
closed or the back burner with its cover installed.
Electronically Lighting the Burners
1. Open the hood.
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.
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.
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LTR50001050, Rev. E
17
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.
Proper Burner Flame
Flame Color and Height
The burner flame has been set in the factory and
should already be adjusted for proper height and
intensity. Periodically, you may wish to check each
burner’s flame for color, height, and intensity.
Remove the grill rack and the flame tamer over the
burner you want to inspect.
When the burner is operating properly, the flame will
appear between light to dark blue, with occasional
yellow bursts (due to impurities in propane -- this is
normal).
When the burner is set on high, the flame spread
out about ½” away from the side of the burner. (See
top figure at right.)
When the burner is set on low, the flame should be
just slightly visible when viewed from the side. (See
bottom figure at right.)
Note: Flame that is mostly yellow or golden in color
is often due to foreign matter in the burner. You
may need to clean your burners. See page 25 for
instruction on removing and cleaning your burners.
G Series Gas Grills
LTR50001050, Rev. E
www.calflamebbq.com
Using Your Grill
Manually Lighting the Burners
Using Your Grill
18
Flame Adjustment
You can adjust the flame height to be higher or lower
according to your preferences. This may be necessary
if the flame goes out on the low flame setting.
1. Light the burner and adjust the flame as low as it
can go without going out.
2. Remove the knob and insert a long flat standard
screwdriver into the hole at the lower right side of
the valve.
3. Turn the flame adjustment screw to adjust the
flame to your preference.
Gas Cylinder Orientation
LP gas cylinder must be up oriented upright during operation for proper vapor withdrawl. Operating the grill
with the cylinder on it side will allow liquid gas to flow into the regulator. Erratic gas flow will occur, resulting
in possible flare-ups or explosion.
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.
G Series Gas Grills
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Optional Grill Accessories
19
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 34.
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
Smoke Tray
Any burner can be switched to accommodate the 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.
BBQ08854P
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.
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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LTR50001050, Rev. E
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Using Your Grill
These grill accessories are optional and may be ordered directly from www.quickbbqparts.com.
Using Your Grill
20
Charcoal Tray
Use Turn part of your Cal Flame grill into a charcoal and gas grill.
Turn off the gas and wait for the grill to cool before setting the
Charcoal Tray in place.
Placement
BBQ11859
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.
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
be used with plain charcoal. Quick-light charcoal can produce excessive heat and may be
dangerous.
When the grill has cooled and the charcoals
are dead, clean the grill as described in the grill
owner’s manual.
Make sure the drip tray is in the grill before
you begin.
Keep the hood up until you are ready to cook.
1. Arrange charcoal in the tray.
2. Replace the grates.
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.
Remove ash from the Charcoal Tray immediately
after use. Do not let it accumulate. Do not use the
grill again until charcoal ash has been removed
from the Charcoal Tray and the drip tray.
Never use the Charcoal Tray over a
Sear Zone infrared burner.
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.
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LTR50001050, Rev. E
21
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 commercialsized 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
Griddle Tray
The griddle tray is an optional feature installed in Cal Flame
barbecue islands. Included with the griddle tray is an enclosure for
storage.
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.
BBQ07862P
Remove two cooking grates for the griddle space. Leave grease
in the front drain when cooking. Wait until the griddle cools down
when done cooking. Use both hands when removing the griddle
and draining the grease.
Before storing the griddle, make sure it is clean and dry. Slide the
griddle into the enclosure for safe and easy storage.
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.
G Series Gas Grills
LTR50001050, Rev. E
BBQ07891P
www.calflamebbq.com
Using Your Grill
Deep Fryer Helper Set
Cleaning and Maintenance
22
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
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.
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.
Cleaning instructions for grill interiors, including racks
and burners, are described after this section.
For light soil, use a damp sponge or cloth.
For heavier stains, use a Scotch-Brite scrubber or
similar product.
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.
2. Rinse
Thoroughly rinse all surfaces and dry them
completely with a clean towel. Do not allow
stainless steel to air dry.
3. Polish
We strongly recommend that you apply a surface
protectant to all exposed stainless steel surfaces.
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
grain until excess liquid is removed and the surface
shines. It should not be oily to the touch, however
some residue is acceptable.
Furniture polish, such as Old English, can be effective
for polishing stainless steel and protecting the
surface.
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
Caution racks, stainless steel sinks, the inside of
cabinets, warming drawers, and ovens.
!
!
NEVER spray WD-40 or Sheila Shine
near an open flame! These products
are extremely flammable while in their
Fire
Hazard aerosol forms.
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 stainproof. If not properly protected and maintained, it can
corrode, pit, and discolor.
Because salt will accelerate rust and
corrosion, grill or barbecue island
owners who live near the beach need to
be diligent in maintaining their stainless
Important
steel hardware. You need to clean and
polish your stainless steel frequently,
apply a protectant, and ensure water
does not collect and puddle.
!
G Series Gas Grills
www.calflamebbq.com
LTR50001050, Rev. E
23
methods
of
rust
removal
we
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.
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.
2. Rust removal with WD-40 or Sheila Shine:
Spray exterior stainless steel surfaces with WD-40 or
Sheila Shine and wipe down with a dry cloth or paper
towel until surface is free of rust. If there is significant
rust or corrosion, use a Scotch-Brite scrubber.
Both of these products will act as a surface protectant
and help resist smudges, stains, and rust.
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
Caution stainless steel, we do not recommend
using nitric acid.
!
Cleaning the Interior of Your Grill
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.
3. The racks, flame tamers, and flavor bars can all be
removed for cleaning and are dishwasher safe.
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.
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.
Cleaning Products and Materials
DO NOT USE these common cleaning products and
materials – they will damage the surface of your
stainless steel.
•
•
•
•
•
•
•
•
•
•
•
CLR
Lime-Away
Oven cleaner
Cleansers such as Ajax or Comet
Ammonia
Bleach
Chlorine
Steel wool pads
Wire brushes
Scrapers
Pumice
We recommend these products for cleaning your
Burners
stainless steel:
• Mild dish detergent such as Dawn
• Formula 409
• Fantastik
• Instant Rust Out (exterior ONLY)
• WD-40 (exterior ONLY)
• Sheila Shine (exterior ONLY)
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.
Baking soda, lemon oil, olive oil, vinegar, or club
soda can also be effective for cleaning light soil on
all stainless steel surfaces.
Do not use steel wool or wire brushes to
scrub your grill.
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Cleaning and Maintenance
There are two
recommend:
Cleaning and Maintenance
24
IMPORTANT: Prior to starting this procedure, turn OFF
all of the gas control knobs, shut off the fuel supply,
and disconnect the fuel line.
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.
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.
Inspect each burner for damage (cracks and holes). If
any damage is found, discontinue grill usage until you
replace the burner.
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.
!
Note
Do not use a wire brush or stainless steel
on any other part of your grill or any
other stainless steel surface except the
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
stainless steel. There are various stainless steel cleaners
available. Always use the mildest cleaning procedure
first, and always scrub in the direction of the grain.
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.
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.
If you spray the burners, ignite them and let them
burn for about 10 minutes to prevent any water from
accumulating inside them.
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.
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LTR50001050, Rev. E
25
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.
G Series Gas Grills
LTR50001050, Rev. E
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Cleaning and Maintenance
Seasonal Cleaning
Cleaning and Maintenance
26
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
Put all of the components
back as they were, as
shown in step 1.
G Series Gas Grills
www.calflamebbq.com
LTR50001050, Rev. E
Appendix
27
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.
G Series Gas Grills
LTR50001050, Rev. E
www.calflamebbq.com
Appendix
Troubleshooting
Appendix
28
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.
G Series Gas Grills
www.calflamebbq.com
LTR50001050, Rev. E
29
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). However, Cal Flame G Series grills do not include a conversion kit and it must be ordered separately.
You can find ordering information on page 32.
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 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 your grill.
Before you begin, make certain the LP gas source has been
disconnected from the grill.
To gain access to the NG regulator, tilt the grill forward.
Step 1: Attaching the regulator behind the grill
1. Remove the LP gas line and LP gas fitting from end of manifold.
2. Attach NG regulator to end of manifold.
You will need:
• Pipe wrench
• Regulator
• Pipe compound suitable
for natural gas
G Series Gas Grills
LTR50001050, Rev. E
www.calflamebbq.com
Appendix
Converting from LP to NG
Appendix
30
Step 2: Changing the burner orifices
1. Replace the main burner orifices
a. Remove the grates, flame tamers, and drip tray
from the grill. See figure below.
You will need:
• 6mm socket or nut driver
H
IDTyour
• Two to five 1.9mm orifices (dependingWon
grill
• Pipe compound suitable for natural gas
HEIGHT
Orifice
WIDTH
WIDTH
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.
Burner
Locking Pin
d. Using a 6mm socket or nut driver, remove the
orifice for the burner.
Burner
e. Apply a small amount of pipe compound to the
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.
G Series Gas Grills
www.calflamebbq.com
LTR50001050, Rev. E
31
a. Remove the grate, burner cap and burner
diffuser from the side burner.
b. Using a 7mm wrench, remove the orifice for
the burner.
c. Apply a small amount of pipe compound to
the orifice threads.
You will need:
• 7mm wrench, socket, or nut driver
• One or two 1.75mm orifices (depending on
your side burner)
• Pipe compound suitable for natural gas
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.
3. Mark the rating plate
After conversion has been completed, mark the
rating plate as NG with an indelible marker.
G Series Gas Grills
LTR50001050, Rev. E
www.calflamebbq.com
Appendix
2. Replace the side burner orifices
Appendix
32
Replacement Parts
See following page for part numbers. To order replacement parts:
•
contact an authorized selling dealer.
•
Call LMS Customer Service at (800) 225-7727.
•
Visit us at www.quickbbqparts.com.
TION
051-CC
14
589-CC
688-CC
21
2
20
9
10350
5
03000
00972
10351
4
01028
18
00659
00641
12
00512
01043
15
00658
19
16
04055
13
10
1
00662
010-CC
6
01016
7
01257
20171
8
00707
00706
3
040
015
17
11
G Series Gas Grills
www.calflamebbq.com
LTR50001050, Rev. E
33
Item No. Part
1
2
3
Control panel
Hood
Drip pan
Grill Size
Part #
3 burner
BBQ10104049-CC
4 burner
BBQ07104050
5 burner
BBQ09104051-CC
3 burner
BBQ07100587-CC
4 burner
BBQ07100588-CC
5 burner
BBQ07100589-CC
3 burner
BBQ07100686
4 burner
BBQ07100687
5 burner
BBQ07100688-CC
4
Thermometer
All
BBQ07410350
5
Flavor bar
All
BBQ04103000
6
Cal Flame logo
All
BBQ04100972
7
Bezel
All
BBQ08410351
8
2” knob
All
BBQ04101028
9
Grates
10
11
12
13
All
BBQ04100659
3 burner
BBQ07100683
4 burner
BBQ07100639
5 burner
BBQ07100641
3 burner
BBQ08000510
4 burner
BBQ08000511
5 burner
BBQ08000512
Regulator (LP)
All
BBQ04101043
Regulator (NG)
All
BBQ04103040
3 burner
BBQ08100656-CC
4 burner
BBQ01000657-CC
5 burner
BBQ08100658
3 burner
BBQ07104053
4 burner
BBQ07104054
Handle
Manifold
Warming rack
14
Back panel
5 burner
BBQ07104055
15
Burner
All
BBQ07100662
16
Flame tamer
All
BBQ04103010-CC
Main burner valve (LP)
All
BBQ04101016
Main burner valve (NG)
All
BBQ04101015
Hood hinge
All
BBQ04101257
3 burner
BBQ07220172
4 burner
BBQ07220170
5 burner
BBQ07220171
17
18
19
Heat shield panel
20
Warming rack bracket, right side
All
BBQ04100707
21
Warming rack bracket, left side
All
BBQ04100706
--
Grill cover (not shown in drawing)
All -- one size fits all
BBQC2345GB
--
Gas conversion kit (LP to NG)
All
BBQ07101045
Appendix
All parts can be used on all three grill sizes except where described below.
G Series Gas Grills
LTR50001050, Rev. E
www.calflamebbq.com
Appendix
34
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.
8. Adjust the Sear Zone burner, make sure the
burner is aligned and in position.
9. Install the locking pin. Through the access door
underneath the grill, find the stud to lock the
burner in place, install the locking pin. Make sure
the locking pin is secured correctly.
10. Repeat steps 2 through 9 if you want to replace
other burners.
11. Put back the grate you just removed. (You don’t
need flame tamers for Sear Zone burners.)
12. Reconnect or turn on the gas line.
If you want to change Sear Zone burners to regular
burners, just follow the above procedure above in a
similar way.
G Series Gas Grills
www.calflamebbq.com
LTR50001050, Rev. E
35
This Limited Warranty is extended to the original purchaser of a Cal Flame G Series grill manufactured after
January 1, 2014 and installed for residential use in the United States and Canada.
R
E D WA R R A N
TY
YEAR
UCTUR
LI
MIT
10 Year Structure
Cal Flame grill structure or frame housing is warranted against rust-through, due to defects
in material or workmanship in normal household use for ten years from the original date of
purchase.
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3 Year Flame Tamers and Warming Rack
Cal Flame tamers and warming rack are warranted against rust-through and operation failure,
due to defects in material or workmanship in normal household use for three years from the
original date of purchase.
1 Year Porcelein Coated Burners
Cal Flame porcelein coated burners are warranted against rust-through and operation failure,
due to defects in material or workmanship in normal household use for ten years from the
original date of purchase.
1 Year Gas Valves and Other Components
Cal Flame gas valves and other components detailed in the Cal Flame grill owners manual,
specifically on the Cal Flame parts list page, are warranted against operation failure due to
defects in material or workmanship in normal household use for one year from the original date
of purchase.
Genuine Cal Flame Parts & Accessories
This Limited Warranty is void if Cal Flame (the
“Manufacturer”) or its designated representative
determines that the grill has been subjected to damage
or failure due to installation of aftermarket parts
that are not genuine Cal Flame branded parts and
accessories. This disclaimer includes, but is not limited
to gas valves and gas nozzles. Genuine Cal Flame
brand parts and accessories are built to our highest
standards of quality, durability and performance, and
they are designed to work with your grill to ensure
optimal performance and function.
Performance
In the event of a defect covered by this Limited
Warranty, notify your Cal Flame dealer or Cal Flame
as soon as possible and use all reasonable means to
protect the grill from further damage. Upon a receipt
of a valid form of proof of purchase, a designated
service representative will correct the defect, subject
to the terms and conditions contained in this Limited
Warranty. There will be no charge for parts, although
providing access to affect the repair is your responsibility
as the grill owner. Freight charges for replacement
parts, labor and labor related trip charges necessary
to repair the grill are also the responsibility of the grill
owner. If the Manufacturer determines that repair of
the covered defect is not feasible, it reserves the right
to provide replacement grill instead. In such an event,
reasonable costs for removal of the original grill,
shipping costs from the factory for the replacement
grill and delivery and installation of the replacement
will be your responsibility as the grill owner. Any
replacement parts and or grill will carry the balance of
the original grill warranty. Grill covers are not included.
This warranty ends either by specified time frame
listed above, owner-transfer, relocation, commercial
installation or installation of any component other
than by manufacturer.
Warranty Limitations
This Limited Warranty is void if Cal Flame or its
designated representative determines that the grill
has been subjected to alteration, neglect, misuse or
abuse, or freight damage caused by the common
carrier; any repairs or fuel conversion have been
G Series Gas Grills
LTR50001050, Rev. E
www.calflamebbq.com
Appendix
Limited Warranty
Appendix
36
attempted by anyone other than a designated
representative; or if the failure is caused by accident,
acts of God or other causes beyond the control of the
Manufacturer. Neglect, misuse and abuse include any
installation, operation or maintenance of the grill other
than in accordance with the instructions contained in
the owner’s manual provided with the grill. Corrosion,
scratching and discoloration due to improper use and
care of this outdoor product, is excluded from this
warranty. This warranty does not cover the stainless
steel grates.
Limitations
The Manufacturer disclaims all warranties, expressed or
implied, in fact or in law, to the extent allowed by your
State’s Law, including the warranty of merchantability
and fitness for use, except as stated specifically
herein. All warranty service must be performed by the
Manufacturer or its designated representative using
authorized Cal Flame parts.
No agent, dealer, distributor, Service Company
or other party is authorized to change, modify or
extend the terms of this limited warranty in any
manner whatsoever. The Manufacturer will not be
responsible for any statements or representations
made in any form that go beyond, are broader than,
or are inconsistent with any authorized literature or
specifications furnished by Cal Flame.
Disclaimers
The Manufacturer and its representatives shall not
be liable for any injury, loss, cost or other damage,
whether incidental or consequential, arising out of
any defect covered by this limited warranty, including
without limitation, loss of use of the grill and cost for
removal of defective product even if the Manufacturer
was advised of the possibility of damage. The liability
of the Manufacturer under this limited warranty, if
any, shall not exceed the original amount paid for the
defective product. Coverage under this limited warranty
shall commence as of the original date of purchase
and the duration of such coverage shall not extend
for any reason whatsoever beyond the stated time
periods. These disclaimers shall be equally applicable
to any service provided by the Manufacturer and its
designated representatives.
Legal Rights
This Limited Warranty gives you specific legal rights.
You may also have other rights that vary from state
to state. Some states do not allow limitations on how
long an implied warranty lasts, so this limitation may
not apply to you.
G Series Gas Grills
www.calflamebbq.com
LTR50001050, Rev. E
37
Appendix
G Series Gas Grills
LTR50001050, Rev. E
www.calflamebbq.com
Locating the product serial number
The serial number of your Cal Flame grill is located on the
back and is visible when the hood is down. 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
www.calflamebbq.com.
www.calflamebbq.com
1462 East Ninth Street
Pomona, CA 91766.
Toll Free: 1-800-225-7727
Fax: 1-909-629-3890
LTR50001050, Rev. E
12/22/14
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