LTR20071038, Rev.
This manual applies to the following grill carts and drop-in grills: Grill Carts CR1000 Single burner cart CR2000 Two burner cart CR3000 Three burner cart CR3000S Three burner cart with side burner CR4000 Four burner cart CR4000C Four burner cart with convection CR4000S Four burner cart with side burner CR4000SC Four burner cart with side burner and convection CR5000DS Five burner cart with double side burners Drop-In Grills BBQ07872 2 Burner Grill BBQ07873 3 Burner Grill BBQ07874 4 B
Table of Contents Read all instructions before you operate your grill. WARNING If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. Safety Instructions . . . . . . . . . . . . . . . . . . . 2 Installation / Assembly . . . . . . . . . . . . . . . .
Safety Instructions Safety Instructions WARNING: Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Read the installation, operating and maintenance instructions thoroughly before installing or servicing this equipment. dedicated 15A GFCI breaker in accordance with local codes or the National Electrical Code, ANSI / NFPA 70, or the Canadian Electrical Code, CSA C22.1.
Safety Instructions blocked. Fresh air must be able to pass though installed vents to safeguard against residual gas accumulation. Failure to allow proper ventilation may cause fire or explosion. • Do not heat any unopened glass or metal container of food on the grill. Pressure may build up and cause the container to burst, possibly resulting in serious personal injury or damage to the grill.
Installation / Assembly Installation / Assembly Most cities and counties require permits for exterior construction and electrical circuits. In addition, some communities have codes requiring residential barriers such as fencing and/or self-closing gates on property to prevent unsupervised access to the property by children under the age of five. Your dealer can provide information on which permits may be required and how to obtain them prior to the delivery of your equipment.
Installation / Assembly Model Number Description Width Depth Height BBQ07852P BBQ07845P BBQ07953P Drop In Standard Side Burner 17 ¾” 14 ½” 19 ¾” 2 ¾” Standard Side by Side Burner 11 ½” 14 ½” 24 ¼” Model Number Description Width Depth Height BBQ07874-F1 4 Burner Flat Drop In Grill 37 ¾” 22 ¾” 8 ¾” B 1 ¾” C 5” D 6 ½” Width 10 ¾” 10 ¾” 13 ½” 28 ¾” 13 ½” Depth 19 ¾” 20” 19” 20 ½” 19 ½” Height 17 ¼” 17 ¼” 2 ½” 10” 3” BBQ0704103031 Model Number BBQ07868P BBQ07869P BBQ07862P BBQ07889P B
Installation / Assembly Model Number BBQ07863P BBQ07857P Description 3 Pull Out Drawer, SS Refr.
Installation / Assembly Gas Requirements and Connection IMPORTANT: Cal Flame™ grills are manufactured to operate on either liquid propane (LP) or natural gas (NG) and cannot be converted. To verify the grill’s operating fuel, check the serial number label in the back of the chassis as you are looking at the grill from the front. Either LP or NG will be marked on the operating tab, indicating the proper operating fuel.
Installation / Assembly LP Gas Tank Requirements For plumbed-in LP installation, use a convertible regulator and set it for LP gas. Maximum line pressure for plumbedin 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.
Installation / Assembly Natural Gas Requirements Always check the rating plate to make sure the gas supply you are hooking up to is the gas type the grill is manufactured for. IMPORTANT: Never connect the grill to an unregulated gas supply. 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.
Installation / Assembly Installing and Replacing Infrared Burners 3. Through the access door underneath the grill, find the round stud and locking pin that locks the burner you want to replace. 1. Disconnect or shut off the liquid propane or natural 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. 4. Carefully remove the locking pin with your fingers. 5.
Installation / Assembly Installing the Transformer All grills with electrical components such as lights or a convection fan will require the transformer to be installed and plugged in before you can use it. This needs to be done before the grill is inserted in the island or modular cart. When the transformer is attached to the grill chassis, use care in placing the grill in the island cutout to avoid hitting the transformer. 1. Remove the transformer and the metal screws from the plastic bag. 2.
Installation / Assembly Installing Grills in Modular Carts Installing Grills in Barbecue Islands You will need a second person to help you to avoid damaging the grill, the transformer, or your barbecue island. Keep fingers away from where the grill will be supported on the cart. Your fingers could become trapped and serious injury could occur. You will need a second person to help you to avoid damaging the grill, the transformer, or your barbecue island. 1.
Installation / Assembly Installing Barbecue Cart End Shelves 1. Prepare the installation of handle: 2 hex screws, 2 washers 2. Use finger to thread the hex screws and washers into the threads on both ends of the handle. 6. Slides the shelf into the brackets from bottom. 7. Make sure to slide into the brackets on both side evenly. 8. Slide the shelf fully onto the mounting brackets. 3. Use ratchet to tighten the hex screws on both ends. The handle has been installed onto the shelf. 9.
Installation / Assembly Installing Side Burners 3. Connect the flexible hose (male end) to the pipe tee. 1. Assemble a 3/8” pipe nipple to the 3/8” pipe tee using Teflon tape or pipe sealant. Use only sealant that is approved for use on LP gas. 4. Install and secure the side burner into the island by simply setting it in place. 2. Install the pipe tee assembly to the grill intake pipe. Tighten assembly and align the branch opening of the tee with the hole of the cabinet. 5.
Operating Your Barbecue Operating Your Barbecue Read all instructions before you operate your grill. We recommend you wash your entire grill with soap and water prior to lighting it for the first time. Oils are used during the manufacturing process and some residual oil may still be on the stainless steel parts of your grill. Washing will reduce the possibility of discoloration. We also recommend you keep your grill covered when not in use.
Operating Your Barbecue Lighting the Grill Each time you light the grill, check the following: • • Inspect the hose before using the grill. If there is excessive abrasion or wear, or if the hose is cut, it must be replaced prior to using the grill. If you need a replacement hose, contact your Cal Flame dealer. Ensure the area around the barbecue is clear of flammable substances such as gasoline, yard debris, wood, etc.
Operating Your Barbecue Basic Grill Operation Before lighting, make sure all burner controls are off. Do not attempt to light the burners if the smell of gas is present. Check the connection with a soap and water solution after attaching the hose. For LP units, make sure there is gas in the tank and it is sitting upright. For natural gas units, make sure the shut off valve is on. 3. Turn the control knob to HIGH and preheat the grill for 15 minutes. Close the top cover during the appliance preheat period.
Operating Your Barbecue Cooking with a Convection Grill A convection grill has an internal fan that circulates heated air evenly throughout the grilling area when the hood is closed. Cooking in this way distributes heat more efficiently so you no longer have to be concerned with “hot spots” on the grill where food tends to burn. The fan switch is located at the far left of the front panel of the grill. EXHAUST VENTS HEAT THAT IS DRAWN IN FROM THE BACK.
Operating Your Barbecue Charcoal Grill Lighting Instructions NEVER use flammable materials and fluids such as gasoline, kerosene, butane or propane, diesel fuel, or alcohol to light or re-light fires. Keep the grill away from such substances when lit. Use high quality hardwood charcoal to ensure a good flame. Charcoal briquettes made from maple, oak, birch, or elm woods will burn cleanly, minimizing smoke and unpleasant odors. 1. Open the hood and remove cooking grates. 2.
Operating Your Barbecue Griddle 30” Warming Drawer When sliding the griddle out of the enclosure, always do it slowly as the heavy weight may cause you to suddenly drop the griddle. Lift the griddle out of the enclosure instead of sliding it all the way out. Preheating Instructions 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.
Operating Your Barbecue High 210ºF – 230ºF Medium 190ºF – 210ºF Low 175ºF – 190ºF • If you use the tray, preheat it while preheating the warming drawer. • Preheat any empty serving dishes to be used while preheating the drawer. • Add cooked, hot food in its cooking container or heat a safe container. • You may use aluminum foil to cover food containers. Safety Practice & Precautions • As with any cooking or heating appliance, never leave the warming drawer unattended when warming food.
Cleaning and Maintenance 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 or cart clear and free from combustible materials, gasoline, and other flammable vapors and liquids. Do not obstruct the flow of combustion and ventilation air.
Cleaning and Maintenance Island Cabinets Be sure to unplug the electrical supply before cleaning any part of your Cal Flame barbecue. Spray cabinet area with a soap and water solution. Rinse with a gentle stream of fresh water. 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.
Cleaning and Maintenance • Use only clean sponges, soft cloths, paper towels, plastic or non-metal soap pads for cleaning or scouring, as recommended in this section. • Be sure to rinse thoroughly and to wipe dry to avoid watermarks. Drawer Clean the drawer with warm soapy water. Drawer Front Clean same as drawer. Gasket Clean with warm soapy water. Knobs The ON/OFF temperature knob may be removed for cleaning. Drawer Cavity Same as drawer above.
Appendix Troubleshooting Appendix Problem: Smell of gas is present Solution: Check for loose connections in the gas line. Perform a leak test following the procedure described in this manual. Problem Burner does not ignite Solution Use the following procedure with the figure below. Check the position of the sparker tip. It should be pointing forward towards the front of the burner. • Make sure there is a blue spark at the electrode tip to the burner.
Appendix Problem: Plugged orifice Solution: Unplug the orifice as follows: • Remove cooking grills, flame tamer and grease tray. • Remove burners from the bottom of the firebox by pulling the cotter pin from beneath the burner peg using a standard screwdriver or needle nose pliers. • Carefully lift each burner up and away from the gas orifice. • Remove the orifice from the control valve. • Gently clear any obstruction with a fine wire.
Appendix Replacement Covers Cal Flame Drop-Ins BBQ010 COVER, GRILL, SMALL, 3 BURNER BBQ011 COVER, GRILL, MEDIUM, 4 BURNER BBQ012 COVER, GRILL, LARGE, 5 BURNER BBQ013 COVER, SIDE BURNER, SINGLE & DOUBLE Cal Flame Carts BBQ835CR4 BARBECUE CART COVER, 4 BURNER, BLACK BBQ835CR5 BARBECUE CART COVER, 3 & 5 BURNER, BLACK Location of Serial Number Plate The serial number of your Cal Flame grill is located on the back and is visible when the hood is down as shown below.
Page 28 2007 Barbecue Grill and Cart Owner’s Manual LTR20071038, Rev.
Warranty Information 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. Warranty Limitations • 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 this Owner’s Manual.
