LTR50001050, Rev.
WARNING If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. Do not store an LP cylinder not connected for use in the vicinity of this or any other appliance. A fire resulting in serious injury or death may occur.
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.
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.
Built-in Construction 3 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 . We strongly recommend that grill owners hire a contractor to construct the built-in enclosure.
WIDTH Built-in Construction Minimum Clearance DEPTH 4 HEIGHT Built-in Dimensions 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.
DEPTH 5 HEIGHT Built-in Construction Minimum Clearance WIDTH WIDTH The dimensions shown below are for Cal Flame appliances only.
Built-in Construction 6 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.
3/8" Fittings To Propane Tank B Then take other end of "T" adapter with hose attached and connect to end of male located underneath and at the back of the grill. (Use gas rated tape seal on all connections). 7 Connect the last open line to the side burner C (Use gas rated tape seal on all connections) Built-in Construction NOTE: You will need to use a gas rated sealer on gas connectors that are not flared. Plumbing for Side Burners 1.
Installation and Connection 8 Installation and Connection 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 . 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.
9 Installation and Connection Cylinder Specification Any LP gas supply cylinder used with this grill must be approximately 12 inches in diameter and 18 inches high. 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. The maximum fuel capacity is 20 lbs.
Installation and Connection 10 Natural Gas Converting Gas Grills IMPORTANT: Cal Flame G Series gas 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 .
11 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.
Using Your Grill 12 Using Your Grill Read all instructions before you operate your grill . We recommend you wash your entire grill with soap and water prior to lighting it for the first time. Oils are used during the manufacturing process and some residual oil may still be on the stainless steel parts of your grill. Washing will reduce the possibility of discoloration. We also recommend you keep your grill covered when not in use.
13 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.
Using Your Grill 14 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.
15 Using Your Grill 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.
Using Your Grill 16 Optional Grill Accessories These grill accessories are optional and may be ordered directly from www.quickbbqparts.com. 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 31.
17 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.
Using Your Grill 18 Deep Fryer Helper Set The Deep Fryer Helper can turn part of your grill into a deep frying station. It is designed to fit in any Cal Flame grill. The Deep Fryer Helper Set is shipped with its own instructions for placement and use . Read them carefully before use . The Deep Fryer Helper Set comes with two commercialsized fryer baskets, a built-in thermometer, and storage hangers allow baskets to be stored within unit.
Cleaning and Maintenance 19 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.
Cleaning and Maintenance 20 There are two recommend: 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 .
21 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.
Cleaning and Maintenance 22 Seasonal Cleaning If you haven’t used your grill in a few months, we recommend that you clean the burners and the interior of your grill. Cleaning the burners periodically will keep them burning evenly and cleanly and help prevent “flashback”, a type of fire in and around the gas tubes. This happens when spiders and small insects inhabit or make nests in the burner tubes, obstructing the gas flow.
23 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 .
Appendix 24 Appendix Troubleshooting Problem: Smell of gas is present Solution: Check for loose connections in the gas line. Perform a leak test following the procedure described in this manual. Problem: Burner does not ignite Solution: Note: Turn off the gas at the source while troubleshooting. Use the following procedure with the figure below. Check the position of the sparker tip. It should be pointing forward towards the front of the burner.
25 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.
Appendix 26 Converting from LP to NG WARNING! You must have an authorized service technician perform this procedure . If these instructions are not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life . 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).
27 You will need: 1 . Replace the main burner orifices • • a. Remove the grates, flame tamers, and drip tray from the grill. See figure below. • 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.
Appendix 28 2 . Replace the side burner orifices a. Remove the grate, burner cap and burner diffuser from the side burner. You will need: b. Using a 7mm wrench, remove the orifice for the burner. • • c. • Apply a small amount of pipe compound to the orifice threads. 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.
29 Appendix 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 C 14 C C 21 2 20 9 5 4 18 12 15 13 19 16 10 1 C 6 7 8 3 17 11 G Series Gas Grills LTR50001050, Rev. D www.calflamebbq.
Appendix 30 All parts can be used on all three grill sizes except where described below. Item No .
31 Appendix 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.
Appendix 32 Limited Warranty 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.
33 Appendix Disclaimers 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.
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.
