Cal Flame CR4000, CR4000C, CR4000SC, CR5000DS, CR1000 Owner's Manual
...
LTR20071038, Rev. B
1/4/07
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 Burner Grill
BBQ07874C 4 Burner Convection Grill
BBQ07875 5 Burner Grill
BBQ07875C 5 Burner Convection Grill
BBQ07870 Charcoal Grill
BBQ07898 Deluxe Single Side Burner
BBQ07899 Deluxe Double Side Burner
BBQ07874F 4 Burner Flat Drop In Grill
BBQ07852 Drop In Standard Side Burner
BBQ07953 Standard Side-by-Side Burner
BBQ07954 Deluxe Side-by-Side Burner
Copyright 2006-2007 California Acrylic Industries, Inc.
All rights reserved. Duplication without written consent is
strictly prohibited.
Cal Spas™ and Cal Flame™ are registered trademarks.
Due to continuous improvement programs, all models,
operation, and/or specications are subject to change
without prior notice.
LTR20071038, Rev. B
1/4/07
CONTACT INFORMATION
For customer service, please contact your authorized
dealer immediately. If you need additional information
and/or assistance, please contact:
C.A.I. Customer Service Department
1462 East Ninth Street
Pomona, CA 91766.
Toll Free: 1-800-CAL-SPAS
Fax: 1-909-629-3890
Table of Contents
Read all instructions before
you operate your grill.
WARNING
If the information in this manual is not
followed exactly, a re or explosion may
result causing property damage, personal
injury or loss of life.
Do not store or use gasoline or other
ammable vapors and liquids in the
vicinity of this or any other appliance.
Do not store an LP cylinder not connected
for use in the vicintiy of this or any other
appliance. A re resulting in serious injury
or death may occur.
If you are installing a natural gas grill,
you are responsible for ensuring that the
natural gas line installed is safe to use.
California Acrylics Industries (C.A.I.) will
not be held responsible for an improperly
installed gas line.
DANGER
What To Do If You Smell Gas
Shut off gas to the appliance.
•
Extinguish any open ame.
•
Open lid.
•
If odor continues, keep away from the
•
appliance and immediately call your
gas supplier or your re department.
Save these instructions!
Safety Instructions. . . . . . . . . . . . . . . . . . . 2
Installation / Assembly. . . . . . . . . . . . . . . . 4
Cabinet Cut-out Dimensions. . . . . . . . . . . . . . . .4
Gas Requirements and Connection. . . . . . . . . .7
Leak Testing Procedure. . . . . . . . . . . . . . . . . . . .7
LP Gas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Natural Gas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Installing and Replacing Infrared Burners . . .10
Installing the Transformer. . . . . . . . . . . . . . . . .11
Installing Grills in Modular Carts . . . . . . . . . . .12
Installing Grills in Barbecue Islands . . . . . . . .12
Installing Barbecue Cart End Shelves. . . . . . .13
Installing the Rotisserie . . . . . . . . . . . . . . . . . .13
Installing Side Burners . . . . . . . . . . . . . . . . . . .14
Operating Your Barbecue . . . . . . . . . . . . 15
Grill Controls . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Lighting the Grill . . . . . . . . . . . . . . . . . . . . . . . .16
Basic Grill Operation . . . . . . . . . . . . . . . . . . . . .17
Cooking with the Rotisserie . . . . . . . . . . . . . . .17
Cooking with a Convection Grill. . . . . . . . . . . .18
Charcoal Grill . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Turning on and off the Lights and Fan. . . . . . .19
Griddle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Drop-In Food Warmer . . . . . . . . . . . . . . . . . . . .20
30” Warming Drawer . . . . . . . . . . . . . . . . . . . . .20
Cleaning and Maintenance . . . . . . . . . . . 22
Drip Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Care of Stainless Steel . . . . . . . . . . . . . . . . . . .22
Covering Your Cart or Grill . . . . . . . . . . . . . . . .22
After Use Care . . . . . . . . . . . . . . . . . . . . . . . . . .22
Griddle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Charcoal Grill . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Drop-in Food Warmer. . . . . . . . . . . . . . . . . . . .23
30” Food Warmer. . . . . . . . . . . . . . . . . . . . . . . .23
Light Bulb Replacement . . . . . . . . . . . . . . . . . .24
Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . 25
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . .25
Replacement Covers . . . . . . . . . . . . . . . . . . . . .27
Location of Serial Number Plate. . . . . . . . . . . .27
Warranty Information. . . . . . . . . . . . . . . . . . . . .30
2007 Barbecue Grill and Cart Owner’s Manual Page 1
LTR20071038, Rev. B
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.
Placement and Location
Cal Flame™ grills and carts are designed for
•
outdoor use only.
Never locate this appliance in an enclosed room,
•
under a sealed overhead structure, or in any
type of enclosed area such as a garage, shed, or
breezeway. Keep clear of trees and shrubs.
Do not place this grill under or near windows or
•
vents that can be opened into your home.
Cal Flame™ grills are not intended for installation
•
in or on recreational vehicles or boats.
Maintain sufcient distance as to not overheat any
•
overhead combustible material such as a patio
cover.
The area surrounding your new grill should be
•
kept clean and free from ammable liquids and
other combustible materials such as mops, rags or
brooms, as well as solvents, cleaning uids, and
gasoline.
Do not use the grill, grill cabinet, or area
•
surrounding the grill as a storage area for
ammable 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 the
grill and is visible when the hood is lowered or on
the right side of the chassis. There is an area on
the back cover of this manual where you can write
down this information.
We recommend that a licensed contractor install
•
your Cal Flame™ grill. Installation must conform to
local codes, or in the absence of local codes, with
either the National Fuel Gas Code, ANSI Z223.1
/ NFPA54, Natural Gas and Propane Installation
Code, CSA B149.1, or Propane Storage and
Handling Code, B149.2), as applicable.
Your Cal Flame™ grill or cart must be plugged
•
into a permanent, grounded 110V outlet with a
dedicated 15A GFCI breaker in accordance with
local codes or the National Electrical Code, ANSI
/ NFPA 70, or the Canadian Electrical Code, CSA
C22.1.
Do not use an extension cord to supply power to
•
your Cal Flame™ grill or cart. Such use may result
in re, electrical shock or other personal injury. Do
not install a fuse in the neutral or ground circuit.
A fuse in the neutral or ground circuit may result
in an electrical shock hazard. Do not ground this
appliance to a gas supply pipe or hot water pipe.
Keep any electrical supply cords and the fuel
supply hose away from any heated surfaces.
To prevent re and smoke damage, remove all
•
packaging material before operating grill.
Before you start cooking, clean the entire grill
•
thoroughly with hot, soapy water. This is necessary
to remove residual solvents, oil and grease used in
the manufacturing process. The grates should also
be thoroughly cleaned in the same manner.
Operation
Do not use grill for other than intended use.
•
In the event that a burner goes out, turn burner
•
knobs to the full OFF position, fully open the grill
hood and let it air out. Do not attempt to use the
grill until the gas has had time to dissipate.
Never use the grill if the drip pan is not properly
•
installed. Drip pan should be pushed all the way
to the rack located just under the grill. Fire or
explosion can result from an improperly installed
drip pan.
Keep all electrical supply cords and the rotisserie
•
motor cord away from the heated areas of the grill.
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
specied clearances listed in this manual.
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
Page 2 2007 Barbecue Grill and Cart Owner’s Manual
LTR20071038, Rev. B
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 re or explosion.
When handling LP gas line and connectors, do
•
not allow them to come in contact with any metal
surfaces of the cart or cabinet. Do not drop LP
connectors.
Do not use fuel such as charcoal briquettes in
•
electric or 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, re 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 at 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 ame. This can scorch utensils and hamper
cleanup. Excessive ames 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
ammable materials, and spillage due to accidental
contact with the utensils.
Do not use water on grease res. Never pick up a
•
aming pan. Turn the appliance off and smother the
aming pan with a tight-tting lid, a cookie sheet or
a at tray. For aming grease outside of the pan,
smother it with baking soda or use a dry chemical
or foam-type re extinguisher.
Never allow clothing, pot holders or other
•
ammable materials come in contact with or be
close to any grate, burner or hot surface until it has
fully cooled. Never wear loose tting 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 airow to the burner
ports. This creates a dangerous condition that
can result in a re behind the valve panel. Inspect
and clean the burners periodically and follow
the guidelines in the Cleaning and Maintenance
section of this manual.
Unless specically recommended in this manual,
•
do not repair or replace any part of the grill. A
qualied technician should perform all service. Any
repairs made by a non- C.A.I. 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 or cart 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 or cart.
Never allow children to sit or stand on any part of
•
the grill or cart.
Carts
Do not attempt to move the stainless steel cart
•
while it is hot or in use.
It is extremely important to lock all caster wheels
•
even on at surfaces.
Do not lean, sit or stand on the stainless steel cart,
•
including the foldout work surfaces.
Do not exceed 50 pounds of weight on the foldout
•
work surfaces.
2007 Barbecue Grill and Cart Owner’s Manual Page 3
LTR20071038, Rev. B
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 ve. Your dealer can provide
information on which permits may be required and how
to obtain them prior to the delivery of your equipment.
We recommend the installation, adjustment and service
of your new grill be performed by C.A.I. qualied
installers and service technicians to ensure proper
operation and prevent accidents.
When planning your Cal Flame™ grill or cart location,
access to gas lines and 110V power supplies should
be considered. The location with the shortest gas
line run is recommended. A grounded, dedicated,
15A, 110V, GFCI power source is required 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 trafc paths,
and windows that open into the home.
Locate barbecue grills and stainless steel carts only in
well-ventilated areas and only on solid, at foundations
(e.g. deck or cement slab). Do NOT place stainless
steel carts on dirt or grass.
Cabinet Cut-out Dimensions
Your Cal Flame™ grill is designed for easy installation
into a non-combustible enclosure. The supporting deck
or counter must be at and level. When determining the
nal location of your grill, adequate cross ventilation
must be present to prevent gas from being trapped in
the event of a leak.
The drawings below show the different types of cabinet
cut-out dimensions for gas grills and accessories.
Model Number Description Width Depth Height
BBQ07870P / CP Charcoal Grill 30 ¾” 22 ¼” 9 ¼”
BBQ07872-1P 2 Burner Grill 23 ¼” 22 ¼” 9 ¼”
BBQ873 3 Burner Grill 23 ¼” 22 ¼” 9 ¼”
BBQ07874-1P 4 Burner Grill 30 ¾” 22 ¼” 9 ¼”
BBQ07875-1P 5 Burner Grill 38 ¼” 22 ¼” 9 ¼”
BBQ07875SP 5 Burner SmartControl Grill 38 ¼” 22 ¼” Center
open
BBQ07898P Deluxe Single Side Burner 12 1/8” 21 ¾” 7 ¼”
BBQ07899P Deluxe Double Side Burner 12 3/8” 21 ¾” 7 ¼”
BBQ07954 Deluxe Side by Side Burner 25 ¼” 13 ¼” 7 ¼”
BBQ07864P Ice Chest 31” 22 ½” 8 ¾”
BBQ07888P Food Warmer 12 ½” 20 ½” 7”
BBQ07842P-12 12” Cocktail Center 12 ¼” 21 ¾” 7”
BBQ07842P-18 18” Cocktail Center 17 ½” 24 3/8” 10”
BBQ07902 30” Drop-in Bar Center 28 ¾” 22 ¾” 12”
BBQ07903 Standard Blender 16 ½” 24 3/4” 11 ¼”
BBQ07877P Pizza Oven 17 1/2” 23 ¼” 9 1/2”
Cut-out for barbecues, side burners and
slide-in accessories
Page 4 2007 Barbecue Grill and Cart Owner’s Manual
LTR20071038, Rev. B
Installation / Assembly
Model Number Description Width Depth Height Cut-out for drop in accessories
BBQ07852P
BBQ07845P Drop In Sink 14 ½” 14 ½”
BBQ07953P
Model Number Description Width Depth Height Cut-out for at drop-in grill and drip tray
BBQ07874-F1 4 Burner Flat Drop In Grill 37 ¾” 22 ¾” 8 ¾”
BBQ0704103031 Drip tray cut-out 21 ¾” 1 ¾” 5” 6 ½”
Drop In Standard Side Burner
Standard Side by Side Burner
A B C D
11 ½” 17 ¾” 2 ¾”
24 ¼” 19 ¾” 4 ¼”
Model Number Description Width Depth Height Cut-out for drawers
BBQ07868P 2 Drawer Storage 10 ¾” 19 ¾” 17 ¼”
BBQ07869P 3 Drawer Storage 10 ¾” 20” 17 ¼”
BBQ07862P Griddle and Griddle Storage 13 ½” 19” 2 ½”
BBQ07889P 30” Warming Drawer 28 ¾” 20 ½” 10”
BBQ07891P Cutting Board and Drawer 13 ½” 19 ½” 3”
2007 Barbecue Grill and Cart Owner’s Manual Page 5
LTR20071038, Rev. B
Installation / Assembly
Model Number Description Width Depth Height
BBQ07863P 3 Pull Out Drawer, SS Refr. 25” 22 7/8” 32 ¼”
BBQ07857P Propane Tank Compartment 14 ¾” 16 ¼” 20 ½”
BBQ07839P-18 Single Access Door 16 ½” 2 ¾” 19”
BBQ07839P-30 Double Access Door 28 ¾” 2 ¾” 19”
BBQ07840P-18
BBQ07840P-30
BBQ07909 Complete Utility Storage Kit 51 ½” 20 ½” 19 ½”
BBQ07910 Paper Towel Storage 8 ¾” 6 ½” 14 ¾”
Cut-out dimensions for the following products are measured to include the
frame.
BBQ07843P Beer Tap Refrigerator 21 ¼” 22” 34 ¼”
BBQ07847P Stainless Refrigertor 21 ¼” 22” 34 ¼”
BBQ07848P
BBQ07908 Ice Maker 15 ¼” 23 ¾” 34 ¼
18” Door and Drawer Combo
30” Door and Drawer Combo
Deluxe Refrigerator, Glass door
17” 20 ¼” 19 ¼”
28 ¾” 20 ¼” 19 ½”
25 ¼” 22” 34 ¼”
Cut-out for refrigerators, cocktail centers
and access doors
Page 6 2007 Barbecue Grill and Cart Owner’s Manual
LTR20071038, Rev. B
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. Attempting to convert Cal Flame™ grills from one fuel to another may
result in serious injury and will void the warranty coverage.
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.
If you do not have an updated ller valve on your existing propane tank, you will need to purchase one at your
local hardware store. Without it you will not be able to attach your tank to your Cal Flame™ grill or rell the
tank at your local propane rell station.
Apply the leak-testing solution by spraying it
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.
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 ame, such as a
lighted match to test for leaks. Use a solution of soapy
water.
Prepare a leak testing solution of soapy water by
1.
mixing in a spray bottle one part liquid soap to
one part water.
Make sure all the control knobs are in the OFF
2.
position.
Turn on the gas.
3.
On natural gas systems, turn the main feed
a.
valve to the grill.
On LP systems, turn the cylinder valve knob
b.
counter clockwise one turn to open.
4.
on joints of the gas delivery system. Blowing
bubbles in the soap solution indicates that a leak
is present.
Stop a leak by tightening the loose joint or by
5.
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.
Turn all control knobs back to the full OFF
6.
position.
If you are unable to stop a leak:
Turn all control knobs back to the full OFF
1.
position.
Shut off the gas supply to the grill and release
2.
pressure in the hose and manifold by pushing in
and turning any of the control valves one quarter
turn counter-clockwise.
On LP systems, remove the cylinder from the
3.
grill.
Call an authorized gas appliance service
4.
technician or an LP gas dealer.
Do not use the appliance until the leak is corrected.
2007 Barbecue Grill and Cart Owner’s Manual Page 7
LTR20071038, Rev. B
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 orices
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 Specication
Any LP gas supply cylinder used with this grill must be:
Constructed and marked in accordance with the
•
Specications for LP-Gas Cylinders of the U.S.
Department of Transportation or the National
Standard of Canada, CAN/CSA-B339, Cylinders,
Spheres and Tubes for Transportation of
Dangerous Goods; and Commission, as applicable.
Approximately 12 inches in diameter and 18 inches
•
high.
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 ll the
cylinder beyond 80% full.
Place the dust cap on the cylinder valve outlet
whenever the cylinder is not in use. Only install the type
of dust cap on the cylinder valve outlet that is provided
with the cylinder valve. Other types of caps or plugs
may result in leakage of propane.
One side of the enclosure shall be completely
1.
open.
Enclosures that have four sides, complete with a
2.
top and bottom:
At least two ventilation openings at cylinder
a.
valve level shall be provided in the sidewall,
equally sized, spaced at 180º (3.14 rad), and
unobstructed. Each opening shall have a total
free area of not less than one square inch per
pound (7.1 cm²/kg) of stored fuel capacity, and
not less than a total free area of 10 square
inches (64.5 cm²).
Ventilation openings shall be provided at oor
b.
level and shall have a total free area of not less
than one square inch per pound (7.1 cm²/kg)
of stored fuel capacity and not less than a
total free area of 10 square inches (64.5cm²).
If ventilation openings at oor level are in a
sidewall, there shall be at least two openings.
The bottom of the openings shall be at oor
level and the upper edge no more than 5
inches (127 mm) above the oor. The openings
shall be equally sized, spaced at 180º (3.14
rad) and unobstructed.
Every opening shall have minimum dimensions
c.
so as to permit the entrance of a 1/8 inch (3.2
mm) diameter rod.
LP Gas Hook Up
An enclosure for an LP gas cylinder shall be vented by
openings at the level of the cylinder valve and at oor
level. The effectiveness of the openings for purposes of
ventilation shall be determined with the LP-gas supply
cylinder in place. This shall be accomplished in one of
the following manners:
Page 8 2007 Barbecue Grill and Cart Owner’s Manual
LTR20071038, Rev. B
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.
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