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Cal Flame BBQ870 Owner's Manual

2006 bbq grills, carts, islands, g3000 sports bar
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LTR20061004, Rev. A
10/28/2005

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  • Page 1 LTR20061004, Rev. A 10/28/2005...
  • Page 2 Table of Contents 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 www.calspas.com Copyright 2004, 2005, 2006 California Acrylic Industries, Inc.

  • Page 3: Table Of Contents

    G3000 Island / Sports Bar Canopy... 21 Operating Your Barbecue Grill Controls... 30 Lighting the Grill ... 31 Basic Grill Operation ... 32 Grilling ... 32 Cooking with the Rotisserie ... 33 Cooking with the Convection 3000 Grill... 33 2006 Barbecue Owner's Manual Page iii...
  • Page 4 Table of Contents Turning on and off the Lights... 36 Charcoal Grill... 37 Griddle... 38 Drop-In Food Warmer ... 38 30” Warming Drawer ... 39 Canopy Waterfall and Barbecue Island Waterfall... 40 LED Lights ... 41 Operating the Cal Flame Entertainment Center Splash Stereo System ...

  • Page 5: Read This First

    Cleaning and Maintenance section of this manual. • 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 or any other island feature until the gas has had time to dissipate.

  • Page 6: Precautions Regarding Children

    Read This First! • 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.

  • Page 7: What To Do If You Smell Gas

    • 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.

  • Page 8: Delivery And Set-Up

    Built-in Design Models If using a rear wall, locate a weatherproof electrical outlet on the side of the grill that the rotisserie motor will be located on. The rotisserie motor requires a 110/120V supply. The power supply cord on the motor is equipped with a 3-prong grounded plug for protection against shock hazard.
  • Page 9 3 Burner Grill BBQ874 4 Burner Grill BBQ874C 4 Burner Convection Grill BBQ875 5 Burner Grill BBQ875C 5 Burner Convection Grill BBQ870 Charcoal Grill BBQ898 Deluxe Single Side Burner BBQ899 Deluxe Double Side Burner BBQ864P Ice Chest BBQ888P Food Warmer BBQ865P 12"...
  • Page 10 Delivery and Set-Up Figure 2: Flat Top Grills and Drop in Accessories Model Number Description BBQ874F 4 Burner Flat Drop In Grill BBQ852 Drop In Standard Side Burner BBQ845P Drop In Sink Model Number Description 2 Drawer Storage 3 Drawer Storage...
  • Page 11 Figure 4: Refrigerators, Cocktail Centers and Access Doors Model Number Description BBQ848P Deluxe Refrigerator, Glass door BBQ847P Standard Refrigerator, SS Door BBQ843P Beer Tap Refrigerator BBQ863P 3 Pull Out Drawer, SS Refr. BBQ857P Propane Tank Compartment BBQ839P-18 Single Access Door BBQ839P-30 Double Access Door 2006 Barbecue Owner's Manual...

  • Page 12: Liquid Propane Gas Requirements And Connection

    Delivery and Set-Up Liquid Propane Gas Requirements and Connection 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: All Cal Flame™ grills are manufactured with the highest regard to safety. For this reason, Cal Flame™...

  • Page 13: Natural Gas Requirements And Connection

    Natural Gas Requirements and Connection 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: All Cal Flame grills are manufactured with the highest regard to safety. For this reason, Cal Flame™...

  • Page 14: Leak Testing Procedure

    6. If you are unable to stop a leak, 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.

  • Page 15: Assembly And Installation

    Assembly and Installation Installing and Replacing Infrared Burners 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, remove the grate and flame tamer on top of the brass burner you want to replace (Figure 7).

  • Page 16: Installing Drop-In Grills

    6. Take the burner out of the grill and store it in a safe and dry place. 7. Install the infrared burner. Align the gas inlet on the burner with the gas supply valve on the grill and torch tube with ignition. Make sure they align perfectly. Slide the stud at the other end into the locking hole.

  • Page 17: Installing Grills In Barbecue Islands

    Installing Grills in Barbecue Islands Before installing 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. Grill should rest on the lip of the frame. For drop in accessories, adequate cross ventilation must be designed into enclosure to ensure drop in grill or side burner does not become overheated.

  • Page 18: Barbecue Island Assembly

    Assembly and Installation Barbecue Island Assembly Stucco and Tile Unit Assembly 1. Place the island sections together on the ground (Figure 12 and 11). 2. Make sure the ground where the barbecue is place is as level as possible for best alignment. NOTE: If the ground is not level, use shims to level out the island sections.
  • Page 19 Figure 16 NOTE: Allow the speed set to dry before proceeding with the next step. 7. Using a small brush or hopper gun, apply stucco to the seam line (Figure 18 and 17). Figure 18 8. Mix grout with water in a container. 9.

  • Page 20: Granite Kit Instructions

    Assembly and Installation Rock / Stone Assembly For Models G-2500, G-2500F, G-2600, G-3000, G-3500F, G-3600 1. Place the island sections together on the ground. 2. Make sure the ground where the barbecue is place is as level as possible for best alignment. NOTE: If the ground is not level, use shims to level out the island sections.

  • Page 21: Connecting Modular Carts

    12. Quickly apply the epoxy mixture to the seam line. Remove the excess epoxy material from the seam line using a razor blade. 13. Let the epoxy material cure for five minutes. 14. Repeat the previous steps until all the seam line is filled with epoxy mixture. 15.

  • Page 22: Installing Side Burners

    2. 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. 3. Install the pipe tee assembly to the grill intake pipe with pipe sealant. Tighten assembly and align the branch opening of the tee with the hole of the cabinet.

  • Page 23: Installing New Access Doors

    Then take other end of "T" adapter with hose attached To Propane Tank and connect to end of male located underneath and at the back of the grill. (Use gas rated tape seal on all connections). Connect the last open line to the side burner...

  • Page 24: Griddle And Griddle Storage

    Assembly and Installation Figure 23. Side burner installation Griddle and Griddle Storage Similar to installing a drawer, you need to have a cutout on your barbecue island as shown in Figure 3. Align the enclosure as shown, opening facing out. Make sure the enclosure is aligned horizontally. Tighten the mounting screws on both side of the enclosure to lock the enclosure in place.

  • Page 25: G3000 Island / Sports Bar Canopy

    Assembly and Installation G3000 Island / Sports Bar Canopy While the G3000 Island / Sports Bar Canopy is intended for outdoor use, some precautions must be taken when using and caring for your new Cal Flame™ equipment. When the equipment is not being used, or especially in times of inclement weather, it is the owners responsibility to remove and store the electronic equipment that is listed in this manual.
  • Page 26 Antenna Match up the coaxial end (female) with the other coaxial end (male) and securely attach them together. Run the single antenna coaxial cable into the 3-way splitter (located under the grill of the G3000 Island/ Sports Bar itself). Canopy Assembly The following instructions will allow you to assembly the canopy section of the G3000 Island/ Sports Canopy.
  • Page 27 Figure 26. Canopy mounting tabs and support sleeves Figure 27. Canopy mounting tabs and support sleeves Mounting the G3000 Island/ Sports Bar Canopy CAUTION: THE FOLLOWING STEP IS A TWO-PERSON PROCEDURE. THE CANOPY, AT THIS STAGE, IS EXTREMELY HEAVY. WE STRONGLY RECOMMEND THAT YOU HAVE SOMEONE HELP YOU.
  • Page 28 Assembly and Installation Awning Installation All screws used for the installation of the awning are self-tapping sheet metal screws. No drilling is necessary. 1. Line up the holes for the awning bracket with the corresponding pre-drilled holes on the awning. Use two carriage bolts for the upper two holes and a flat-head Phillips for the single lower hole.
  • Page 29 2. Attach screen to top metal frame using nuts and bolts. 3. Center and attach the TV box to the screen, with the TV facing the barbecue grill (Figure 30). 4. Connect all wires from the TV box into a waterproof box and to the black cable (Figure 31).
  • Page 30 Assembly and Installation 8. Insert all connection cables through the connector one by one (Figure 34). 9. Attach and secure the connector to the black flex (Figure 35). Figure 34 10. Insert all connection cables through the hole drilled on the post (Figure 36). 11.
  • Page 31 12. Secure and tighten the lock nut on the black flex as shown (Figure 38). 13. Connect all connection cables to each other by matching colors (Figure 39). Figure 38 14. Arrange all cables inside the metal post (Figure 40). 15.

  • Page 32: Electrical Diagram

    Assembly and Installation 16. Connect all TV cables to the DVD unit (Figure 42). Figure 42 Electrical Diagram See diagram next page. 2006 Barbecue Owner's Manual Page 28 LTR20061004, Rev. A...
  • Page 33 Operating Your Barbecue 2006 Barbecue Owner's Manual Page 29 LTR20061004, Rev. A...

  • Page 34: Operating Your Barbecue

    Operating Your Barbecue It is recommended to 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.

  • Page 35: Lighting The Grill

    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. 2006 Barbecue Owner's Manual LTR20061004, Rev. A Figure 44.

  • Page 36: Basic Grill Operation

    1. Make sure the drip tray is in place. 2. Light the grill burners using the instructions below. 3. Turn the control knob to HIGH and preheat the grill for 15 minutes. Close the top cover during the appliance preheat period.

  • Page 37: Cooking With The Rotisserie

    3. The rod of the rotisserie system is assembled into the motor by placing the pointed end into the motor and resting the threaded end on the support at the side of the grill. Once the rod is pushed as far as possible into the motor, the grooved end of the rod should rest on the right side bracket.
  • Page 38 This leads to uneven cooking within the cooking compartment and makes use of the outdoor grill somewhat haphazard. Accordingly, there is need for a barbecue grill which overcomes this problem in the prior art. Exhaust vents heat that is drawn in from back.
  • Page 39 Use a meat thermometer and take the guesswork out of cooking meat and seafood. The fan must be turned on in order for the Convection 3000 Grill to cook the items that are listed below. IMPORTANT: After the desired cooking temperature is reached, remove meat from the heat source and let it stand 10 to 15 minutes before carving.

  • Page 40: Turning On And Off The Lights

    Cook until shells crack open (if shell doesn’t open, throw away) Cook until shells crack open (if shell doesn’t open, throw away) Cook until shells crack open (if shell doesn’t open, throw away) CONVECTION GRILL COOKING MATRIX Temperature Cook Time 420ºF 40 minutes 390ºF...

  • Page 41: Charcoal Grill

    • NEVER allow children or pets unattended in an area where grill is being used. Never allow children to sit, stand or play on or around the grill at any time. When in use, certain areas of the grill get hot enough to cause severe burns.

  • Page 42: Griddle

    Drop-In Food Warmer Attach this three-pan food warmer to your favorite bartending center or grill and serve a variety of hot, fresh hors d’ oeuvres and side dishes. The food warmer has three steamer pans and a built-in fuel drawer.

  • Page 43: 30" Warming Drawer

    IMPORTANT • The water in the container pan is a scald and burn hazard as it gets hot. Do not attempt to empty it until it is cooled. • Do not burn sterno fuel with the drawer open. • Do not leave sterno fuel burning unattended. Do not leave children unattended around food warmer during and immediately after use.

  • Page 44: Canopy Waterfall And Barbecue Island Waterfall

    Operating Your Barbecue Safety Practice & Precautions • As with any cooking or heating appliance, never leave the warming drawer unattended when warming food. • Only certain types of glass, heat proof glass-ceramic, ceramic, earthenware or glazes are suitable for temperature changes.

  • Page 45: Led Lights

    LED Lights LED lights use an ON/OFF switch to change one show to the next. (See Figure 45.) • Turn OFF and then ON again in one second or less to go to the next show. • Turn OFF and then ON again in four to five seconds to reset to the first show. •...

  • Page 46: Operating The Cal Flame Entertainment Center

    Operating the Cal Flame Entertainment Center Operating the Cal Flame Entertainment Center Splash Stereo System Figure 51. Cal Flame Entertainment System This system can be used to listen to AM or FM Stereo signals, CD’s and also audio from the optional DVD and TV Tuner on our Entertainment Cal Flame unit.
  • Page 47 Remote Control Operation Eject/ DVD TV/DVD Auto Program Skip/Search Erase/Add Channel Up Menu Enter Return Channel Down Vol - Program SubTitle Stop Pause/Replay NEXT PREV Figure 52. Remote control NOTE: These buttons will not affect the volume of wireless headphones or a wired RF modulator. When using these devices, the volume must be adjusted with the headphone volume control or with your radios volume control.
  • Page 48 Operating the Cal Flame Entertainment Center AUTO PROGRAM Button Select the regular channel broadcast TV or CABLE TV for AUTO PROGRAM. All the channel numbers for TV or CABLE TV will be scanned. The broadcasting signals will be detected and automatically stored. ENTER Button Use this button to end the choice on the menu.

  • Page 49: Cal Flame Entertainment System Operation

    4. Press either CHANNEL up or down to select the function. Make sure the highlight bar is SET PICTURE and then press ENTER. 5. Select the item to adjust. For example, to adjust brightness, press CHANNEL up or down buttons to select BRIGHTNESS and press ENTER.

  • Page 50: Operating The Dvd System In Tv Mode

    Operating the Cal Flame Entertainment Center NOTE: Although encased in a plastic housing with weather seals, this system and remote control are not waterproof. You must be take every step necessary to keep this system dry. Water damage is not covered by the manufacturers warranty.
  • Page 51 Operating the Cal Flame Entertainment Center 3. Press the A/V button on the DVD Remote Control to switch the Video from OUT to IN. 4. Press the Channel Up or Down buttons on the TV remote control to select TV Channel. Switching Back to DVD Operation: 1.

  • Page 52: Cleaning And Maintenance

    The food particles will fall onto the briquette tray and burn or fall into the drip tray. If the grill is allowed to cool before cleaning, the removal of those residual particles from food will be more difficult.

  • Page 53: Drip Pan

    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.

  • Page 54: Granite Top

    Cleaning and Maintenance Note: DO NOT use oven cleaners or abrasive cleaners on enameled surfaces. They may damage the finish, causing accelerated wear. 30” Food Warmer • Be careful cleaning any part of this appliance, particularly the drawer box and back of the drawer face. All parts of the drawer can be cleaned with hot soapy water, rinsed, dried and buffed with a heavy pile cloth.
  • Page 55 Do's • Do dust surfaces frequently • Do clean surfaces with mild detergent or stone soap • Do thoroughly rinse and dry the surface after washing • Do blot up spills immediately Don'ts • Don't use vinegar, lemon juice or other cleaners containing acids. •...

  • Page 56: Care Of Stainless Steel Carts & Grills

    Cleaning and Maintenance Coffee, tea, food, fruit, lipstick, juices Caution: Vinegar may damage some tile. DO's and DON'Ts of Tile Care • Do test scouring pads in a small area first. • Do use a silicone sealer on grout joints if continuous staining is a problem. •...

  • Page 57: Covering Your Stainless Steel Cart

    #304 stainless steel and only clean when the grill is cool and in indirect light. Never use steel wool to clean your grill and never clean the grill when it is hot. Be especially careful when cleaning the Highlighted (shinny) areas or your grill. Only clean these areas when absolutely necessary.
  • Page 58 Cleaning and Maintenance Gently pry light cover away from housing. NOTE: Do not pry the light cover with a screwdriver or other metal item. You may damage the light cover as a result. Using a tissue or small piece of paper, grasp bulb and pull it away from socket. Using a tissue or small piece of paper, carefully push new bulb into socket making sure both wires on bulb go into the light socket evenly.

  • Page 59: Appendix

    Obstruction in the gas line Solution: Remove fuel line from grill. Do not smoke or perform any maintenance in the vicinity of an open flame. Open gas valve for one second to blow out any debris. Close off gas valve and reconnect fuel line securely.
  • Page 60 2. Check gas supply at a connections. 3. Repeat lighting procedure and if grill still fails to operate properly, turn off gas at source, turn the control knobs to the off position and wait for the grill to cool down and check the following:...
  • Page 61 Appendix Figure 55. Widening the cross flow channel G3000 Waterfall • Make sure 110V power is connected to the barbecue island input line. • Make sure the pump cord is connected to a 110V outlet line. • Check the water level before turning the pump on. •...

  • Page 62: Parts List

    BARBECUE846P-18 18" JUICE BAR, PARTS ONLY BARBECUE846P-30 30" JUICE BAR, PARTS ONLY COVERS FOR CAL FLAME DROP-INS BARBECUE010 COVER, GRILL, SMALL, 3 BURNER BARBECUE011 COVER, GRILL, MEDIUM, 4 BURNER BARBECUE012 COVER, GRILL, LARGE, 5 BURNER BARBECUE013 COVER, SIDE BURNER, SINGLE & DOUBLE...
  • Page 63 COVERS FOR CAL FLAME CARTS BARBECUE835CR4 BARBECUE CART COVER, 4 BURNER, BLACK BARBECUE835CR5 BARBECUE CART COVER, 3 & 5 BURNER, BLACK SYNTHETIC SIDE PANELS BARBECUE04101901 31 _” X 33” - BARBECUE synthetic panel BARBECUE04101902 46” x 33” - BARBECUE synthetic panel BARBECUE04101903 70 _’...

  • Page 64: Warranty Information

    Appendix 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 The Limited Warranty is void if the barbecue has been subject to negligence, alteration, misuse, abuse, repairs by non- C.A.I.
  • Page 66 LTR20061004, Rev. A 10/28/2005...

  • Page 68: Pomona, Ca

    Please make a record of the following. It will be valuable if service is required. Barbecue Model: Barbecue Serial Number: Date Purchased: Date Installed: Dealer’s Phone Number: Dealer’s Address: C.A.I. Customer Service Department 1462 East Ninth Street Pomona, CA 91766 Toll Free: 1-800-CAL-SPAS Fax: 1-909-629-3890 www.calspas.com...

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