Question about Cal Flame 5-Burner

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6 burner Cal Flame in counter grill won't work

We have a 5 burner Cal Flame propane grill. This grill is about 5 years old but it has not worked properly for about 3 years. The knobs get so hot you cannot touch them when you are grilling. The knobs will hardly turn on and off you need a lot of wrist strength to even turn them at all. Many of the knobs have gotten so hot the fiber inside the knob has melted and I cannot buy these fiber inserts , according to Cal Spa you have to buy the whole knob. The latest thing is the grill will not even turn on at all , one burner will light but it acts as if there is no gas going to the other burners.......This thing has been a piece of **** for almost 3 of the 5 years we have had it. It looks like brand new but it just doesn't work...I am going to replace it but my son is buying his first house and if it can be fixed I would give it to him...Do you think there is any hope for it or should I just chuck it.Thanks for you time. Jim

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  • joe-carrie Mar 01, 2009

    My issue is almost the same the burners wont all light on my Cal 5 Burner. Im not sure how to clean it and Cal is no help at all. They say find someone who repairs grills. Well good luck finding that. I only had mine about 2 years and half the burners wont light. Can anyone please help?



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SOURCE: cal flame gas conversion

hi my name is mark, there are several possablitys why it can not be converted, one could be the orifice is pressed in manifold, another is it might require a different burners with air shutters and a regulater. it was problably designed for propane only, to save cost.

Posted on Mar 14, 2009


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Grill won't start

if your sure the propane tank is full, and the valve is open, (counter clockwise, and the control knob is on? you should not only smell it after 20 seconds, but if you put your ear near the grill you should hear a sound like air leaking.If you hear nothing and smell nothing, good chance there is a blockage in the line, or the burner holes are filled with drippings. First off, get a wire brush and scrub the burners where you see the small holes that the flame normally comes out of, then try the grill again, if still nothing (and your 100% sure the tank is full, the tank is on, and the control knob is on high) you may need to start taking apart the grill, looking for a blockage, many times its below the control knob where you will see an adjustable screen, spider webs and such will get in there and block the flow. Remember to not do any of that with the tank on the grill, remove the tank first.;

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Only left side of burners working

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Linda, changing the battery in the electronic ignition will probably solve the problem. To change it, unscrew the ignitor button cap and remove it. The battery will be in the holder inside. Take note of which way the old, burned battery is facing, because that's the way you want the new battery facing, when you install it. While the old battery is out, check inside the battery holder for corrosion on the terminals. If you see any, use a Q-Tip & WD40 to clean the corrosion off.

Hope this helped you troubleshoot and solve the problem. Happy Grilling!!

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1 Answer

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jcw - It sounds like the regulator is locked up from turning on the gas tank valve. Happens a lot with the new OPD Valves on the grill tanks.

1. Turn the tank valve OFF and disconnect the hose from the tank.
2. Turn the burner(s) ON for 1 Minute, Then turn them OFF.
3. After 5 minutes reconnect the hose to the tank and open the valve VERY, VERY, SLOWLY (Slow
motion, slow).
4. Once the tank valve is fully open light one burner and turn it to HIGH. Did the burner light and
does the flame height look correct? Id so, light the remaining burner the way. Did it light and the
flame height look correct? If so, you solved the problem (with a little help).

If the above didn't solve the problem, the Hose/regulator Assembly needs to be replaced. What happened was this, when you turned the tank upside to "burp" the tank. The OPD Valve shot a hot load of gas to the regulator, when you opened it as you normally would and permanently locked up the grill's regulator. That "burping" trick used to work with the old style tanks. Won't work with the new ones. You can get a new hose/regulator assembly at any home center or hardware store, that sells grills and accessories. They run about $30.00. Take your old one with you for comparison purposes. Once you install the new one and connect it to the tank. Open the Valve Very, Very Slowly, until it is fully open. Or you may have the same problem again.

Hope this helped to solve the problem. Happy Grilling!!

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I have a ducane 5 burner grill, its about 7 yrs old. it wont light up it seems that there is some kind of blockage from the propane tank to the burners. i tried bleeding the sysyrem but it didnt work....

The Propane tank is equipped with an OPD (Overfill Protection Device). More often than not it has locked of the grills regulator. (I'm assuming you have already checked and cleaned the burners) To solve the regulator problem do the following:

1. Turn the tank valve OFF.

. Disconnect the hose from the tank and wait 5 minutes.

. After 5 minutes, reconnect the hose to the tank.

. Turn the tank valve ON VERY, VERY SLOWLY (Slow Motion, slow), until the valve is fully open.

. Light the burner that's farthest from the tank first and turn it to it's highest setting. Does the flame
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Remember, after turning the tank OFF for any reason, always turn the tank back ON Very, Very Slowly.

If that didn't solve the problem, you need to replace the grill's hose/regulator assembly. You can buy one at any home center or hardware store that sells gas grills and accessories. Take your old one with you for comparison purposes.

I hope all of this helped you troubleshoot and solve the problem. Please let me know and Happy Grilling!

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1 Answer

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hi my name is mark, there are several possablitys why it can not be converted, one could be the orifice is pressed in manifold, another is it might require a different burners with air shutters and a regulater. it was problably designed for propane only, to save cost.

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