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Kalamazoo K42DB-1-NA Use And Care Manual Download Page 5

+1.800.868.1699

1

Table of Contents

Safe Operation 

4

Liquid Propane Tank Safety 

6

Gas Requirements 

8

Leak Testing 

13

Locating the Grill 

14

Required Clearances 

14

Ventilation Hood Information 

15

Grill Dimensions  

17

Initial Assembly 

28

Get to Know Your Grill 

32

Grill Controls 

36

Lighting Your Grill 

39

Ignition System Power Supply 

41

Burner Adjustments 

43

Valve Adjustments 

43

Cooking with Your Grill 

49

Caring for Your Grill 

57

Troubleshooting 61

Electrical Diagrams 

63

Installation Checklist 

67

Summary of Contents for K42DB-1-NA

Page 1: ...Kalamazoo Gas Grills Kalamazoo Gas Grills U S E A N D C A R E G U I D E U S E A N D C A R E G U I D E ...

Page 2: ......

Page 3: ...re to heed the warnings or follow the safety instructions and practices described in this Use and Care Guide is not covered by the warranty DANGER IF YOU SMELL GAS 1 Shut off gas to the appliance 2 Extinguish any open flame 3 Open grill lid 4 If odor continues keep away from the appliance and immediately call your gas supplier or fire department Failure to follow these instructions could result in...

Page 4: ... for your Kalamazoo Grill we are here to help Contact Kalamazoo Outdoor Gourmet Customer Service at 1 800 868 1699 or customerservice KalamazooGourmet com Please have your model number and serial number ready or include it in your email Model Number F K42DB 1 NA F K42DT 1 NA Fuel Type F Natural Gas Serial Number F K54DB 1 NA F K54DT 1 NA F Liquid Propane Cylinder F Bulk Liquid Propane This Use and...

Page 5: ... Clearances 14 Ventilation Hood Information 15 Grill Dimensions 17 Initial Assembly 28 Get to Know Your Grill 32 Grill Controls 36 Lighting Your Grill 39 Ignition System Power Supply 41 Burner Adjustments 43 Valve Adjustments 43 Cooking with Your Grill 49 Caring for Your Grill 57 Troubleshooting 61 Electrical Diagrams 63 Installation Checklist 67 ...

Page 6: ...KalamazooGourmet com 2 ...

Page 7: ... 1 800 868 1699 3 Important Safety Information ...

Page 8: ...on or the grill is hot do not touch the grilling surface warming rack any part of the grill s interior or any surface of areas surrounding the grilling surface These areas become extremely hot and may cause severe burns Likewise do not touch any part of the grill lid other than the handle Do not touch any surface of the cleanout trays or open the cleanout when the grill is hot Do not use any clean...

Page 9: ...e the gas flow is redirected and can create a fire behind the control panel This will damage the grill and make it unusable Frequent inspections and care are recommended See the care section beginning on page 57 California Proposition 65 Warning The burning of gas cooking fuel generates some by products that are on the list of substances which are known by the State of California to cause cancer o...

Page 10: ...ct Kalamazoo Outdoor Gourmet or an authorized dealer for details Conversion kit installation must be done by a qualified technician The LP gas cylinder must include a collar to protect the cylinder valve from damage Ensure proper ventilation of the cylinder The cylinder supply system must be arranged for vapor withdrawal The LP gas supply cylinder to be used must be constructed and marked in accor...

Page 11: ... 90 degrees 1 57 rad and unobstructed See Figure 2 The opening s shall have a total free area of not less than 1 in2 lb 14 2 cm2 kg of stored fuel capacity b Ventilation opening s shall be provided at floor level of the enclosure and shall have a total free area of not less than 1 2 in2 lb 7 1 cm2 kg of stored fuel capacity If ventilation openings at floor level are in a side wall there shall be a...

Page 12: ...o the grill via 0 5 NPT male with a 0 375 flare adapter included Input Pressure via LP regulator hose assembly 11 W C Manifold Pressure 10 5 W C To connect the LP regulator hose assembly to the LP tank first make sure the main valve on the tank is completely closed Make sure also that all control valves on the front of the grill are OFF Thread the regulator inlet over the tank valve Use care to en...

Page 13: ...s for any gas to clear Finally continue with the normal lighting procedure The installation must conform with local codes In the absence of local codes the installation must conform with the National Fuel Gas Code ANSI Z223 1 NFPA 54 Storage and Handling of Liquefied Petroleum Gases ANSI NFPA 58 Natural Gas and Propane Installation Code CSA B149 1 or Propane Storage and Handling CSA B149 2 FIGURE ...

Page 14: ...igid pipe semi rigid tubing and or a connector that complies with the Standard for Connectors for Outdoor Gas Appliances and Manufactured Homes ANSI Z21 75 CSA 6 27 IMPORTANT Always close gas supply shut off valve before disconnecting the grill gas supply hose All pipe sealants must be an approved type IMPORTANT Diameter and length of the gas supply pipe may limit the pressure and BTU delivery of ...

Page 15: ...embly included connects to the grill via 0 625 flare fitting Input Pressure 11 0 W C 27 4 mbar Manifold Pressure 10 W C 26 1 mbar All pipe sealants must be an approved type and safe for use with LP gas INCLUDED 10 FLEXIBLE GAS HOSE CONNECTS TO GRILL WITH FLARE FITTING NO PIPE SEALANT NEEDED HERE FITTING ON GRILL CAN BE ROTATED 90 STRAIGHT DOWN IF PREFERRED INSTALLER SUPPLIED SHUT OFF VALVE WITH 1 ...

Page 16: ...rills configured for liquid propane LP gas Grills configured for use with natural gas are shipped with a gray hose with a quick connect fitting Connection 1 2 NPT male Quick connect hose assembly included connects to the grill via a 0 625 flare fitting Input Pressure 7 0 W C 17 4 mbar Manifold Pressure 4 0 W C 10 mbar INSTALLER SUPPLIED SHUT OFF VALVE WITH 1 2 MALE NPT CONNECTION FOR GRILL INCLUDE...

Page 17: ... the gas connections that are external to the grill If the valves or other internal connections need to be checked please call a qualified technician or Kalamazoo Outdoor Gourmet customer service at 1 800 868 1699 To Conduct the Test Make a soap solution of one part liquid dish soap and one part water Make sure all grill control valves are in the OFF position Turn the gas supply ON Use a spray bot...

Page 18: ...t the counter top or other surface extend 9 inches beyond the sides and back of the grill as a safety clearance to protect people from injury Do not place the grill on a surface that is unable to safely support the weight of the grill or may cause it to be unstable Never place the grill where the gas hose creates a safety hazard see Figure 1 Tripping over an exposed gas hose may create a gas leak ...

Page 19: ...oes not make it okay to use an outdoor grill in a building breezeway shed or other such enclosed area The bottom of the vent hood must be located no more than 36 inches above the grill grates The closer the hood is positioned to the grill grates the more effectively it will capture smoke The front of the vent hood must be positioned at least 4 inches beyond the front of the grill If the hood is po...

Page 20: ...KalamazooGourmet com 16 ...

Page 21: ... 1 800 868 1699 17 Product Dimensions ...

Page 22: ...mm A A 27 1 2 699mm 44 1 4 1124mm 30 1 2 776mm 24 3 8 618mm INCLUDING REAR COVER RIVETS 11 280mm 1 1 2 39mm 23 1 4 589mm 24 611mm 40 1 8 1019mm 1 5 8 41mm SECTION A A CHASSIS DIMENSIONS ELECTRICAL CORD LOCATION OUT BOTTOM OF CHASSIS GAS HOSE LOCATION OUT BOTTOM OR OUT REAR OF CHASSIS ...

Page 23: ... 1 800 868 1699 19 RUSS CAN UPDATE AR TS 40 1 4 1022mm WIDTH INCLUDING RIVETS AND ACCESS COVER ...

Page 24: ...8mm A A 27 1 2 699mm 56 1 4 1429mm 30 1 2 775mm 24 3 8 618mm INCLUDING REAR COVER RIVETS 11 280mm 1 1 2 39mm 52 1 8 1323mm 1 5 8 41mm 24 611mm 35 1 4 894mm SECTION A A CHASSIS DIMENSIONS GAS HOSE LOCATION BOTTOM EXIT OR REAR EXIT OF CHASSIS ELECTRICAL CORD THROUGH BOTTOM OF CHASSIS ...

Page 25: ... 1 800 868 1699 21 4 3 8 18mm ING REAR RIVETS 52 1 4 1327mm WIDTH INCLUDING RIVETS AND ACCESS COVER ...

Page 26: ...B MAIN CHASIS IS 52 125 1324 mm WIDE MAIN CHASIS IS 10 254 mm TALL FROM FACE OF STRUCTURE NOT INCLUDING COUTNERTOP OVERHANG REQUIRED IF THERE IS A FRONT COUTNERTOP OVERHANG 5 127mm OPENING FOR GAS CONNECTION HOSE MAY PASS THROUGH REAR OR BOTTOM AS NEEDED 4 102mm OPENING REQURED FOR GROUNDED ELECTRICAL EXTENSION CORD CENTERED 2 51mm TO 3 76mm FROM REAR OF CUTOUT NOTES 52 25 1328 mm MINIMUM 53 5 135...

Page 27: ...ABLE 3 4 19mm 35 889mm 4 5 114mm 42 1067mm 29 1 8 739mm 1 26mm MINIMUM COUNTERTOP THICKNESS 2 1 4 57mm MAXIMUM COUNTERTOP THICKNESS HEIGHT ADJUSTABLE 3 4 19mm 1 26mm MINIMUM COUNTERTOP THICKNESS 2 1 4 57mm MAXIMUM COUNTERTOP THICKNESS 35 889mm 4 5 114mm 54 1372mm 29 1 8 740mm ...

Page 28: ...lamazooGourmet com 24 K42DT Freestanding Grill RUSS CAN UPDATE 83 2109mm 42 1 8 1070mm 20 1 2 519mm 8 1 4 208mm 54 1 4 1379mm 44 1 4 1124mm 25 1 4 641mm 30 1 2 776mm 16 1 4 413mm 25 1 4 641mm 28 7 8 735mm ...

Page 29: ... 1 800 868 1699 25 K54DT Freestanding Grill RUSS CAN UPDATE 54 1 8 1375mm 54 1 4 1379mm 20 1 2 519mm 95 2414mm 56 1 4 1429mm 8 1 4 208mm 30 1 2 775mm 25 1 4 641mm 25 1 4 641mm 16 1 4 413mm 28 7 8 734mm ...

Page 30: ...KalamazooGourmet com 26 ...

Page 31: ... 1 800 868 1699 27 Initial Assembly ...

Page 32: ...anout pans when the grill is hot D Position the HEAT DIFFUSERS above the main burners inside the grill E Place the COOKING GRATES into the grill above the heat diffusers F Position the WARMING RACK at the desired level on the WARMING RACK SUPPORTS G H See page 33 for rotisserie rod installation instructions I If not already attached mount the CONTROL KNOBS onto the valve stems J For K42DT and K54D...

Page 33: ... 1 800 868 1699 29 FIGURE 9 NATURAL GAS CONNECTION page 12 BULK LIQUID PROPANE CONNECTION page 11 PROPANE CYLINDER CONNECTION page 8 A B C D E G F H I J ...

Page 34: ...KalamazooGourmet com 30 ...

Page 35: ... 1 800 868 1699 31 Operation ...

Page 36: ...erie Spit and Forks Use for rotisserie cooking Always balance the food on the spit as well as possible by centering its weight around the spit Secure the food tightly with the rotisserie forks and tighten the thumb screws well Butchers string may be used in addition to the rotisserie forks to hold rolled roasts securely Always wear protective gloves and use caution when handling a hot rotisserie s...

Page 37: ...uge stainless steel diffusers sit between the burners and cooking surfaces The special patterns and angles diffuse the main burner heat G Main Burners These stainless steel burners provide the primary heat for the grill H Main Control Panel See the following section on grill controls FIGURE 11 2 1 Insert pointed end of rotisserie spit into RIGHT opening FIRST SECOND insert blunt end of rotiserie s...

Page 38: ...r the pans could spill I Interior Task Lights Helpful for grilling after sunset J Cleanout Pans Separate cleanout pans for each control zone make cleaning up less of a messy proposition Each pan is one inch deep and can be removed for cleaning K Cleanout Tray The cleanout tray holds the cleanout pans It can be fully removed for cleaning by tilting up and over the roller bearings when fully extende...

Page 39: ... the grill to access the power cord Run the customer supplied extension cord down through the grommeted hole and out the bottom of the grill M Propane Cylinder Area For the K42DT and K54DT freestanding models access the LP cylinder by opening the cabinet door s N LP Cylinder Retention Strap For the K42DT and K54DT plumbed for use with an LP cylinder secure the cylinder using the included strap O L...

Page 40: ...n on the knob turn counter clockwise for the range of burner control between HIGH and LOW FIGURE 16 FIGURE 17 Grill Controls Each grill control knob corresponds to an individual burner control The symbol to the right of the knob indicates which type of burner and the burner position that knob controls The electronic ignition system works with one burner at a time Activate the electronic ignition p...

Page 41: ... 1 800 868 1699 37 ...

Page 42: ... the grill 5 Have insulated gloves with long cuffs ready and available While You are Cooking 1 Never move the grill while it is in use or when it is hot 2 The use of alcohol prescription or non prescription drugs may impair your ability to properly assemble or safely operate the grill 3 Do not touch the grill lid any surfaces inside or around the cooking surfaces or any surfaces inside the cleanou...

Page 43: ...return the valve back to the OFF position Wait five minutes for the gas to clear before trying again to light the burner 7 Once the burner has lit you must continue pressing in on the valve while the safety thermocouple heats up This can take up to 20 seconds Once the bezel light changes from flashing white to flashing blue release the control knob The bezel light should change to a steady orange ...

Page 44: ...til the thermocouple has heated up This can take up to 20 seconds If you release the control knob too early the safety device will stop the gas flow 5 Repeat with other burners as needed Rotisserie Burner s 1 Open the grill lid 2 Make sure all control knobs are in the OFF position 3 Turn the main gas supply on 4 Keeping your face well away from the unit hold a match or lighter wand in front of the...

Page 45: ... To protect against electric shock do not immerse cord or plugs in water or other liquid 2 Unplug from the outlet when not in use and before cleaning Allow to cool before putting on or taking off parts 3 Do not operate any outdoor cooking gas appliance with a damaged cord plug or after the appliance malfunctions or has been damaged in any manner Contact the manufacturer for repair 4 Do not let the...

Page 46: ...stics The flame should be blue and stable with only a small amount of orange if any at the tips There should be little noise and no lifting On HIGH the inner cone see Figure 19 A should be approximately 3 8 inch long On HIGH the outer cone see Figure 19 B should be approximately 1 inch high Visually compare the flames in your grill and adjust if necessary using the instructions that follow Rotisse...

Page 47: ... the burners may need more combustion air Adjust the air shutter to a more open position Too much air may cause the flames to lift off the burner This is a dangerous condition that must be avoided Do not open the air shutter too far Too much air will also make it more difficult to light the burner You may test burn the grill to fine tune the air shutter by mounting the control knob without re inst...

Page 48: ...the Molex connectors for each electronic control bezel plus the blade connectors for the rotisserie motor and task lighting switches FIGURE 22 A B C E D To Reinstall the Control Panel 1 Reconnect the Molex connectors to each control bezel and the blade connectors for the rotisserie and task lighting switches 2 Position the keyway holes on the control panel over the studs on the body of the grill 3...

Page 49: ...n using an old toothbrush Rotisserie Burner s These burners have no air shutters and need no combustion air mixture adjustment The LOW settings can be adjusted in the same manner as the Main Burners Set the LOW adjustment so that the rotisserie burners do not easily blow out when operating on LOW ...

Page 50: ...KalamazooGourmet com 46 ...

Page 51: ... 1 800 868 1699 47 Cooking Tips ...

Page 52: ...KalamazooGourmet com 48 ...

Page 53: ...nless steel brush or a grate scraper for cleaning the cooking surfaces Long handled grill tongs 18 long Other Helpful Accessories Cast iron skillets dutch ovens fajita pans and other cookware Thin and flexible turner for burgers and delicate fish fillets Silicon basing brushes Kalamazoo laser cut custom grilling surfaces with patterns optimized for cooking meat fish and vegetables Preheating Alway...

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Page 55: ...ss fed ground beef for the best flavor Chef Bobby Flay offers a tip to compensate for the way a juicy burger plumps up on the grill By recessing the patty in the middle before cooking the burger becomes flat when it plumps up Just use your fingers to recess the middle of each patty a bit from both sides The next step in a perfect burger is to brush it with olive oil This helps form the flavorful c...

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Page 57: ...en vegetables make a great side dish The technique for grilling green beans and asparagus is the same and the secret is to use a little lemon juice Prepare the grill for cooking over a direct fire with a grilling temperature of 500 F A Kalamazoo Outdoor Gourmet laser cut vegetable grill surface sized so that the veggies won t fall down into the fire is very helpful Whisk together equal parts lemon...

Page 58: ...KalamazooGourmet com 54 ...

Page 59: ...oked when it turns opaque and the meat flakes cleanly under firm pressure Shrimp and Lobster Tails Shrimp and lobster are fully cooked when the flesh turns opaque Beef Steaks Gourmet USDA Rare 120 F 140 F Medium rare 130 F 150 F Medium 140 F 160 F Medium well 150 F 170 F Beef Roasts Gourmet USDA Rare 125 F 140 F Medium rare 135 F 150 F Medium 145 F 160 F Medium well 160 F 170 F Beef Burgers Gourme...

Page 60: ...KalamazooGourmet com 56 ...

Page 61: ... 1 800 868 1699 57 Product Care ...

Page 62: ...the surfaces brown The more you use your grill the more thoroughly seasoned your surfaces will become Ideally you want your surfaces to become black and remain that way You can re season your surfaces at any time Re seasoning may be necessary if your grill sits idle for long periods of time or you cook highly acidic foods Cleanout Pans Empty and clean your cleanout pans on a regular basis We recom...

Page 63: ... main gas supply Remove the cooking surfaces and the heat diffusers Release the burner Figure 23 A from the burner support bracket at the rear Figure 23 B by removing the retaining pin Figure 23 C You can now lift the burner off the burner support bracket from the rear and then slide it rearward off the orifice Figure 23 F Visually inspect each burner to confirm it is structurally sound and that n...

Page 64: ...fices remove the control panel according to the instructions beginning on page 44 Remove the main burners according to the instructions on page 59 Use a 1 2 wrench to carefully thread the orifices Figure 24 A off the valve bodies Figure 24 B Shine a flashlight through the orifice to look for any obstructions Remove obstructions with a needle Use extreme care not to enlarge the hole Reinstall and t...

Page 65: ...ng the burner see page 40 Grill won t get to temperature If the grill does not get hot within 10 minutes of starting check the flame height of the main burners On HIGH the flames on the main burners should be approximately 1 inch tall If they are not check the following LP cylinder has enough gas to deliver proper pressure Refill the tank if necessary In some situations in cold ambient temperature...

Page 66: ...KalamazooGourmet com 62 ...

Page 67: ... 1 800 868 1699 63 Electrical Diagrams ...

Page 68: ... 2 COM NO NC 2 2 2 2 10 2 COM NO NC 2 2 2 2 10 2 COM NO NC 2 2 2 2 10 2 ROTISSERIE BURNER MAIN BURNER MAIN BURNER MAIN BURNER ROTISSERIE MOTOR SWITCH 2 VALVE SWITCH HOT SURFACE IGNITER FLAME SENSOR 2 2 2 J2 J1 J4 J7 J5 J6 2 2 2 120 VAC 12V HALOGEN POWER SUPPLY BOARD LIGHT POWER SUPPLY BOARD LIGHT SWITCH 2 2 ...

Page 69: ... 2 10 2 COM NO NC 2 2 2 2 10 2 COM NO NC 2 2 2 2 10 2 ROTISSERIE BURNER MAIN BURNER MAIN BURNER MAIN BURNER ROTISSERIE MOTOR SWITCH 2 VALVE SWITCH HOT SURFACE IGNITER FLAME SENSOR 2 2 2 J2 J1 J4 J7 J5 J6 2 2 2 120 VAC 12V HALOGEN POWER SUPPLY BOARD LIGHT POWER SUPPLY BOARD COM NO NC 2 2 2 10 2 2 MAIN BURNER LIGHT SWITCH ROTISSERIE BURNER ...

Page 70: ...KalamazooGourmet com 66 ...

Page 71: ... 1 800 868 1699 67 Installation Checklist ...

Page 72: ...s installed F Warming rack installed place in stowed position to allow rotisserie rod installation F Rotisserie rod and forks installed F Primary cooking surfaces installed F Grill connected to grounded outdoor rated extension cord and GFI circuit F Hot surface igniter glows when each burner control knobs is held in F Interior task lights working F Rotisserie motor working F Each burner control va...

Page 73: ...informed of external shut off valve location as well as shut off valve inside grill model dependant F Unit and supply connections have been tested and are free of leaks F LP cylinder connected to dual stage regulator at 11 water column pressure OR F Bulk LP supply regulated to 11 water column pressure OR F Natural gas supply at 7 water column pressure F Lid opens and closes freely without binding ...

Page 74: ...KalamazooGourmet com 70 ...

Page 75: ...p hopper like firebox improved the heat dynamics and made it easier to clean And above all it was designed to combine the convenience of a gas grill with the superior cooking capabilities of a charcoal grill The outcome was a gigantic departure from the previous expectations of stainless steel grill The Birth of a New Company These unique grills developed a passionate and loyal following over the ...

Page 76: ...KalamazooGourmet com 72 ...

Page 77: ... to help you up your grill game and take your barbecue to the next level Grill Master s Essential Accessories Long cuffed leather gloves and precision 16 inch tongs both protect your hands above a hot grill Steak Knives A beautiful wood fired steak deserves a beautiful steak knife Treat yourself to Kalamazoo s stunning collection of knives All accessories can be ordered by calling 1 800 868 1699 o...

Page 78: ...ime of printing Because Kalamazoo Outdoor Gourmet is always focused on product improvement we reserve the right to make changes at any time This includes all specifications of the product 2022 Kalamazoo Outdoor Gourmet LLC Not to be reproduced wholly or in part without specific written permission from Kalamazoo Outdoor Gourmet LLC Kalamazoo Outdoor Gourmet Chicago Headquarters 810 West Washington ...

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