Barbeques Galore G4CDXL Instructions For Assembly And Use

Page 1

WELCOME TO THE WORLD OF BARBEQUES GALORE OUTDOOR COOKING

INSTRUCTIONS FOR ASSEMBLY AND USE OF

CORDON BLEU L2-SERIES BARBEQUES

For the safe use and enjoyment of your new barbeque.

These instructions contain important information that needs to be followed for the safe assembly

and use of your new barbeque. Please read through carefully and completely prior to assembly.

Take care to remove all packaging materials & protective coatings from the bbq before first use.

For Barbeque Models: G2CBL, G4CBL, G4CDXL

Tools required:

2 x adjustable spanners

1 x Phillips head screwdriver

1 x Regular screwdriver

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Congratulations on your purchase

Australia has an excellent safety record when it comes to gas appliances. This reflects both the

high quality of appliances sold, as well as growing consumer awareness about safety.

We urge you to follow the guidelines below together with these instructions for safe use, to

prevent overheating and to produce great cooking results.

 This barbeque is an outdoor appliance only. Under no circumstances should it be used

indoors.

 This barbeque has not been approved for marine use.

 Do not perform any servicing on the barbeque yourself. This includes internal adjustment of

the regulator and gas valves. Servicing can only be carried out by authorised technicians.

 It is important that you install your barbeque exactly as described in these instructions. In

particular: you should keep the barbeque clear of combustible material, and you should

check for leaks whenever a new connection is made.

 Do not store chemicals or flammable materials near this appliance.

 Do not place articles on or against, or enclose this appliance.

 The barbeque gets extremely hot while in use. Keep children away from the appliance until

it has cooled to normal temperatures.

 It is a good idea to tie back long hair and loose clothing while cooking in case of unexpected

flare ups.

 Fat fires are the most common cause of problems in barbeques. They are caused by a

build-up of grease in the grease channelling tray and the inside of the barbeque frame. A fat

fire can be difficult to put out, and will be dangerous if it spreads to the gas hose. You

should keep your barbeque clean to avoid this occurrence. Fat fires will void the warranty.

 Do not transport the barbeque whilst it is hot because there is a risk that the contents of the

grease cup will fall out.

 NEVER leave a barbeque unattended with any burners switched on. Always switch off all

burners and cylinders when the barbeque is not in use.

 Take care when touching a hot barbeque, especially on surfaces close to the firebox or

roasting hood.

 It is fine to pre-heat with all burners on HI and the hood closed, but NEVER let the

temperature on the hood thermometer exceed 250ºC on the hood thermometer.

 When cooking with the hood closed, turn one or more burners to LO or OFF as required to

keep the barbeque from getting too hot. NEVER let the temperature on the hood

thermometer exceed 250ºC on the hood thermometer.

 NEVER leave all burners on HI for more than 15 minutes, always stay in control by

adjusting burners to LO and OFF as required to maintain suitable cooking temperatures.

 Follow all manufacturers’ instructions to periodically check for gas leaks.

By following these instructions for safe and easy operation, you will enjoy years of satisfying,

trouble free outdoor cooking. And when you’re fully up and running, you can visit your retailer for

some great accessories and cooking tips to make your experience even more rewarding. But

first things first....

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Where to put your barbeque

This barbeque is an outdoor appliance only. Under no circumstances should it be used indoors.

You must observe the clearances listed on the data sticker on your barbeque. These tell you

how close you can put the barbeque to combustible surfaces (wood, gyprock, trees, wooden

fences etc.). If you don’t follow these clearances, nearby surfaces will heat up and could catch

fire.

If you purchased your barbeque in a cart:

You don’t need to be concerned with side clearances. The barbeque-cart combination has been

laboratory tested, and complies with relevant Australian Standards.

Keep the barbeque sheltered from the wind. Wind interferes with the flames and can prevent

your barbeque from heating up properly and can even damage some components.

Make sure the surface is level. This is safer, and makes cooking easier.

Don’t put the barbeque too close to windows or anywhere else where cooking smoke is likely to

cause a problem.

For Build-In Barbeques and Islands:

 Ensure you leave sufficient clearance underneath the barbeque for removal and cleaning

of grease channelling trays and receptacles.

 For non-combustible build-in construction, leave a minimum 50 mm clearance behind the

barbeque and do not block any side or front vents on the barbeque to allow the appliance

to function properly. The 615 mm dimension below includes this 50 mm.

 Ensure you leave sufficient space behind the barbeque to allow for the use of any

roasting hoods, in particular when they are in the fully opened position. See clearance

diagram below.

 The distances from the barbeque to combustibles stated on the data plate must still be

observed.

When installing the barbeque into a dedicated structure, ensure that the following is

observed:

Width:

2B: 560 to 565 mm

4B: 880 to 885 mm

Min 310 mm

Min 615 mm

Cylinder cabinet top

and bottom ventilation

details as detailed

below must be

observed.

Bbq must be separated from the cylinder cabinet.

Min 45 mm rear clearance

to allow the hood to open

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Where to put your barbeque (continued)

 Adequate clearance around the barbeque must be provided for safe and efficient

operation the clearances shown in the diagram below ensures that the burners have a

supply of fresh air to operate correctly. Failure to provide enough fresh air to the burners

can cause the production of potentially deadly noxious gases.

 The structure must be made of non-combustible material. Also, you need to ensure that

there is a clearance of at least 300 mm between the sides and rear of the barbeque and

any combustible material (e.g. wooden fences and gyprock walls and painted surfaces).

If part of the structure is composed of combustible materials, ensure that the combustible

material is separated from the sides and rear of the barbeque by at least 300mm.

 There must be at least 1000 mm vertically above the appliance and any combustible

material.

 At least 45 mm clearance is required from the rear of the build-in barbeque support

bracket body to allow the roasting hood to open freely. When fully open, the hood leans

back slightly to prevent accidental closure.

In addition, where the cylinder is kept in an enclosed space underneath or near the build-

in barbeque, the following must be observed:

 The cylinder must rest on a base to ensure that water will not accumulate, and that the

cylinder is clear of the surrounding soil.

 There must be at least 200 square cm of ventilation openings per cylinder stored, at both

the top and bottom of the cylinder compartment, so that any accumulating gas can

quickly escape to the outside air. At least 50 square cm of the lower ventilation must be

within 15 mm of the base of the enclosure.

 There must be a separation panel between the gas cylinder and the barbeque so that if a

high pressure gas leak occurs, there is no direct path between the cylinder compartment

and the bbq firebox.

Note that all these conditions are met by using prefabricated island (code: PBIM4L) available

from your local Barbeques Galore store.

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Where to put your barbeque (continued)

This appliance must only be used in an above ground, open air situation with natural ventilation,

without stagnant areas, where gas leakage and products of combustion are rapidly dispersed by

wind and natural convection. Any enclosure in which the appliance is used must comply with

one of the following:

(2) Within a partial enclosure that includes an overhead

cover and no more than two walls.

(1) Any enclosure with walls on all sides, but at

least one permanent opening at ground level,

and no overhead cover.

(3) Within a partial enclosure that includes an overhead

cover and more than two walls, the following shall apply:

(i) At least 25% of the total wall area is

completely open; and

(ii) At least 30% of the remaining wall area is

open and unrestricted.

(iii) In the case of balconies, at least 20% of the

total of the side, back and front wall areas

shall be and remain open and unrestricted.

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Checking the gas type and supply

Before assembling your barbeque, you should ensure your barbeque is suited to the type of gas

which you are going to use:

LPG, also known as Propane or Universal LPG:

Barbeques suited to LPG should have an orange sticker on the side saying “UNIVERSAL LPG”.

This is most commonly supplied as a portable 4 kg or 9 kg gas cylinder, which can be refilled or

swapped at petrol stations or your place of purchase when empty. Follow the assembly instruction

steps for how to fit and connect your portable cylinder.

Some homes have twin 45 kg LPG cylinders permanently installed near an outside wall. These

cylinders supply LPG gas to multiple appliances in the home via copper pipes, and are filled as

required by the gas supply company.

Natural Gas:

Barbeques suited to natural gas should have a white sticker on the side saying “NATURAL GAS”.

This is piped to your home in a similar fashion to water, so there are no cylinders to refill. You will

need to contact your local gas company to determine if Natural Gas is available in your area.

Fixed LPG Supply or Natural Gas Supply:

Barbeques which are connected to twin 45 kg LPG cylinders or to Natural Gas must be installed by

a licensed gasfitter, in accordance with the requirements of AS 5601, and local gas authority

requirements.

There are two approaches to installation:

(1) Permanent Piped Connection: Your barbeque may be permanently connected to the main

gas lines or LPG cylinders via copper pipe. This must be done entirely by the gasfitter, in

accordance with requirements of AS 5601, and local gas authority requirements. Your gasfitter will

ensure that your barbeque is permanently connected to the supply via copper pipe, the gas

pressure in the lines is adequate, pipe sizes are correct, all connections are secure, and that all

necessary components (such as secondary regulators and manual shutoffs) are included where

regulations require them. Once this is done, the barbeque cannot be moved. It is a permanent

fixture of the property.

(2) Bayonet Point: Alternatively, you can have the gas fitter terminate the gas line using a

“bayonet point”. This allows you to connect and disconnect the barbeque using a special hose and

bayonet termination. Such a hose is provided in the Natural Gas conversion kit NGCK250VJ.

Follow the instructions supplied with the kit to complete the connection. For LPG installations, an

appropriate hose is available from most barbeque retailers.

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Checking the gas type and supply (continued)

Even if your barbeque area already has a bayonet point, you will still need to call upon a gas fitter

to ensure that gas pressure is sufficient for your barbeque, and to ensure your barbeque functions

correctly before leaving. Where a gas fitter is required, the gasfitter must test the safety and

operation of the appliance before leaving, including gas pressure, ignition and burner operation.

Conduct a leak test before use.

To the installer: You must instruct the consumer on safe operation, and ensure these instructions

are left with the consumer before leaving the site.

To Change the Gas Type of Your Barbeque:

Your barbeque was manufactured to use LPG. It can thus be connected to LPG without any

alteration.

If you wish to connect your barbeque to natural gas, it will need to be converted beforehand using

the correct conversion jets (code: NGCJCDB) available at your nearest Barbeques Galore store.

This must be done by a licensed gas fitter or an authorised gas appliance technician. Connection

to the natural gas supply must be done by a licensed gasfitter.

If connecting to a standard bayonet outlet, the correct hose and governor assembly must be used

(code: NGCK250VJ) available at your nearest Barbeques Galore store). If connecting direct to the

gas supply, the gasfitter will need to use governor (code: RCV250) and appropriate fittings.

It is extremely dangerous to use the barbeque with the wrong type of gas. Fire or explosion may

result. Always conduct a leak test before use –see details later in this manual under “Safety leak

testing”.

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Contents list. Carefully unpack the carton and check all the parts:

1 x Firebox & Hood

Assembly

1 x Hood Handle with

screws, washers & bezels

2 x M6 Hex Nuts

1 x Cart / Cabinet

separator panel

1 x Hotplate

2 x Grease Channelling

Tray Brackets

4 x "S" Shaped Brackets

1 x Grease Cup(4B)

1 x Grease Channelling Tray

1 x Grease Channelling

Tray Handle

1 x Warming Rack

2 x Cooking Grills (4B)

1 x Cooking Grill (2B)

2 x M6*60mm Round Head

Screws

4 x M4*8mmRound Head

Screws (4B)

4 x M4*8mm Round Head

Screws (2B)

17 x M6*12mm Flat Head

Screws (4B)

14 x M6*12mm Flat Head

Screws (2B)

6 x Washer

φ 6.4 / 14.5mm

4 x M6*15mm Round Head

Screws

4 x Metal Washers

4B Deluxe only has these additional parts:

1 x AC / DC Transformer 20W

4 x Ceramic Tiles

1 x Ceramic Tile Rack

1 x Electronic Ignitor

1 x Ignitor Cover Box

1 x Motor Bracket

1 x Battery

1 x DC Motor

1 x Rotisserie Kit

1 x Motor Adaptor

Before you start, check that you have all the contents as above. Remove all items

Including any packing materials from the firebox and hood assembly.

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Assembly instructions

If you are assembling a cart model or steel island, make sure you have

the separately supplied steel cart (code MC2CBL for 2B, code

MC4CBL for 4B).Assemble the cart(s) before you start on the firebox /

hood assembly.

If you are assembling multiple units together (e.g. 2B and 4B to make

one 6B bbq), assemble the bbqs to their respective carts first.

If you are fitting side shelves and / or a side burner, make sure you

have the separately supplied pack of 2 shelves (code MC2CDFFL) or

pack of 1 shelf + 1 side burner (code MC2CDFSL).

If you are assembling a build-in or a non-steel island, make sure you

have the separately supplied build-in kit (code CDBIKL) and if

purchased, the separately supplied island (code PBIM4L for 4B

alustone island).

If you purchased an island, assemble the island before you start on the

firebox / hood assembly.

If you want to run up to two adjacent gas modules (e.g. 2B and 4B) from

a single gas supply, you will need separately supplied corrugated gas

extension pipe (code: CBGASEXT).

Keep the bbq head resting on its polystyrene foam base until ready to

instal onto the cart or island.

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Assembly instructions (continued)

STEP 1 ALL MODELS: Attach the hood handle to the hood.

WHAT YOU NEED:

2 x Washers 15 / 6.5*mm

2 x M6*12mm Round Head Screws

2 x Handle Bezels

(Above components are factory pre-assembled onto the hood handle not in the bolt pack)

CAREFULLY OPEN THE BBQ HOOD TO ACCESS THE HANDLE HOLES FROM INSIDE

From inside the hood, with the hood open, fit the screw first through the washer, then through the

hood, then through the bezel and into the hood handle as shown. Tighten firmly.

Remove the screw on the Handle View from inside the hood: View from outside the hood:

STEP 2 ALL MODELS: Attach the grease channelling tray brackets.

WHAT YOU NEED

2 x Grease Channelling Tray Brackets

4 x M4*8mm Round Head Screws (4B)

4 x M4*8mm Round Head Screws (2B)

Screw the left and rights side brackets to the separator panel. Make sure the stopper screw heads

are at the top back inside edge as shown below.

Page 11

Assembly instructions (continued)

(These next two steps assume that you have already assembled the

cart using the instructions included with the cart)

STEP 3 CART MODELS ONLY: Fix the cart / cabinet separator panel

into place.

WHAT YOU NEED

9 x M6*12mm Flat Head Screws (4B)

8 x M6*12mm Flat Head Screws (2B)

Locate the separator panel in place and start the screws (two each side, three on the back, 4B has

two in the top front corners, 2B has 1 only in front corner). Get all the screws started, and only then

tighten all screws firmly.

BEFORE ATTACHING THE BBQ IN THE NEXT STEP, ADJUST

THE DOORS AND CASTORS IF REQUIRED SO THAT THE

CART AND DOORS ARE LEVEL AND THE DOORS OPEN AND

CLOSE EASILY. REFER TO THE CART ASSEMBLY

INSTRUCTIONS FOR MORE DETAILS.

Page 12

Assembly instructions (continued)

STEP 4 CART MODELS ONLY: Fix the firebox and hood assembly onto

the cart.

WHAT YOU NEED

4 x "S" shaped brackets

8 x M6*12mm Flat Head Screws

4 x Metal Washers

(a) Insert four “S” shaped brackets into the cart slots, oriented as shown, and fix with 4 x

M6*12mm Flat Head Screws to lock the bracket to the cart side panel.

(b) With help, carefully lower the head unit onto the cart, fix 4 x M6*12mm Flat Head Screws

and 4 x Metal Washers through the hole on “S” shaped bracket and lock it to the head.

Tighten all screws firmly.

Take care when fitting the barbeque in

place to also thread the hose and

regulator through the access hole in the

left side of the separator panel.

For deluxe models only: the three

electric cables need also to thread

through the right side of the access

hole in the separator panel.

The “S” shaped brackets must have the nutsert at the

top and facing inwards as shown above

Page 13

Assembly instructions (continued)

STEP 5 ONLY IF JOINING ADJACENT BBQS:

If you are joining two carts together, e.g. a 2B and 4B to make a 6B, then first assemble each unit

onto its respective cart as above. Adjust the cart heights to match each other, and join the adjacent

carts and fireboxes as detailed below.

(a) Bolt the adjacent carts together

WHAT YOU NEED

4x M6*15mm screws

4x M6 hex nuts

Join the two carts using two M6*15mm screws, and hex nuts as shown below:

Follow the instructions that came with the cart to properly level the carts and adjust the castors if

necessary so they are all in contact with the ground once the carts are level.

Doors and bbq

head units not

shown for clarity

Page 14

Assembly instructions (continued)

(b) If the two adjacent modules are both barbeques, then bolt the

adjacent fireboxes together

WHAT YOU NEED TO JOIN THE BBQ FIREBOXES:

2 x M6 Hex Nuts

2 x Washers φ 6.4 /14.5mm

2 x M6*60mm screws

Join the 4B and 2B firebox using two M6*60mm screws, washers and hex nuts as shown.

(Note that the fibre washer goes immediately against the firebox inside the bbq)

Carts not shown

for clarity

Page 15

Assembly instructions (continued)

STEP 6 IF ATTACHING SIDE SHELVES:

Unscrew the 12 existing M6 x 15mm flat head screws as indicated

on the side panels. Keep the screws safely aside.

Page 16

Assembly instructions (continued)

STEP 7 CART MODELS ONLY: Attach the folding side shelf brackets

WHAT YOU NEED

4 x M6*40 mm long screws

.

STEP 8 CART MODELS ONLY: Attach the side shelf

Screw the side table bracket set to the left side of the bbq

using 4 pieces M6*40mm long screws and the two screws

already pre-fitted to the bracket set.

With the side shelf vertical,

hook it into place.

Tilt the shelf upwards and lock

it into its horizontal position

Push the edges down

to lock the shelf firmly

Page 17

Assembly instructions (continued)

STEP 9 CART MODELS ONLY: If the folding feature is not required,

the shelf can be bolted firmly in

place.

WHAT YOU NEED

2 x M6*12mm Locking nuts and bolts

for each shelf.

If folding is not required, lock the shelves into place with 1 x nut and bolt front and back as

below.

If you have two side shelves, attach the second side shelf in the

same way as the first, on the other side of the barbeque. Then

proceed direct to STEP 13.

If you have purchased a side burner, proceed with STEP 10 as

below.

Page 18

Assembly instructions (continued)

STEP 10 CART MODELS ONLY: Attach the side burner (if purchased)

WHAT YOU NEED

5 x M6*15mm short screws

Screw 4 pieces M6*15mm short screws

into the right side of the bbq as shown.

Do not screw in all the way. Leave a

5mm gap to allow the side burner to

hang over these screws in the next step.

Page 19

Assembly instructions (continued)

STEP 11 CART MODELS ONLY: Connect the side burner corrugated

gas pipe

The side burner corrugated gas pipe will already be connected to the side burner. You will need

to connect the other end to the bbq.

Use 1 piece M6*15mm short screw which

was removed from the bbq previously and

thread it through the side shelf and back

into the bbq control panel front corner hole

as shown. Tighten all screws.

(a) Remove the grease

channelling tray and use two

spanners to disconnect the

cap from the manifold outlet,

(one spanner to hold the

manifold, the other to loosen

the cap).

(b) Thread the

corrugated gas pipe from

the side burner through

the bbq as shown. You

will need to gently bend

the pipe a little to help

guide it into place.

(c) Connect the

corrugated gas pipe to the

manifold using two

spanners (one spanner to

hold the manifold, the

other to tighten the fitting).

Tighten firmly.

Page 20

A leak test as outlined later must be done when connecting to the gas and before lighting the bbq.

Once you have assembled both side shelves, proceed to Step 13

Assembly instructions (continued)

Only if you have purchased a build-in or an island:

STEP 12 BUILD-IN / ISLANDS ONLY: Attach the build in support

brackets and separator panel.

WHAT YOU NEED

1 x separately supplied build-in kit (code CDBIKL) includes:

2 x brackets

8 x M6*35mm screws

1 x 4B front dress piece

Only for 2 burner build-in, you may also require separately supplied grease channelling tray front

dress piece (code: CDBIK2)

(a) Carefully lay the firebox / hood assembly on its back as shown.

(b) Unscrew the existing M6*15 mm flat head screws on the side panels as indicated below.

(d) Adjust the corrugated

gas pipe so that it is neat

and out of the way. It is

safe to bend this pipe

gently by hand.

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