Cal Flame G3000 User manual

Due to continuous improvement programs, all models, operation, and/or specifications are subject to change without prior notice.

$5.00

2005 Owner’s Manual

BARBECUES

DROP-IN GRILLS

ISLANDS

CARTS

G3000 ISLAND / SPORTS BAR

manufactured after December 1, 2004

LTR20051004, Rev. 12/17/04

www.calspas.com

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

without written consent is strictly prohibited.

Cal Spas™ and Cal Flame™ are registered trademarks.

Due to continuous improvement programs, all models, operation, and/or specifications are subject to

change without prior notice.

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12/17/04

Read This First!

General Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Precautions Regarding Children . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Other Common Sense Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

What To Do If You Smell Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Delivery and Set-Up

Planning the Best Location For Your Barbecue . . . . . . . . . . . . . . . . . . . . . . . . . .4

Liquid Propane Gas Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Natural Gas Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Assembly and Installation

Infrared Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Barbecue Island Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Granite Kit Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Barbecue Cart End Shelves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Modular Carts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Side Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

New Access Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Griddle and Griddle Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

G3000 Island / Sports Bar Canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Operating Your Barbecue

Cal Flame Familiarization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Operating the Grill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Cooking with the Rotisserie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Cooking with the Convection 3000 Grill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Turning on and off the Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Charcoal Grill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Griddle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Drop-In Food Warmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

30” Warming Drawer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Canopy Waterfall and Barbecue Island Waterfall . . . . . . . . . . . . . . . . . . . . . . .39

LED Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Operating the Cal Flame Entertainment Center

Splash Stereo System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Table of Contents

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Entertainment Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Cal Flame Entertainment System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Operating the DVD System In TV Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Cleaning and Maintenance

Cleaning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Care of Stainless Steel Carts & Grills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Covering Your Stainless Steel Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

After Use Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Appendix

Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Table of Contents

Barbecue Owner’s Manual

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Read This First!

YOU ARE RESPONSIBLE FOR ENSURING THAT A NATURAL GAS LINE IS INSTALLED

AND SAFE TO USE. WE HIGHLY RECOMMEND THAT YOU HAVE A LICENSED TECHNI-

CIAN RUN ALL NATURAL GAS LINES AND CONNECT ALL NATURAL GAS HOOK-UPS.

CALIFORNIAACRYLICS INDUSTRIES (C.A.I.) WILL NOT BE HELD RESPONSIBLE IN ANY

WAY FOR AN IMPROPERLY CONNECTED GAS LINE.

THE LIGHTING INSTRUCTIONS FOR THE ISLANDS AND CARTS IS IDENTICAL.

FOLLOW THESE INSTRUCTIONS CAREFULLY, AS ANY DEVIATION MAY RESULT IN

SERIOUS INJURY OR POSSIBLY DEATH.

General Safety Precautions

Please read before installing and operating your new Cal Flame™ grill.

•Your new gas grill should be professionally installed by a licensed contractor. Refer to the instructions

in this manual to ensure proper and safe installation and operation.

•To prevent fire and smoke damage, remove all packaging material before operating grill.

• Before you start cooking,, clean the grill thoroughly with hot, soapy water. This is necessary to

remove residual solvents, oil and grease which may have remained from the manufacturing process.

The grates should also be thoroughly cleaned in the same manner.

• Spiders and other insects can nest in the burners of the grill and block the gas and airflow to the

burner ports. This creates a dangerous condition that can result in a fire from behind the valve panel.

Inspect and clean the burners periodically and follow the guidelines in the Cleaning and Maintenance

section of this manual.

• In the event that a burner goes out and gas escapes, turn off the burner knobs, open the grill hood fully

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.

• Unless specifically recommended in this manual, do not repair or replace any part of the grill. A quali-

fied technician should perform all of the service. Any repairs made by a non- C.A.I. approved dealer

technician will void your warranty.

• Never use the grill without the drip pan in place, pushed all the way to the rack located just under the

grill. Without it, hot grease could leak downward and produce a fire or explosion hazard.

• Keep any electrical supply cord or the rotisserie motor card away from the heated areas of the grill.

• Never use the grill or side burner in windy conditions. If located in a consistently windy area (ocean-

front, mountaintop, etc.) a windbreak will be required. Always adhere to the specified clearances

listed in this manual.

• The area surrounding your new grill should be kept clean and free from flammable liquids and other

combustible materials such as mops, rags or brooms, as well as solvents, cleaning fluids, and gaso-

line.

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Read This First!

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• Do not use the grill as a storage area for flammable or plastic items, which may ignite. Do not store

any materials inside or near barbecue island. Do not store the liquid propane (LP) cylinder in the

vicinity of this or any other appliance when it is not being used.

• 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.

• 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.

Precautions Regarding Children

• Never leave children unattended in the area where the grill is being used.

• Do not store items of interest to children around or below the grill or island.

• Never allow children to sit or stand on any part of the grill or island.

Other Common Sense Precautions

• Never leave the grill and side burners unattended while using high flame settings. Boil-overs cause

smoking and greasy boil-overs may ignite.

•Always use the proper size pan. Select utensils with flat 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

flame. This can scorch utensils and hamper cleanup. Excessive flames 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 inward, so they do not extend over adjacent work areas or cook-

ing areas. This reduces the risk of burns, ignition of flammable materials, and spillage due to acciden-

tal contact with the utensils.

• Do not use water on grease fires. Never pick up a flaming pan. Turn the appliance off and smother the

flaming pan with a tight-fitting lid, a cookie sheet or a flat tray. For flaming grease outside of the pan,

smother it with baking soda or use a dry chemical or foam-type fire extinguisher.

• Never let clothing, potholders or other flammable materials come in contact with or close to any

grate, burner or hot surface until it has cooled. 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.

•Proper apparel is a safety consideration. Never wear loose fitting or hanging garments while using

your new grill.

• Only use dry potholders - do not use a towel or other bulky cloth in place of potholders. Moist or

damp potholders 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.

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• Do not use charcoal in a gas grill or side burner.

• 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 flat even 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.

• Do not block the vents located in the cabinet area of your Cal Flame™ Island or stainless steel cart as

gas may build up in case of leak and cause serious damage.

•Your grill must be plugged into a permanent, grounded 110V outlet with a dedicated 15A GFCI

breaker. Do not use an extension cord to supply power to your Cal Flame™ Island, grill or cart. Such

use may result in fire, 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.

•Do not reach over your grill or any other surfaces when hot or in use.

What T

o Do If You Smell Gas

1. Shut off gas to grill.

2. Extinguish any open flame.

3. Open lid.

4. If odor persists, immediately call your gas supplier or your fire department.

DO NOT TRYTO FIX THE PROBLEM YOURSELF..

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Delivery and Set-Up

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Delivery and Set-Up

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 prop-

erty to prevent unsupervised access to the property by children under the age of five. Your dealer can pro-

vide information on which permits may be required and how to obtain them prior to the delivery of your

equipment.

Safe and satisfactory operation of your new grill depends upon its proper installation. The installation,

adjustments and service of your new grill must be performed by C.A.I. qualified installers and service

technicians. This is necessary to ensure proper operation and prevent accidents.

Planning the Best Location For

Your Barbecue

Location

Your barbecue is for outdoor use only!

When planning your Cal Flame™ Island or cart location, be sure to consider the shortest gas line run pos-

sible. Also, take into consideration the necessity of having a 110V power source for use of your

appliances (e.g. lights, rotisserie, refrigerator, receptacles, etc.).

When determining a suitable location, take into account concerns such as exposure to wind, proximity to

traffic paths, and windows that open into the home.

Locate BARBECUE Islands grills and stainless steel carts in well ventilated areas, and only on

solid, flat foundations (e.g. cement slab or deck). Do NOT place barbecue islands / outdoor kitchens

or stainless steel carts on dirt or grass.

Built-in Installation

Your new grill is designed for easy installation into a non-combustible enclosure. The supporting deck

and counter must be level and flat. When determining the final location of your grill, provide ventilation

in the enclosure so that gas will not become entrapped in the event of a leak. Make sure that you have one

vent placed at floor level and the other at five inches above floor level.

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. Do not cut or remove the

grounding prong from the plug.

Cabinet Cut-Out Dimensions for Gas Grill and Accessories

Safe and satisfactory operation of your new grill depends upon its proper installation. The installation,

adjustments and service of your new grill must be performed by C.A.I. qualified installers and service

technicians. This is necessary to ensure proper operation and prevent accidents.

Figures 1 through 4 show the four different kinds of cut-outs, the appliances each cut-out will accommo-

date, and the cut-out dimensions for each appliance.

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Figure 1

Model Hardware Cutout Dimension

Width (In) Depth (In) Height (In)

BARBECUE872 2 Burner Grill 23 1/2 22 1/2 9 1/4

BARBECUE873 3 Burner Grill 23 1/2 22 1/2 9 1/4

BARBECUE874 4 Burner Grill 30 3/4 22 1/2 9 1/4

BARBECUE874C 4 Burner Convection Grill 30 3/4 22 1/2 9 1/4

BARBECUE875 5 Burner Grill 38 1/4 22 1/2 9 1/4

BARBECUE875C 5 Burner Convection Grill 38 1/4 22 1/2 9 1/4

BARBECUE870 Charcoal Grill 30 3/4 22 1/2 9 1/4

BARBECUE898 Deluxe Single Side Burner 12 1/4 22 7 3/4

BARBECUE899 Deluxe Double Side Burner 12 1/4 22 7 3/4

12" Cocktail Center 12 1/4 22 7 3/4

18" Cocktail Center 17 1/4 24 10

Drop In Ice Chest 30 3/4 22 1/2 9 1/4

Drop In Food Warmer 12 1/4 22 7 3/4

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Figure 2

Model Hardware Cutout Dimension

Width (In) Depth (In) Height (In)

BARBECUE874F 4 Burner Flat Drop In Grill 38 1/4 22 1/2 >18"

BARBECUE852 Drop In Standard Side Burner 11 1/4 17 3/4 >3 1/2"

Drop In Sink 14 14 >12"

Drop In Food Warmer 12 22 >7 3/4”

Figure 3

Model Hardware Cutout Dimension

Width (In) Depth (In) Height (In)

Propane Tank Access Door 14 1/2 16 1/4 20 1/4

Single Access Door 16 1/2 2 1/2 19 1/2

Double Access Door 28 1/2 2 1/2 19 1/2

2 & 3 Drawer Storage 10 1/2 19 3/4 17 1/4

One Big One Small Drawer 10 1/2 19 3/4 17 1/4

Griddle and Griddle Storage 13 1/2 19 2 1/2

Warming Drawer 28 3/4 21 10

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Figure 4

Model Hardware Cutout Dimension

Width (In) Depth (In) Height (In)

Outdoor Pull Out Refrigerator / Deluxe Refrigerator 25 >26" 34 1/8

Standard Refrigerator Stainless Steel Door 21 1/4 >26 34 1/8

Beer Tap Refrigerator 21 1/4 >23" 34 1/8

Liquid Propane Gas 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™ grills are either manufactured to operate on either liquid

propane (LP) or natural gas (NG) and cannot be converted. To verify the grill’s

operating fuel, remove the bottom drip pan and check the serial number label on

the left. Either LPor 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 void the warranty coverage.

NOTE: If you do not have an updated filler valve on your existing propane tank, you will need to pur-

chase one at your local hardware store, as you will not be allowed to refill the tank at any filling

station.

LP Gas Hook Up

NOTE: An enclosure for an LP gas cylinder shall be vented by openings at the level of the cylinder valve

and at floor level. The effectiveness of the opening(s) for purposes of ventilation shall be deter-

mined with the LP-gas supply cylinder in place. This shall be accomplished in one of the fol-

lowing manners:

1. One side of the enclosure shall be completely open.

2. Enclosures that have four sides, complete with a top and bottom:

a. At least two ventilation openings at cylinder valve level shall be provided in the sidewall, equally

sized, spaced at 180˚ (3.14 rad), and unobstructed. Each opening shall have a total free area of not

less than one square inch per pound (7.1 cm≈/kg) of stored fuel capacity, and not less than a total

free area of 10 square inches (64.5 cm≈).

b. Ventilation opening(s) shall be provided at floor level and shall have a total free area of not less

than one square inch per pound (7.1 cm≈/kg) of stored fuel capacity and not less than a total free

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area of 10 square inches (64.5cm≈). If ventilation openings at floor level are in a sidewall, there

shall be at least two openings. The bottom of the openings shall be at floor level and the upper

edge no more than 5 inches (127 mm) above the floor. The openings shall be equally sized,

spaced at 180˚ (3.14 rad) and unobstructed.

c. Every opening shall have minimum dimensions so as to permit the entrance of a 1/8 inch (3.2 mm)

diameter rod.

LP Gas Manifold Pressure

For plumbed-in LP installation, use a convertible regulator and set it for LP gas.

LP Gas Supply Pressure

Maximum line pressure for plumbed-in propane is 14” WC psi (3.5 kPa). Minimum line pressure for

propane is 11” WC.

LP Gas Pressure Regulator

The unit must be used with the gas pressure regulator. The regulator will control and maintain a uniform

gas pressure in the manifold. The burner orifices have been sized for the gas pressure delivered by the

regulator.

LP Gas Cylinder Specification

Any LP gas supply cylinder used with this grill must be 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.) Always use the cylinder dust cap on the

cylinder valve outlet during transport and when the cylinder is not connected to the grill.

Transporting the LP Gas Supply Cylinder

Transport only one cylinder at a time. Transport each cylinder in an upright and secure manner with the

control valve turned off and the dust cap in place.

Leak Testing Procedure for LP Gas

Perform a leak test at least once each 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 sys-

tem 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 flame, such as a

lighted match to test for leaks. Use only a leak testing solution of sudsy water.

1. Prepare a leak testing solution of sudsy water by mixing in a spray bottle one part liquid soap to one

part water.

2. Make sure all the control knobs are in the OFF position.

3. Turn the cylinder valve knob counter clockwise one turn to open.

4. Apply the leak-testing solution by spraying it on joints of the gas delivery system. Blowing bubbles in

the soap solution indicates that a leak is present.

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6. Stop a leak by tightening the loose joint or by replacing the faulty part with a replacement part recom-

mended by the manufacturer. Do not attempt to repair the cylinder valve if it is damaged. The cylin-

der must be replaced.

7. If you are unable to stop a leak, shut off the gas supply at the cylinder valve and remove the cylinder

from the grill. Call an authorized gas appliance service technician or an LP gas dealer. Do not use the

appliance until the leak is corrected.

8. Push in and turn any control knob to release pressure in the hose and manifold.

9. Turn off the control knob.

Natural Gas 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™ grills are either manufactured to operate on either liquid

propane (LP) or natural gas (NG) and cannot be converted. To verify the grill’s

operating fuel, remove the bottom drip pan and check the serial number label on

the left. Either LPor 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 void the warranty coverage.

IMPORTANT: Never connect the grill to an unregulated gas supply.

The installation of this appliance must conform with local codes or, in the absence of local codes, to the

national fuel gas code, ANSI Z223.1a-1998. Installation in Canada must be in accordance with the stan-

dard CAN/CGA-B149.2, Propane Installation Code.

Natural gas connections must be performed by a licensed contractor or local gas company representative.

Ensure that the service supplying the grill is fitted with a shut off valve conveniently positioned near the

grill and giving ease of access.

Your Cal Flame™ grill for use with natural gas comes equipped with its own regulator which MUST

NOT be removed. If, this regulator needs to be replaced use only the type specified by Cal Flame™ for

this appliance.

1. Remove the rear panel from the barbecue to gain access to the regulator and gas connection point.

2. Connect a suitable flex connector to the grill regulator.

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Assembly and Installation

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Assembly and Installation

Infrared Burners

Figure 5

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 (Fig-

ure 6).

3. Through the access door underneath the grill, find the round stud and locking pin that locks the burner

you want to replace (Figures 7 and 8).

Figure 6 Figure 7

Figure 8

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4. Carefully remove the locking pin with your fingers.

5. Raised the stud from the locking hole and move the burner forward carefully to release it from the

ignition and gas supply valve.

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 lock-

ing hole.

8. Adjust the infrared burner, make sure the burner is aligned and in position.

9. Install the locking pin. Through the access door underneath the grill, find the stud to lock the burner

in place, install the locking pin. Make sure the locking pin is secured correctly.

10. Repeat steps 2 through 9 if you want to replace other burners.

Figure 9

11. Put back the grate you just removed. (You don’t need flame tamer for infrared burners.)

12. Reconnect or turn on the gas line.

You have just successfully replaced the regular burner with infrared burner. If you want to change back to

regular burners, just follow the procedure above in reverse order.

Barbecue Island Sections

Stucco Assembly

1. Place the island sections together on the ground (Figure 10).

2. Make sure the ground where the barbecue is place is as level as possible for best alignment (Figure

11).

NOTE: If the ground is not level, use shims to level out the island sections. This needs to be done before

you place the bolts.

3. Connect the speakers, lights, and main power cables before sliding the sections together.

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Figure 10 Figure 11

4. Insert the bolts through the pre-drilled holes from the inside of the barbecue island (total of four bolts

on each side) (Figure 12).

5. Insert the upper bolts as shown (Figure 13). Tighten the bolts all the way using a 9/16" wrench.

Figure 12 Figure 13

6. Prepare and fill the gap or seam line with speed set (Figure 14).

7. Using your fingertips, push and flatten out the speed set into the seam line (Figure 15).

Figure 14 Figure 15

NOTE: Allow the speed set to dry before proceeding with the next step.

8. Using a small brush or hopper gun, apply stucco to the seam line (Figures 16 and 17).

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Figure 16 Figure 17

9. Mix grout with water in a container.

10. Fill the tile seam line with grout using a small spatula or your finger (Figure 18).

11. Clean the grout with a damp rag (Figure 19).

12. Let the grout and stucco dry for at least three hours.

Figure 18 Figure 19

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. This needs to be done before

you place the bolts.

3. Connect the speakers, lights, and main power cables before sliding the sections together.

4. Insert the bolts through the pre-drilled holes from the inside of the barbecue island (total of four bolts

on each side).

5. Insert the upper bolts as shown. Tighten the bolts all the way using a 9/16" wrench.

6. Prepare mortar in a container.

7. Apply mortor to the gaps left open between the island assembly (front and back).

8. Let it dry for 15 to 30 minutes and brush the area where the mortar mix was applied.

9. Prepare grout in a second container.

10. Fill the tile seam with grout using a small spatula or your finger.

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Assembly and Installation

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11. Clean the grout with a damp rag.

12. Let the grout and mortar dry for at least three hours.

Granite Kit Instructions

Granite kits come in the following colors. Each contains various tinting colors as listed below:

Sapphire Brown New Venetian Gold Uba Tuba (Labrador) Giallo Veneziano

Black White Black Red-Brown

White Yellow White Yellow

Blue Blue Green Black

Brown White

1. Pour a small amount of epoxy and a small drop of each tint color on a piece of a cardboard.

2. Apply a small amount of the first tint color to the epoxy material using a mixing stick.

3. Mix the epoxy material well with the first tint color.

Note: Refer to the granite tint color reference chart.

4. Apply a small amount of the second tint color to the epoxy mixture.

5. Mix the epoxy mixture well with the second tint color.

6. Apply a small amount of the next tint color to the epoxy mixture.

7. Mix the epoxy mixture well with the next tint color and compare it with the color of the granite top.

8. If the colors do not match, add a tiny amount of tint color (one at a time) and mix it until you match

the color of the granite top with the epoxy mixture.

9. Once you match the color of the epoxy mixture to the color of the granite top , apply and mix a tiny

amount of hardener to the epoxy mixture.

10. Quickly fill one portion of the seam line with the epoxy mixture using a razor blade.

11. Remove the excess epoxy material from the seam line using a razor blade.

12. Let the epoxy material cure for five minutes.

13. Mark small dots in the seam line using a black permanent marker.

14. Pour a small amount of epoxy and hardener separately on a piece of cardboard.

15. Mix the epoxy material well with the hardener.

16. Quickly apply the epoxy mixture to the seam line with a razor blade.

17. Remove the excess epoxy material from the seam line using a razor blade.

18. Let the epoxy material cure for five minutes.

19. Repeat the previous steps until all the seam line is filled with epoxy mixture.

20. Clean the surface of the seam line with acetone.

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Barbecue Cart End Shelves

1. Prepare the installation of handle: 2 hex screws, 2 washers

2. Use finger to thread the hex screws and washers into the threads on both ends of the handle.

3. Use ratchet to tighten the hex screws on both ends. The handle has been installed onto the shelf.

4. Take the three screws off on both sides of the cart to install the mounting bracket.

5. Install the mounting brackets on both sides. Make sure the mounting brackets are in the correct orien-

tation. Two mounting brackets have been installed onto the cart.

6. Slides the shelf into the brackets from bottom as shown.

7. Make sure to slide into the brackets on both side evenly.

8. Slide the shelf fully onto the mounting brackets.

9. Lift and rotate the shelf so it slide back into the brackets.

10. Keep the shelf in the normal open position.

11. Prepare to install stop brackets under the mounting brackets on both sides.

12. Remove one screw and loose the another screw so the stop bracket can be placed as shown. Tighten

both screw to hold the stop bracket.

The shelf has been installed onto the cart.

Modular Carts

Modular carts consists of main center modular, side modular, corner connection modular and end shelf

modular. Individual modular cart comes in a carton box pre-assembled. Customers are required to piece

together the individual modular using the hardware supplied when they install the modular cart system.

1. The modular cart system is designed for outdoor use only. It’s dangerous to use the system inside or

at place without good ventilation.

2. Choose a place outdoor you want to use and store the system.

3. Unpack the carton boxes include the main center modular, optional side modular and corner connec-

tion modular.

4. Find the connection hardware (screws and nuts) in the cartons.

5. First connect the corner connection modular with the main center modular on both side (if applicable)

Make sure the center modular and connection modular are aligned.

6. Connect the side modular with the corner connection modular on both sides (if applicable). Make sure

all the modular are perfectly aligned.

7. Add the end shelf on both sides of side modular (if applicable)

8. If use propane as fuel, connect the propane tank with main center modular and a separate propane

tank for side modular (if applicable)

9. If using natural gas, connect the center modular with the gas line, and also side modular (if applica-

ble). A manual shut-off valve is recommended for safety reasons.

10. Connect tap water and drainage line (if applicable)

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Assembly and Installation

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Side Burners

1. Install side burner into an area of 17-1/2" long, 11" wide and 3" deep.

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.

4. Connect the flexible hose (male end) to the pipe tee with pipe sealant.

5. Install and secure the side burner into the island by simply setting it in place.

6. Connect the female end of the flexible hose to the side burner intake pipe with pipe sealant.

7. Connect gas supply to the grill.

8. Check for gas leaks using soap water solution.

Figure 20. Side burner installation

BARBECUE GASLINE

C

B

A

B

C

A

Connect the last open line to the side burner

(Use gas rated tape seal on all connections)

Then take other end of "T" adapter with hose attached

and connect to end of male located underneath and at

the back of the grill. (Use gas rated tape seal on all

connections).

Open barbecue door. Install hose with regulator on propane

tank. Then connect other end to "T" adapter. Make sure to

use gas rated tape seal when installing adapter to insure

proper seal.

Grill

Items Included with Barbecue

1) "T" adapter (3/8")

2) 2 each Hose 3/8" Fittings

3) Regulatorw/ Hose

NOTE: You will need to use a gas rated

sealer on all gas connectors (Tape,

pipe dope, ect.)

To Propane Tank

3/8" Fittings

From Grill

From Side Burner

"T" Adapter (3/8" Threaded)

To side burner, located

underneath behind burner.

To grill, located

underneath and

behind grill

Gas Line

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