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$5.00
2005 Owner’s Manual
BARBECUES
DROP-IN GRILLS
ISLANDS
CARTS
G3000 ISLAND / SPORTS BAR
manufactured after December 1, 2004
www.calspas.com
Due to continuous improvement programs, all models, operation, and/or specifications are subject to change without prior notice.
LTR20051004, Rev. 12/17/04
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C o m m i t m e 9 n 7 t t 9 o 1 E x E 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 California Acrylic Industries, Inc. All rights reserved. Duplication without written consent is strictly prohibited. Cal Spas™ and Cal Flame
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Table of Contents 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 B
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Table of Contents 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 & G
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Read This First! 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. CALIFORNIA ACRYLICS 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 SERIO
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Read This First! • 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 stru
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Read This First! • 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 m
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Delivery and Set-Up 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
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Delivery and Set-Up 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/
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Delivery and Set-Up 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
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Delivery and Set-Up 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
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Delivery and Set-Up 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 plum
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Delivery and Set-Up 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
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Assembly and Installation 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 Figur
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Assembly and Installation 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 lo
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Assembly and Installation 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 finger
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Assembly and Installation 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. Plac
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Assembly and Installation 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.
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Assembly and Installation 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
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Assembly and Installation 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. Ins
