Calflame 2005 Spa User manual

LTR20051000, Rev D
7/21/2005

2005 Spa Owner's Manual Page ii
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: [phone]
www.calspas.com
Copyright 2004, 2005 California Acrylic Industries, Inc. All rights reserved. Duplication without
written consent is strictly prohibited.
Cal Spas™, Adjustable Therapy System™, ATS™, Bio-Clean™, Cal Balance™, Cal
Entertainment System™, Cal Zone Quest 1000™ and Cal Zone Quest 2000™, Cal Sweep™, Cal
Select™, Fitness Spa Series™, Spa Cal™, and XL Heat Exchanger are registered trademarks.
Due to continuous improvement programs, all models, operation, and/or specifications are
subject to change without prior notice.
LTR20051000, Rev D
7/15/2005
7/21/2005

Table of Contents
2005 Spa Owner's Manual 7/21/2005
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 ................................................ 38
LED Lights............................................................................................................ 39

Table of Contents
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Operating the Cal Flame Entertainment Center
Splash Stereo System ......................................................................................... 40
Entertainment Systems........................................................................................ 40
Cal Flame Entertainment System Operation ....................................................... 43
Operating the DVD System In TV Mode.............................................................. 44
Cleaning and Maintenance
Cleaning Instructions............................................................................................ 46
Care of Stainless Steel Carts & Grills .................................................................. 51
Covering Your Stainless Steel Cart ..................................................................... 51
After Use Care ..................................................................................................... 51
Appendix
Troubleshooting Procedures................................................................................ 52
Parts List .............................................................................................................. 55
Warranty Information............................................................................................ 57

Read This First!
2005 Spa Owner's Manual Page 1
7/21/2005
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 TECHNICIAN 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 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 qualified
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 (oceanfront,
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 gasoline.
•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.

Read This First!
Page 2 2005 Spa Owner's Manual
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•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 cooking
areas. This reduces the risk of burns, ignition of flammable materials, and spillage due to accidental 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.
•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.

Read This First!
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•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 To 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 TRY TO FIX THE PROBLEM YOURSELF..

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 property to
prevent unsupervised access to the property by children under the age of five. Your dealer can provide
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 possible.
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.
Figure 1 through Figure 4 show the four different kinds of cut-outs, the appliances each cut-out will
accommodate, and the cut-out dimensions for each appliance.

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 ¼
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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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 1/2 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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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 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 LP or 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 purchase 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 determined with the LP-
gas supply cylinder in place. This shall be accomplished in one of the following 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 180Þ (3.14 rad), and unobstructed. Each opening shall have a total free area of not less than
one square inch per pound (7.1 cm²/kg) of stored fuel capacity, and not less than a total free area of 10
square inches (64.5 cm²).
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 cm²/kg) of stored fuel capacity and not less than a total free area of 10
square inches (64.5cm²). 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
2005 Spa Owner's Manual Page 7
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Delivery and Set-Up
Page 8 2005 Spa Owner's Manual
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inches (127 mm) above the floor. The openings shall be equally sized, spaced at 180Þ (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 system 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.
5. Stop a leak by tightening the loose joint or by replacing the faulty part with a replacement part
recommended by the manufacturer. Do not attempt to repair the cylinder valve if it is damaged. The
cylinder must be replaced.

Delivery and Set-Up
2005 Spa Owner's Manual Page 9
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6. 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.
7. Push in and turn any control knob to release pressure in the hose and manifold.
8. 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 LP or 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 standard
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.

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 (Figure 6).
3. Through the access door underneath the grill, find the round stud and locking pin that locks the burner you
want to replace (Figure 7 and Figure 8).
Figure 6 Figure 7
Figure 8
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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 locking 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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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 fingertips, push and flatten out the speed set into the seam line (Figure 15).
Figure 14 Figure 15
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Assembly and Installation
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 (Figure 16 and Figure 17).
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.
2005 Spa Owner's Manual Page 13
6. Prepare mortar in a container.
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Assembly and Installation
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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.
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.

Assembly and Installation
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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 orientation.
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 connection
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 applicable). A
manual shut-off valve is recommended for safety reasons.
10. Connect tap water and drainage line (if applicable)

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. 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.
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
Figure 20. Side burner installation
Page 16 2005 Spa Owner's Manual
7/21/2005