Calflame G-3000 Sports Bar 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: [phone]
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™ 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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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
Barbecue Owner’s Manual
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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 CONNECTALL NATURAL GAS HOOK-UPS.
CALIFORNIAACRYLICS INDUSTRIES (C.A.I.) WILL NOT BE HELD RESPONSIBLE INANY
WAY FOR AN IMPROPERLY CONNECTED GAS LINE.
THE LIGHTING INSTRUCTIONS FOR THE ISLANDSAND 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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Barbecue Owner’s Manual
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 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 TRYTO FIX THE PROBLEM YOURSELF..
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Barbecue Owner’s Manual
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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Barbecue Owner’s Manual
Delivery and Set-Up
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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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