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Cal Flame G3000 Owner's Manual

Barbecues drop-in grills, islands, carts, g3000 island / sports bar
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See also: User Manual
$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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  • Page 1 $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...

  • Page 2: Contact Information

    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.

  • Page 3: Table Of Contents

    G3000 Island / Sports Bar Canopy ........19...
  • Page 4 Entertainment Systems ......... . .41 Cal Flame Entertainment System Operation ......45 Operating the DVD System In TV Mode .

  • Page 5: Read This First

    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.

  • Page 6: Precautions Regarding Children

    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.

  • Page 7: What To Do If You Smell Gas

    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.

  • Page 8: Delivery And Set-Up

    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.
  • Page 9 4 Burner Grill BARBECUE874C 4 Burner Convection Grill BARBECUE875 5 Burner Grill BARBECUE875C 5 Burner Convection Grill BARBECUE870 Charcoal Grill BARBECUE898 Deluxe Single Side Burner BARBECUE899 Deluxe Double Side Burner 12" Cocktail Center 18" Cocktail Center Drop In Ice Chest Drop In Food Warmer Barbecue Owner’s Manual...
  • Page 10 Delivery and Set-Up Model BARBECUE874F 4 Burner Flat Drop In Grill BARBECUE852 Drop In Standard Side Burner Drop In Sink Drop In Food Warmer Model Propane Tank Access Door Single Access Door Double Access Door 2 & 3 Drawer Storage One Big One Small Drawer Griddle and Griddle Storage Warming Drawer...

  • Page 11: 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.
  • Page 12 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.

  • Page 13: Natural Gas Requirements

    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.

  • Page 14: Assembly And Installation

    Assembly and Installation Assembly and Installation Infrared Burners 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).

  • Page 15: Barbecue Island Sections

    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.
  • Page 16 Assembly and Installation Figure 10 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 6.
  • Page 17 Figure 16 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 Rock / Stone Assembly For Models G-2500, G-2500F, G-2600, G-3000, G-3500F, G-3600...

  • Page 18: Granite Kit Instructions

    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 Black...

  • Page 19: Barbecue Cart End Shelves

    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.

  • Page 20: Side Burners

    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.

  • Page 21: New Access Doors

    New Access Doors 1. Provide a cut out and a door jamb with inside dimensions as follows: 16 1/4" X 19 “ for a single door 28 1/4” x 19 3/8” for double doors 2. Secure the steel frame with 16 #10 x 1” truss head phillips screws. 3.

  • Page 22: Griddle And Griddle Storage

    Assembly and Installation Griddle and Griddle Storage Similar to installing a drawer, you need to have a cutout on your barbecue island as shown in Figure3. Align the enclosure as shown, opening facing out. Make sure the enclosure is aligned horizontally. Tighten the mounting screws on both side of the enclosure to lock the enclosure in place.

  • Page 23: G3000 Island / Sports Bar Canopy

    G3000 Island / Sports Bar Canopy While the G3000 Island / Sports Bar Canopy is intended for outdoor use, some precautions must be taken when using and caring for your new Cal Flame™ equipment. When the equipment is not being used, or especially in times of inclement weather, it is the owners responsibility to remove and store the electronic equipment that is listed in this manual.
  • Page 24 Antenna Match up the coaxial end (female) with the other coaxial end (male) and securely attach them together. Run the single antenna coaxial cable into the 3-way splitter (located under the grill of the G3000 Island/ Sports Bar itself). Canopy Assembly The following instructions will allow you to assembly the canopy section of the G3000 Island/ Sports Canopy.
  • Page 25 Figure 24. Canopy mounting tabs and support sleeves Figure 25. Canopy mounting tabs and support sleeves Mounting the G3000 Island/ Sports Bar Canopy CAUTION: THE FOLLOWING STEP IS A TWO-PERSON PROCEDURE. THE CANOPY, AT THIS STAGE, IS EXTREMELY HEAVY. WE STRONGLY RECOMMEND THAT YOU HAVE SOMEONE HELP YOU.
  • Page 26 Assembly and Installation Awning Installation All screws used for the installation of the awning are self-tapping sheet metal screws. No drilling is neces- sary. 1. Line up the holes for the awning bracket with the corresponding pre-drilled holes on the awning. Use two carriage bolts for the upper two holes and a flat-head Phillips for the single lower hole.
  • Page 27 Assembly and Installation Awning Open/ Close Switch The two-position (male) connector has 2 metal prongs at the end of it. These prongs fit into the female receptacle of the other connector. Match up the two-position wire (female) with the two-position wire (male) and securely attach them together (Figure 24 - Insert).
  • Page 28 Assembly and Installation 8. Insert all connection cables through the connector one by one (Figure 32). 9. Attach and secure the connector to the black flex (Figure 33). Figure 32 10. Insert all connection cables through the hole drilled on the post (Figure 34). 11.
  • Page 29 Assembly and Installation 12. Secure and tighten the lock nut on the black flex as shown (Figure 36). 13. Connect all connection cables to each other by matching colors (37). Figure 36 Figure 37 14. Arrange all cables inside the metal post (Figure 38). 15.

  • Page 30: Electrical Diagram

    Assembly and Installation 16. Connect all TV cables to the DVD unit (Figure 40). Electrical Diagram See diagram next page. Page 26 Figure 40 www.calspas.com Barbecue Owner’s Manual 12/17/04...
  • Page 31 Assembly and Installation Page 27 Barbecue Owner’s Manual 12/17/04 www.calspas.com...

  • Page 32: Operating Your Barbecue

    Operating Your Barbecue Cal Flame Familiarization The following controls (Figure 41) are for the Cal Flame™ drop-in grills, stainless steel carts, Chef Series, Master Chef Series and Gourmet Series Islands. Please familiarize yourself with these controls prior to operation of your Cal Flame™ barbecue.
  • Page 33 4. Place the food on the grill and cook to desired completion. Adjust heat setting if necessary. The con- trol knob may be set to any position between HIGH and LOW. 5. Allow the grill to cool and clean the drip tray after each use. Electronically Lighting the Grill and Infrared Burners 1.

  • Page 34: Cooking With The Rotisserie

    Operating Your Barbecue Ensure the lid is open before lighting the flame. 1. Set all barbecue grill control knobs to OFF and open the gas supply. 2. Remove the cooking grid and flame tamers from the burner you wish to light. 3.

  • Page 35: Cooking With The Convection 3000 Grill

    Rotis Spit Bushing Rotis Spit Handle Rotis Spit Bracket The rotisserie burner is an infrared type, which provides intense searing radiant heat. Preferred by profes- sional chefs over other methods, this intense heat is ideal for searing in the natural juices and nutrients found in quality cuts of meat.
  • Page 36 Operating Your Barbecue A problem with present-day barbecue grills is that the heat within the cooking compartment is non-uni- form. The heat in the central portion of the cooking department tends to be much more intense than the heat in the side portions of the cooking compartment. This leads to uneven cooking within the cooking compartment and makes use of the outdoor grill somewhat haphazard.
  • Page 37 Exhaust Vents - Heat That Is Drawn In From Intake Opening Is Then Redistributed Out Through These Vents Opening (Intake) Lights Front View (Recirculation Shown) Opening (Intake) Hot Air Redistribution Channels Rear View (Intake Design Shown) Use a meat thermometer and take the guesswork out of cooking meat and seafood. The fan must be turned on in order for the Convection 3000 Grill to cook the items that are listed below.

  • Page 38: Turning On And Off The Lights

    Operating Your Barbecue Poultry 165ºF to 170ºF Turkey 165ºF to 170ºF Stuffing 165ºF Sausage 160ºF Raw Ham 160ºF Pre-Cooked Ham 140ºF Fish 140ºF Tuna and Shark 125ºF Shrimp Lobster Scallops Clams Muscles Oysters CONVECTION GRILL COOKING MATRIX Item Weight/size Temperature Cook Time Steak 2”THK/ 3 lbs.

  • Page 39: Charcoal Grill

    Figure 45. Location of halogen light switch Your Cal Flame Grill is equipped with either one halogen light (CR-3000) or two halogen lights (CR- 4000 & CR-5000). This feature is added for safety and convenience when cooking in poorly illuminated areas and provides an inviting display of deliciously grilled food.

  • Page 40: Griddle

    Griddle This drawer style griddle fits perfectly with all Cal Flame™ series grills for your cooking convenience. It slides into the enclosure for easy storage. When sliding the griddle out of the enclosure, always do it slowly as the heavy weight may cause you to suddenly drop the griddle.

  • Page 41: 30" Warming Drawer

    6. To extinguish the sterno fuel flame, open the drawer and carefully replace the fuel holder covers. Flames will go out. IMPORTANT • The water in the container pan is a scald and burn hazard as it gets hot. Do not attempt to empty it until it is cooled.
  • Page 42 Operating Your Barbecue 175ºF – 190ºF • If you use the tray, preheat it while preheating the warming drawer. • Preheat any empty serving dishes to be used while preheating the drawer. • Add cooked, hot food in its cooking container or heat a safe container. •...

  • Page 43: Canopy Waterfall And Barbecue Island Waterfall

    Canopy Waterfall and Barbecue Island Waterfall Although the canopy waterfall and the barbecue island waterfall have different appearances and locations, they operation in the same manner. • Fill the tank with water and make sure the water level is above the submersible pump. •...
  • Page 44 Operating the Cal Flame Entertainment Center High-speed Random color Cross-fade 13 fixed colors Page 40 A rapid series of intense flashes of varying colored light. Colors cycle back and forth gracefully between blue and green. Total cycles lasts one minute.

  • Page 45: Operating The Cal Flame Entertainment Center

    Always close the CD protection door. Remember, water damage is not covered by the warranty. Entertainment Systems Cal Flame units equipped with the TV / DVD systems use this Splash stereo to broadcast the TV or DVD audio signals. Barbecue Owner’s Manual...
  • Page 46 Operating the Cal Flame Entertainment Center Remote Control Operation Eject/ DVD TV/DVD Auto Program Skip/Search Erase/Add Channel Up Menu Enter Return Channel Down Vol - Program SubTitle Stop Pause/Replay NEXT PREV Figure 49. Remote control NOTE: These buttons will not affect the volume of wireless headphones or a wired RF modulator.
  • Page 47 TV screen. This is useful to the hearing impaired or anyone who wants to watch a program without a sound. There are two types of closed captioning available: C1 Barbecue Owner’s Manual 12/17/04 Operating the Cal Flame Entertainment Center COLOR TINT SHARPNESS www.calspas.com...
  • Page 48 Operating the Cal Flame Entertainment Center (Caption 1)and C2 (Caption 2). C1 displays the full translation of the primary language in your area. C2 may be used as a source for secondary languages, simplified English, or other translations trans- mitted in your area. Closed captioning is not available on all channels or at all times. Only specific programs are encoded with closed captioning information.

  • Page 49: Cal Flame Entertainment System Operation

    These instructions describe basic functions. Please see the DVD manufacturers operating instructions for other features and functions. These instructions are delivered with the Cal Flame owners manual in a clear plastic bag inside the stainless steel cabinet Operation 1.
  • Page 50 Operating the Cal Flame Entertainment Center The DVD system is used to feed the audio signal from the TV Tuner to the stereo. You will need to switch the audio and Video modes with DVD remote to properly receive picture and sound.

  • Page 51: Cleaning And Maintenance

    GRILL. Cleaning Instructions Island Cabinets Be sure to unplug the electrical supply before cleaning any part of your Cal Flame BARBECUE. Spray cabinet area with a soap and water solution. Rinse with a gentle stream of fresh water. Burners IMPORTANT: All of the gas control knobs must be turned to the off position and the fuel should be off and fuel line disconnected prior to starting this procedure.

  • Page 52: Drip Pan

    Charcoal Grill To prevent burns or injury, make sure grill is completely cool before cleaning. The CR-1000 charcoal grill is made from non-magnetic, 304 grade stainless steel. After initial usage, areas of the grill may discolor from the grill’s heat.

  • Page 53: Led Light Replacement

    cleaned with hot soapy water, rinsed, dried and buffed with a heavy pile cloth.. Be sure to rinse thoroughly and to wipe dry to avoid watermarks. Note: DO NOT use oven cleaners or abrasive cleaners on enameled surfaces. They may damage the fin- ish, causing accelerated wear.
  • Page 54 Cleaning and Maintenance • Clean stone surfaces with a few drops of neutral cleaner, stone soap (available from Monticello Gran- ite) or a mild liquid dishwashing detergent and warm water. • Use a clean rag for best results. • Too much cleaner or soap may leave a film and cause streaks. •...

  • Page 55: Synthetic Panel

    • Standing water or other liquids can deteriorate tile and grout, and should always be removed. Cleaning Wash with detergent solution, and rinse. To clean dingy grout, occasionally apply a solution of chlorine bleach and water to stand not more than 5 minutes; rinse thoroughly and wipe dry. General-purpose household cleaners may also be used if label says can be used on ceramic tile;...

  • Page 56: Care Of Stainless Steel Carts & Grills

    Do NOT use wire wool pads, scrappers, harsh abrasive, scoring materials, bleaches, or harsh cleaners on your Cal Flame Stainless Steel cart and/or grill, or allow salt and vinegar mixtures to remain in contact for a long period of time. This will cause scratching, scoring, rusting and pitting of your product.

  • Page 57: Appendix

    Troubleshooting Procedures If Grill Fails to Operate Properly: 1. Turn off gas at source, turn the Control Knobs to the ‘OFF’ position and wait five minutes before try- ing again. 2. Check gas supply at a connections. 3. Repeat lighting procedure and if grill still fails to operate properly, turn off gas at source, turn the con- trol knobs to the off position and wait for the grill to cool down and check the following: Cannot Ignite 1.
  • Page 58 Replace cotter pins. Replace cooking components and grease collectors. If an obstruction is suspected in the control valve, please contact your local Cal Flame dealer for assistance.
  • Page 59 Appendix 5. Insert the power cord of the new submersible pump through the flex pipe. 6. Connect the power cord of the submersible pump to the barbecue outlet line. 7. Connect the main power source to the barbecue island. Page 55 Barbecue Owner’s Manual 12/17/04 www.calspas.com...

  • Page 60: Parts List

    BARBECUE852-1P 11", SINGLE SIDE BURNER, NG, PARTS ONLY Deluxe Single Side Burner BARBECUE898P SIDE BURNER, 1 EA LP, DROP-IN DELUXE, CAL FLAME, [PARTS ONLY] BARBECUE898-1P SIDE BURNER, 1 EA NG, DROP-IN DELUXE, CAL FLAME, [PARTS ONLY] Deluxe Double Side Burner...
  • Page 61 COVERS FOR CAL FLAME CARTS BARBECUE835CR4 BARBECUE CART COVER, 4 BURNER, BLACK BARBECUE835CR5 BARBECUE CART COVER, 3 & 5 BURNER, BLACK SYNTHETIC SIDE PANELS BARBECUE04101901 31 _” X 33” - BARBECUE synthetic panel BARBECUE04101902 46” x 33” - BARBECUE synthetic panel BARBECUE04101903 70 _’...

  • Page 62: Warranty Information

    Appendix Warranty Information See your Cal Flame Barbecue dealer for a copy of the applicable warranty, details and any questions you may have regarding the warranty coverage on your barbecue. Warranty Limitations The Limited Warranty is void if the barbecue has been subject to negligence, alteration, misuse, abuse, repairs by non- C.A.I.
  • Page 63 Extent of Warranty This 2005 Cal Flame™ Warranty is only valid on Chef, Master Chef, and Gourmet models delivered in the continental United States and Canada, and extends through the selling dealer to the original purchaser at the original site of installation. This warranty becomes valid at time of purchase and ends either by specified time-frame listed above, or upon owner transfer, or relocation.
  • Page 64 Please make a record of the following. It will be valuable if service is required. Your new Cal Flame Island Barbecue serial number is located on a metal plate inside the door below the grill on the door. You will need this number to properly register your barbecue and activate coverage.

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