Gross Star

0
REV. ECN NO. DATE BY APPD. DESCRIPTION OF REVISION
TOTAL #
OF PAGES
PSS # xxxx-xxx-xxx
Gross Star sink top and final assembly
Model Numbers
= TQC (Touch Quality Control) = CTQ (Critical to Quality)

Gross Star sink top and final assembly 0000-000-000
PAGE 2
MATERIALS
B10037 – Rinse bar (2 needed)
C1001428 – Spray nozzle (12 needed)
PROCEDURES
Installing the spray nozzles to the rinse bar
The Gross Star unit uses 2 rinse bars, 1
is installed in the front of the unit and 1 in the
back. Each rinse bar holds 6 spray nozzles.
1. Beginning at the threaded end of the rinse bar,
screw 5 nozzles in each bar. You will install the
sixth end nozzle after you mount the rinse bar to
the sink (Fig. 1 and Fig. 2).
2. Use pliers to tighten the nozzles. Tighten so all
the nozzles on one rinse bar face the back and
all the nozzles on the second rinse bar face the
front (Fig. 3).
TOOLS
Pliers
Fig. 1
Fig. 2
Fig. 3
B10037 C1001428
B10037
B10037
C1001428
C1001428

PAGE 3
MATERIALS
1300712 = Teflon tape
PROCEDURES
Installing the spray nozzles to the rinse bar
(continued)
1. Set the 2 rinse bars side by side. All 10
nozzles should face each other. If they do
not, adjust the nozzles until they do (Fig. 1
and Fig. 2).
2. Apply Teflon tape to the threaded ends of
the 2 rinse bars. Starting at the second
thread wrap clockwise 4 complete turns,
unless otherwise noted (Fig. 3).
TOOLS
Pliers
Fig. 1
Fig. 2
Fig. 3
B10037
C1001428
1300712
B10037
B10037
C1001428
C1001428

PAGE 4
MATERIALS
PROCEDURES
Attaching rinse bars to sink
During assembly the sink is positioned
with its back half down.
1. To align the threaded rinse bar holes in the
sink, attach a section of threaded pipe to each
rinse bar connection and adjust until the bar is
straight. Remove the threaded pipe (Fig. 1).
2. Thread the rinse bars into the holes hand tight
(Fig. 2).
3. Tighten the rinse bars using an adjustable
wrench (Fig. 3).
TOOLS
Small section of threaded pipe
12” adjustable crescent wrench
Fig. 1
Fig. 2
Fig. 3
Threaded pipe
B10037
B10037

Page | 5
MATERIALS
PROCEDURES
Attaching rinse bars to sink (continued)
1. Angle the top rinse bar with the nozzles positioned
slightly down with the jets aiming toward the crease in
the sink (Fig. 1).
2. Using an adjustable wrench, angle the bottom rinse
bar so the nozzles are positioned slightly up with the
jets aiming toward the crease (Fig. 2).
You can adjust the rinse bar at any time. If
during the water test you find the nozzles are not
angled correctly, you can adjust the angle using an
adjustable wrench (Fig. 3).
TOOLS
Fig. 1
Fig. 2
Fig. 3
Position nozzle
slightly down
Aim jets
toward crease
C1001428
B10037
Crease
C1001428
B10037
B10037
C1001428

Page | 6
MATERIALS
B100-63 – Rinse bar bracket — right
B100-64 – Rinse bar bracket — left
C1000300 – 5/16” nyloc nuts (2 needed)
PROCEDURES
1. Slide the bracket over the open end of
the rinse bar and attach it to the 2 studs
(Fig. 1).
2. Thread on 2 nyloc nuts to secure the
bracket (Fig. 2).
3. Tighten using a nut driver then install
the other bracket (Fig. 3).
TOOLS
7/16” nut driver
Fig. 1
Fig. 2
Fig. 3
B10037
B10037
B10037
B100-64
B100-64
B100-64
C1000300
C1000300

Page | 7
MATERIALS
PROCEDURES
1. With the brackets in place thread the end
nozzles into the 2 rinse bars and tighten
(Fig. 1 and Fig. 2).
There is a threaded hole at the end of
the rinse bars. Leave the hole open for
now. During leak testing the hole will let
metal shavings or other debris escape
from inside the rinse bars. After leak
testing you will thread a Teflon taped bolt
into the hole (Fig. 3).
TOOLS
Fig. 1
Fig. 2
Fig. 3
B10037
C1001428
B10037
B10037
Threaded hole
C1001428

Page | 8
MATERIALS
B1003115 – Disposal basket strainer
Plumber’s putty
PROCEDURES
Installing a basket strainer (for units with a
disposal)
1. Remove the basket strainer from the
disposal unit (Fig. 1).
2. Disassemble the basket strainer (Fig 2).
3. Apply a rope of plumber’s putty around the
inside ring of the sink flange (Fig. 3).
TOOLS
Power drill
¼” Phillips head bit
Fig. 1
Fig. 2
Fig. 3
B1003115
B1003115
Sink flange

Page | 9
MATERIALS
Sink flange
Plumber’s putty
PROCEDURES
Installing a basket strainer (for units with a
disposal) (continued)
1. Flatten the plumber’s putty and spread it
around the complete inner ring on the sink
flange (Fig. 1).
2. Orient the sink flange so you will be able to
read the writing when looking down from the
front of the sink. Remember, the sink is
positioned on its back so the writing should be
upside down (Fig. 2).
3. Insert the sink flange into the drain hole on the
sink, pressing firmly so the sink flange seats
properly (Fig. 2).
TOOLS
Fig. 1
Fig. 2
Fig. 3
Sink
flange
Sink
flange
Sink
flange

Page | 10
MATERIALS
PROCEDURES
Installing a basket strainer (for units with a disposal)
(continued)
1. Slide the backup ring over the mounting ring and
hand tighten the 3 screws. Position the assembly
over the base of the sink flange on the underside
of the sink (Fig. 1).
2. Pull the snap ring open slightly and press it
around the outside flange of the mounting ring.
Work it onto the mounting ring until it snaps into
place (Fig. 2).
3. Tighten the screws a little at a time working your
way around each screw maintaining an even
pressure. Continue tightening until each screw is
firmly against the backup flange. Once tightened,
remove any excess plumber’s putty from around
the sink flange, top and bottom (Fig. 3).
TOOLS
Power drill
¼” Phillips head bit
Fig. 1
Fig. 2
Fig. 3
Backup ring
Mounting ring
Mounting ring
Mounting ring
Backup ring
Backup ring

Page | 11
MATERIALS
B105972 – Basket strainer
PROCEDURES
Installing a basket strainer (for units without a
disposal)
1. Slide the brass nut over the tailpipe so it
rests on the flange (Fig. 1).
2. Place the plastic washer inside the brass
nut (Fig. 2).
3. Hand tighten the brass nut around the
basket strainer (Fig. 3).
TOOLS
Fig. 1
Fig. 2
Fig. 3
Brass nut
Tailpipe
Brass nut
Brass nut
Tailpipe
Plastic
washer
Tailpipe
Basket
strainer

Page | 12
MATERIALS
B105972 – Basket strainer assembly
B10125 – Sink strainer stainless steel washer
Plumber’s putty
PROCEDURES
Installing a basket strainer (for units without
a disposal) (continued)
1. Place the assembly inside a vice, tailpipe
up, and tighten the brass nut securely
(Fig. 1).
2. Wrap a bead of plumber’s putty around
the inside flange of the basket strainer,
then flatten the putty around the flange
(Fig. 2).
3. Insert the basket through the drain hole
in the sink. Press firmly so the basket
strainer seats properly (Fig. 3).
TOOLS
Vice
Channel lock pliers
Fig. 1
Fig. 2
Fig. 3
Tailpipe
Tailpipe
Brass nut
Basket strainer
Brass nut
Basket strainer
Basket strainer

Page | 13
Tailpipe
Fig. 2
Fig. 3
MATERIALS
PROCEDURES
1. Slide the rubber gasket over the tailpipe
and fit it onto the bottom of the sink flange
(Fig. 1).
2. Attach the fiber gasket over the rubber
gasket (Fig. 2).
3. Slide on the stainless steel gasket (Fig. 3).
TOOLS
Spanner wrench
Fig. 1
Sink
flange
Rubber
gasket
Brass nut
Fiber gasket Rubber gasket
Sink flange
Fiber gasket
B10125
Rubber gasket
Sink flange
Brass nut
Tailpipe

Page | 14
MATERIALS
PROCEDURES
1. Thread the locking nut over the 3 gaskets
(Fig. 1).
2. Tighten the locking nut with a spanner
wrench. Once tight, remove any excess
plumber’s putty that may have squeezed
out during assembly (Fig. 2).
TOOLS
Spanner wrench
Fig. 1
Fig. 2
Sink flange
Locking nut
Locking nut
Spanner wrench
Sink flange
Brass nut
Tailpipe
B10125
Brass nutTailpipe
Fiber gasket

Page | 15
MATERIALS
B10095 – Trash exhaust hookup
B10072 – Blank
B108355 – 8-32 x 3/8” Phillips head screws
PROCEDURES
Installing a trash exhaust hookup
1. If the unit uses a trash exhaust, you will need
to install a trash exhaust hookup. It fits over
the hole on the plumbing side of the unit.
Before installing, make sure it has a rubber
gasket attached. Do not use it without the
gasket (Fig. 1).
2. Set the trash exhaust hookup in place and
attach it with 3 screws (Fig. 2).
3. Install a blank on the other side of the unit
using the same screws; again, making sure it
has a rubber gasket. If the unit is not equipped
with a trash exhaust, install a blank on both
sides of the unit (Fig. 3).
TOOLS
Power drill
¼” Phillips bit
Fig. 1
Fig. 2
Fig. 3
Rubber gasket
B10095
B10095
B10072
B108355

Page | 16
Fig. 1
MATERIALS
B1001088 – Fresh formulin faucet
B1001045 – Plastic ¾” x ½” male to female reducer
B1001047 – Swivel end hose barb
C1001232 – ¾” plastic barb
B1003246 – ¾” plastic 90° barb
7285011 – Hose clamp (2 needed)
100319 – Braided clear hose — 4” section
1300712 – Teflon tape
PROCEDURES
Installing a fresh formulin faucet
1. Starting at the formulin plumbing side, remove
the nut and washer from the threaded end of a
fresh formulin faucet (Fig. 1).
2. Wrap Teflon tape around all male fittings.
Starting on the second thread, wrap 4
complete turns clockwise. Do not tape the
threaded end of the faucet yet (Fig. 2).
3. Position the faucet valve on the right side of
the faucet, which when facing toward the front
of the sink, would be on your left, and slide it
through the hole in the unit (Fig. 3).
TOOLS
Fig. 3
Fig. 2
B1001088
B1001047
B1003246
B1001045
B1001088
B1001088
Valve positioned
on right

Page | 17
MATERIALS
B1001088— Fresh formulin faucet
PROCEDURES
Installing a fresh formulin faucet (continued)
1. Slide on the washer you removed earlier
and thread on the nut (Fig. 1).
2. Using a deep wall socket, tighten the nut.
Be careful not to over tighten on the plastic
threads (Fig. 2).
3. Wrap Teflon tape to the threaded fitting on
the faucet shaft. Starting on the second
thread, wrap 4 complete turns. Cover
about ½” of the threaded fitting (Fig. 3)
TOOLS
Ratchet
1 1/8” deep well socket
Fig. 1
Fig. 2
Fig. 3
B1001088
1300712
B1001088
B1001088

Page | 18
MATERIALS
B1001045 – Plastic ¾” x ½” male to female
reducer
3M Silicone Lubricant
PROCEDURES
1. Thread the barbed fitting onto the reducer.
You will use this to temporarily hold the
barbed fitting upright, making it easier to
attach the 4” braided hose (Fig. 1).
2. Using a heat gun, heat 1 end of the
braided hose (Fig.. 2)
3. Spray silicone inside the heated end of the
4” braided hose to lubricate it (Fig. 3).
TOOLS
Heat gun
Fig. 1
Fig. 2
Fig. 3
B1001045
B1001047
100319
100319

Page | 19
MATERIALS
reducer
PROCEDURES
(continued)
1. Work the braided hose onto the plastic
barb (Fig. 1).
2. With the hose secured, remove the
reducer from the bottom of the barb
(Fig. 2).
3. Thread the reducer onto the taped
faucet shaft and tighten the fitting using
an adjustable wrench (Fig. 3).
TOOLS
Fig. 1
Fig. 2
Fig. 3
B1001045
B1001047
100319
B1001047
100319
B1001088B1001045

Page | 20
MATERIALS
reducer
C1001232 – ¾” plastic hose barb
7285011 – Hose clamps (2 needed)
PROCEDURES
1. Thread the ¾” plastic hose barb into the
formulin collar closest to the back of the
sink and tighten using an adjustable
wrench (Fig. 1).
2. Slide 2 hose clamps onto the open end of
the hose (Fig. 2).
3. Thread the hose barb and hose onto the
reducer. Finger tighten only (Fig. 3).
TOOLS
Fig. 1
Fig. 2
Fig. 3
C1001232 B1001088
B1001045
B1001047
7285011
100319
B1001045B1001047
7285011
100319

PAGE 21
MATERIALS
reducer
C1001232 – ¾” plastic barb
7285011 – Hose clamp (2 needed)
PROCEDURES
(continued)
1. Bend the hose and work it onto the barb
(Fig. 1).
2. Work the hose onto the barb until the
hose is straight with no kinks and adjust
the clamps so that 1 clamp is over each
barb (Fig. 2).
3. Tighten each clamp with a nut driver
(Fig. 3).
TOOLS
¼” nut driver
Fig. 1
Fig. 2
Fig. 3
C1001232
100319
7285011
B1001047
B1001045
B1001088
C1001232
100319
B1001047
B1001045
B1001088
7285011
C1001232
7285011
100319

PAGE 22
MATERIALS
B1002998 – 1” hole plug
B1001041 – Threaded plug
PROCEDURES
Installing hole plugs
1. If the unit does not take a fresh formulin
faucet, press a 1” hole plug into the
formulin faucet hole on the base of the
sink (Fig. 1).
2. Also, screw a threaded plug into the
formulin collar (Fig. 2).
3. Tighten the threaded plug using an
adjustable wrench (Fig. 3).
TOOLS
Fig. 1
Fig. 1
Fig. 1
B1002998
B1001041
B1001041

PAGE 23
MATERIALS
B1003246 – Plastic ¾” 90° barbed elbow
PROCEDURES
Installing fresh formulin fittings
1. For units that take a fresh formulin faucet,
thread a 90° barbed elbow into the bottom
threaded hole on the underside of the sink.
If the unit does not take fresh formulin,
leave this hole open. It will be blocked by
the threaded plug in the sink top (Fig. 1).
2. Tighten the fitting using an adjustable
wrench (Fig. 2).
3. Make sure the barb points towards the
plumbing side of the sink (Fig. 3).
TOOLS
Fig. 1
Fig. 2
Fig. 3
B1003246
B1003246
B1003246

PAGE 24
MATERIALS
B10077 – Stainless 1” x 4¾” pipe, long threaded on
one end
B1001041 – Plastic threaded plug
Soft cloth
PROCEDURES
Installing waste plumbing
1. If the unit accepts waste, thread a Teflon-
taped section of stainless pipe into the waste
collar on the top side of the sink (Fig. 1).
2. To keep from marking the pipe during
tightening, lay a section of cloth over the
pipe. Using channel lock pliers grasp the
pipe firmly and tighten the pipe (Fig. 2).
3. If the unit does not accept waste, attach a
threaded plug into the waste collar and
tighten using an adjustable wrench (Fig. 3).
TOOLS
Channel lock pliers
Fig. 1
Fig. 2
Fig. 3
B10077
B10077
B1001041

Page | 25
MATERIALS
PROCEDURES
Installing waste plumbing fittings
1. If the unit accepts waste, thread a barbed
elbow into the waste collar, which is the
top threaded hole when looking at the sink
basin. If the unit does not accept waste,
leave this fitting open. It will be blocked by
a threaded plug on the sink side (Fig. 1).
2. Tighten the fitting with an adjustable
wrench (Fig. 2).
3. Position the elbow so it is facing left, away
from the plumbing, and slightly up (Fig. 3).
TOOLS
Fig. 1
Fig. 2
Fig. 3
B1003246
B1003246
B1003246

Page | 26
MATERIALS
B1002690 – Pre-rinse hand sprayer kit
1300712 –Teflon tape
PROCEDURES
Installing a pre-rinse hand sprayer
1. Remove the threaded adapter from
the end of the flexible hose. Make
sure the black washer remains in the
hose (Fig. 1).
2. Wrap Teflon tape around one end of
the threaded adapter, clockwise, 2
complete turns, and thread the taped
end into the hose (Fig. 2).
3. Tape the other end of the adapter,
clockwise, 2 complete turns (Fig. 3).
TOOLS
Fig. 1
Fig. 2
Fig. 3
Washer
1300712
1300712

Page | 27
MATERIALS
B1002690 – Pre-rinse hand spray kit
1300712 –Teflon tape
PROCEDURES
Installing a pre-rinse hand sprayer
(continued)
1. Remove the hand sprayer assembly
from the other end of the hose (Fig. 1).
2. Thread the adapter end of the hose
through the bottom of the sink to the
plumbing section (Fig. 3).
3. Connect the adapter to the open female
connector under the sink (Fig.3).
TOOLS
Fig. 1
Fig. 2
Fig. 3
Hand
sprayer
1300712
Adapter

Page | 28
MATERIALS
B1002690 – Pre-rinse hand sprayer kit
PROCEDURES
Installing a pre-rinse hand sprayer (continued)
1. Tighten the connection using a pair of
adjustable wrenches. Use 1 wrench to hold
the female connector and the other to turn
the hose fitting with adapter (Fig. 1).
2. Feed the open end of the hose up through
the Gross Star unit and out the hand
sprayer hole at the top of the sink (Fig. 2).
3. If necessary, insert the washer into the
hand sprayer end of the hose (Fig. 3).
TOOLS
2 adjustable crescent wrenches
Fig. 1
Fig. 2
Fig. 3
Sink top
Sink top
Flexible
hose

Page | 29
MATERIALS
PROCEDURES
Installing a pre-rinse hand sprayer (continued)
1. Slide the metal ring washer over the base of
the hand sprayer (Fig. 1).
2. Thread the hose fitting onto the hand
sprayer, hand tighten only (Fig. 2).
3. To keep the hose away from potential pinch
points when you mount the sink to the bottom
section, wrap the hose around the faucet and
vacuum breaker assembly (Fig. 3).
TOOLS
Fig. 1
Fig. 2
Fig. 3
B1002690
B1002690

Page | 30
MATERIALS
107554 – Parker hose — cut to lengths of 28”
(supply hose), 25” (cold water hose), and 23” (hot
water hose)
PROCEDURES
Installing the sink top to its base
1. Slide the faucet hose ends into the drain to
keep them out of the way (Fig. 1).
2. Using 2 people carefully set the unit on its
base (Fig. 2).
3. Unwrap the hand sprayer and slide the
hose through the hole until the sprayer is
firmly seated into the sink top (Fig. 3).
TOOLS
Fig. 1
Fig. 2
Fig. 3
107554
B1002690

Page | 31
MATERIALS
C1000584 – 3/8”-16 x 5/8” bolt (4 needed)
1075973 – 3/8” crush washer (4 needed)
PROCEDURES
Installing the sink top to its base (continued)
1. Thread the bolts and lock washers through
the 4 mounting brackets and into the
tapped holes in the bottom section (Fig. 1).
2. Tighten the bolts using a ratchet with a
deep well socket (Fig. 2).
3. To tighten one bolt, you will need to use a
ratchet extension (Fig. 3).
TOOLS
Ratchet
11/16” deep well socket
Ratchet extension
Fig. 1
Fig. 2
Fig. 2
C1000584
1075973

Page | 32
MATERIALS
107554 – Parker hose — cut to lengths of 28” (supply
hose), 25” (cold water hose), and 23” (hot water hose)
PROCEDURES
Connecting the hoses
1. Remove the 3 measured and cut lengths of
hose from the drain hole and separate the
lengths (Fig. 1).
2. Spray a silicone lubricant inside each hose
(Fig. 2).
3. Starting with the shortest hose and working to
the longest, slide each hose onto the barbed
fitting on the solenoid valve. If the unit is
equipped with a disposal, you will also need to
thread the disposal’s braided hose end onto
the threaded solenoid valve. The disposal
hose is the only threaded fitting (Fig. 3).
TOOLS
Fig. 1
Fig. 2
Fig. 3
107554
107554
107554
23”
25”
28”

Page | 33
MATERIALS
100319 – Braided clear hose
PROCEDURES
Connecting the hoses (continued)
1. If the unit uses a carboyd waste container,
spray lubricant inside braided hose end
leading from the carboyd waste unit and
work the hose onto the barbed 90° fitting
leading from the waste collar (Fig. 1 and
Fig 2).
2. For units equipped with a carboyd fresh
formulin, attach the braided hose leading
from the fresh formulin container to the 90°
barbed fitting leading to the fresh formulin
faucet (Fig. 3).
TOOLS
Fig. 1
Fig. 2
Fig. 3
100319
B1003246
B1003246 100319

Page | 34
MATERIALS
187086 – Cable ties
PROCEDURES
Readying the unit for wiring
1. Pull the stored electrical wires
through the openings on both sides of
the unit (Fig. 1).
2. Place the wires in the sink until you
are ready to attach them to their
corresponding switches (Fig. 2).
3. Use cable ties to secure all loose
wires in the base of the unit (Fig. 3).
TOOLS
Fig. 1
Fig. 2
Fig. 3
187086

Page | 35
MATERIALS
B10081 – Hand spray deflector
C-1003056 – Double-backed tape
PROCEDURES
Wiring the Gross Star unit
1. Cut 3 strips of double-backed tape and
apply them to the bottom of the hand spray
deflector (Fig. 1).
2. Remove the double-sided tape backing
from the hand spray deflector (Fig. 2).
3. With the tape on the bottom of the
deflector, push the wires to the left and
work the deflector through the slot on the
right-sided front of the unit. Push the
deflector as far back as it will go and press
down on the bottom for the tape to adhere
to the unit (Fig. 3).
TOOLS
Fig. 1
Fig. 2
Fig. 3
C-1003056
B10081
B10081
B10081
C-1003056

Page | 36
Fig. 3
MATERIALS
B10049 – Receptacle plate cover
B1005177 – Blank switch
PROCEDURES
Wiring the Gross Star unit (continued)
1. Slide a switch through the small opening on
the bottom of a receptacle plate cover. Press it
in place until it locks. If the unit is not equipped
with a specific function, such as Elevate for a
hydraulic lift, then install a blank switch.
Remove the protective film from the front of
the cover (Fig. 1).
2. Working on the left side of the unit, grasp the
single wire marked REC1/GFCI and feed it
through the opening in the cover plate (Fig. 2).
The ends of all wires used with the
Gross Star are marked, making identification
easy (Fig. 3).
TOOLS
Fig. 1
Fig. 2
B10049
B1005177
B10049
B1005177

Page | 37
MATERIALS
236036 – 6-32 screws (4 needed)
1000665 – Terminal connectors (3 needed)
PROCEDURES
1. Attach the cover to the base of the unit (Fig. 3).
2. Measure about 6” of wire from the slot in the
plate and cut off the excess wire (Fig. 2).
3. Remove about 4” of the outside protective
cover to expose the 3 wires and cut off the
stringy insulation (Fig. 3).
4. Strip off about ½” of plastic insulation from the
3 wires and using a crimping tool, add terminal
connectors to the ends (Fig. 4)
TOOLS
¼” Phillips head screwdriver
Wire cutter
Wire stripper
Crimping tool
Fig. 1
Fig. 2
Fig. 3
Fig. 4
B10049
B10049
B10049
B1005177
B1005177
B10049
B1005177
1000665

Page | 38
MATERIALS
105932 – Receptacle
PROCEDURES
1. Attach the brown wire to the gold screw
on a receptacle (Fig. 1).
2. Attach the blue wire to the silver screw
(Fig. 2).
3. Attach the green and yellow striped
ground wire to the receptacle’s green
screw (Fig. 3).
TOOLS
¼ “ Phillips head screwdriver
Fig. 1
Fig. 2
Fig. 3
105932
1000665
1000665
1000665
105932
105932

Page | 39
Fig. 1
Fig. 2
Fig. 3
MATERIALS
1001237 – Receptacle cover plate
105932 – Receptacle
236036 – 6-32 Phillips head screws (2 needed)
PROCEDURES
1. Fit a receptacle cover over the front of
the receptacle (Fig. 1).
2. Slide the assembly over the slot, lining
up the screws with the holes (Fig. 2).
3. Tighten the screws to secure the
receptacle and cover (Fig. 3).
TOOLS
1001237
1000665
105932
B1005177
1001237
1001237
B10049
B10049
B10049

Page | 40
MATERIALS
B10050 – Switch/alarm cover plate
B1001158 – Red light alarm
B1001135 – Alarm reset button
B1001025 – Audible alarm
B1005196 – Disposal button
B1002999 – 7/8” hole plug
PROCEDURES
1. A 5-switch/alarm plate cover can control
up to 5 devices. Install the specific
switches or alarms for the unit you are
building. Attach a hole plug in any slots not
used. For example, this unit is not
equipped with a disposal or a fresh
formulin option. So we will insert a hole
plug in the slot and ready the connections
for future use (Fig. 1 and Fig. 2).
2. On the right side of the unit, select the wire
marked COM ALARM SIREN (Fig 3).
TOOLS
Fig. 1
Fig. 2
Fig. 3
B1001025
B10050
B1002999
B1001025
B1001135
B1001158
B1005196
B10050

Page | 41
MATERIALS
106483 – Ring terminals (2 needed)
PROCEDURES
1. Measure about 6” of wire and cut off the
excess (Fig. 1).
2. Strip away about 4”, remove the insulation,
and separate the blue, brown, and ground
wire. The ground wire is not needed, so
cut it off (Fig 2).
3. Using a crimping tool, install ring terminals
to the blue and brown wires (Fig 3).
TOOLS
Wire cutter
Wire stripper
Crimping tool
Fig. 1
Fig. 2
Fig. 3
106483

Page | 42
MATERIALS
106483 – Ring terminals (2 needed)
PROCEDURES
1. Using a Phillips head screwdriver, remove
the 2 screws from the audio alarm
terminals and attach the brown wire to the
plus or positive side and the blue wire to
the minus or negative sign (Fig. 1).
2. Select the wire marked COM AUDIBLE
ALARM SILENCE (Fig. 2).
3. Cut the wire to length, expose the blue,
brown, and ground wire, and cut off the
ground wire (Fig. 3).
TOOLS
Wire cutter
Wire stripper
Fig. 1
Fig. 2
Fig. 3
B10050
B1001025
106483

Page | 43
MATERIALS
B1002999 – 7/8” hole plug
PROCEDURES
1. Strip the ends of the brown and blue wires.
Insert the brown wire into the slot on the
#4 side and blue into the slot on the #3
side of the alarm reset button (Fig. 1).
2. Tighten the connections with a Phillips
head screwdriver (Fig. 2).
3. Select the wire labeled DISPOAL SWITCH
(Fig. 3).
TOOLS
Fig. 1
Fig. 2
Fig. 3
B1001158
B1002999
B1001025
B1001135
B1005196
B1001025
B1005196
B1001135
B1001158

Page | 44
MATERIALS
B1002999 – 7/8” hole plug
235094 – Female terminal connectors
107087 – Cable tie
PROCEDURES
1. Measure and cut the length of disposal wire
needed to reach the switch, remove all
insulation, and cut off the ground wire (Fig. 1).
2. Strip the wires and using a crimping tool, install
female terminal connectors to both wires. Slide
the brown wire over the disposal terminal
marked 5B (Fig. 2).
3. If the unit is not currently equipped with a
disposal, do not connect the blue wire. Instead,
use a cable tie to keep it out of the way. So, if
the customer ever decides to add a disposal to
the unit, the wiring is ready (Fig. 3).
TOOLS
Wire cutter
Wire stripper
Crimping tool
Fig. 1
Fig. 2
Fig. 3
B1005196
B1001025
235094
235094
B10050

Page | 45
MATERIALS
PROCEDURES
1. Select the wire labeled WASTE FORM
ALARM (Fig. 1).
2. Measure, cut, separate, and strip the 3
wires, and cut off the green wire. The
waste formulin alarm light has one terminal
marked X1 and another terminal marked X
2. Insert the brown in the X1 terminal and
tighten the screw (Fig. 2).
3. Insert the blue wire into the terminal
marked X2 and tighten the screw to hold
the wire in place (Fig. 3)
TOOLS
Wire cutters
Wire strippers
Fig. 1
Fig. 2
Fig. 3
B1001158
B1001158
X1 – for
brown wire
X2 – for
blue wire

Page | 46
MATERIALS
B1002999 – 7/8” hole plug
PROCEDURES
1. Select the wire labeled FRESH FORM
LEVEL ALARM (Fig. 1).
2. Measure and cut the wire to length
(Fig. 2).
3. If the unit is not equipped with the
fresh formulin option, use a section of
electrical tape to secure the cut end of
the wire (Fig. 3).
TOOLS
Wire cutter
Electrical tape
Fig. 1
Fig. 2
Fig. 3

Page | 47
MATERIALS
B1002999 – 7/8” hole plug
107087 – Cable ties
B108355 – 8-32 screws (4 needed)
PROCEDURES
1. Use a cable tie to hold the taped wire in
place (Fig. 1).
2. Set the cover in place being careful not to
pinch any wires between the plate and unit
(Fig. 2).
3. Add the 4 screws and tighten (Fig. 3).
TOOLS
Electrical tape
Wire cutters
Fig. 1
Fig. 2
Fig. 3
B10050

Page | 48
MATERIALS
Waste, Alarm, Reset, and Audible decals
B1002999 – 7/8” hole plug
PROCEDURES
1. Spray the panel with alcohol and wipe with
a soft lint-free cloth to remove any excess
grease, oil, or dirt that may prevent the
decals from sticking (Fig. 2).
2. Carefully apply the decals identifying each,
button, switch, or alarm (Fig. 2 and Fig. 3).
TOOLS
Isopropyl alcohol in a spray bottle
Soft lint-free cloth
Fig. 1
Fig. 2
Fig. 1
B10050
B10050
B10050

Page | 49
MATERIALS
Weldment sink section
PROCEDURES
Mounting the top to the Gross Star
1. Mount the weldment sink section to the
back of the sink (Fig. 1).
2. Once set in place, mark the screw mount
areas on the back panel and remove the
top and back again (Fig. 2).
3. Use a center punch on the marked area to
either enlarge an existing hole or to make
a new one (Fig. 3).
TOOLS
Marker
Center punch
Fig. 1
Fig. 2
Fig. 3

Page | 50
MATERIALS
108115 – 10-32 x 3/8” pan head screws
PROCEDURES
Mounting the top to the Gross Star
(continued)
1. Remount the top and back section, and
attach screws to the back of the unit to
secure the top (Fig. 1).
2. Align the access panel with the studs on
the sink top and slide it in place (Fig. 2).
3. Lock the access panel in place with the
thumb screws (Fig. 3).
TOOLS
Fig. 1
Fig. 2
Fig. 3
Stud

Page | 51
MATERIALS
1000452 – 3/8” NPT chrome union (2 needed)
SS16 pipe sealant
PROCEDURES
Assembling the vacuum breaker
1. Separate the top and bottom sections of 2
unions (Fig. 1).
2. Apply pipe sealant to the end of the male
threads on the 2 union’s top sections (Fig.
2 and Fig. 3).
TOOLS
Fig. 1
Fig. 2
Fig. 3
Top section
with male and
female fittings
Bottom section
with female fitting
1000452
Pipe sealant
applied to union’s
end threads
1000452
1000452

Page | 52
MATERIALS
PROCEDURES
Assembling the vacuum breaker (continued)
1. Thread the union’s top end into its bottom
end (Fig. 1).
2. Working on 1 union at a time, lock the
reassembled union in a vice (Fig. 2).
3. Using an adjustable wrench, tighten the
top end into its bottom (Fig. 2).
TOOLS
Vice
Fig. 1
Fig. 2
Fig. 3
1000452
1000452
1000452

Page | 53
Fig. 1
Fig. 2
Fig. 3
MATERIALS
101918 – 3/8” NPT nipple 2¾” long (2 needed)
Loctite 290
PROCEDURES
1. Wrap Teflon tape around the threads on one end
of both 2¾” nipples. Throughout the vacuum
breaker assembly, when applying Teflon tape
always start at the second thread and only wrap
the tape 1 complete turn, clockwise (Fig. 1).
2. Apply 2 drops of Loctite to the female threads in
the union’s pipe-sealed top end (Fig. 2).
Throughout the vacuum breaker assembly,
always apply 2 drops of Loctite to all female
threads before making any male to female
connections. For the initial vacuum breaker
assembly, all parts are hand tightened.
3. Thread the taped end of (1) 2¾” nipple into the
union (Fig. 3).
TOOLS
1019181300712
1000452
101918
1000452
1300712

Page | 54
MATERIALS
1000492 – 3/8” NPT nipple 7¼” long (2 needed)
105119 – Vacuum breaker
1001917 – 3/8” NPT nipple1¾” long
Loctite 290
PROCEDURES
1. After applying Loctite to the union’s bottom
end, thread a 7¼” nipple, taped at both
ends, into the union (Fig. 1).
2. Apply Loctite to the 2 female threaded
fittings in the vacuum breaker and attach
the open end of the taped 7¼” nipple into
the breaker’s bottom end (Fig. 2).
3. Thread a 1¾” nipple, taped on both ends,
into the threaded side of the vacuum
breaker (Fig. 3).
TOOLS
Fig. 1
Fig. 2
Fig. 3
101918
1000452
10004921300712
1000492
1300712
1300712
105119
100492
105119
1001917

Page | 55
MATERIALS
1001917 – 3/8” NPT nipple1¾” long
1000450 – 90° elbow fitting
Loctite 290
PROCEDURES
1. Apply Loctite to both ends of a 90° elbow
and thread 1 end of the elbow onto the
open end of the 1¾” nipple (Fig. 1).
2. Thread a second 7¼” nipple, taped on both
ends, into the 90° elbow fitting (Fig. 2).
3. After applying Loctite to both female ends
of a second union, thread the bottom of the
union (you will see pipe sealant in the top
end) onto the the 7¼” nipple (Fig. 3).
TOOLS
Fig. 1
Fig. 2
Fig. 3
1300712
105119
1000450
1001917
1000492
1000492
1000492
1300712
1300712
105119
1001917
1000450
1000452

Page | 56
MATERIALS
1001917 – 3/8” NPT nipple1¾” long
Loctite 290
PROCEDURES
1. Thread the taped end of the second 2¾”
nipple into the union (Fig. 1).
2. Attach a pair of soft jaw adapters to a vice
(Fig. 2).
3. Place the assembly with the vacuum
breaker down, inside the vice. Make sure
the vacuum breaker is positioned just
outside the vice jaws and tighten for a
secure fit (Fig. 3).
TOOLS
Vice
Soft jaw adapters
Fig. 1
Fig. 2
Fig. 3
Soft jaw adapters
101918
1000452
1000492
101918
1000452
1000492
1001917
105119

Page | 57
MATERIALS
1001917 – 3/8” NPT nipple1¾” long
1075903 – Brass nuts (4 needed)
Loctite 290
PROCEDURES
1. Thread 2 brass nuts onto both 2¾” nipples.
The top nut should be about 1” down the
threads. Position the nuts so they are about
even on the threads (Fig. 1).
2. Use an adjustable wrench to tighten the
nuts together. This way the nuts will act like
jam nuts. So as you tighten the nuts all the
fittings on that side of the assembly will also
tighten. Try to keep both sides even (Fig. 2).
3. Tighten the bottom end of the unions to
snug up the threaded connections (Fig. 3)
TOOLS
Vice
Soft jaw adapters
12” adjustable crescent wrenches
Fig. 1
Fig. 2
Fig. 3
1075903
101918
1000452
1000492
1075903
1075903
101918
101918
1000492
1000452
1000452

Page | 58
MATERIALS
1001917 – 3/8” NPT nipple1¾” long
B100100-10 – Vacuum breaker mounting plate
Loctite 290
PROCEDURES
1. With the fittings snug, loosen the brass nuts
with an adjustable wrench and remove them
from the nipple. Remove the vacuum breaker
assembly from the vice (Fig. 1).
2. Lock the vacuum breaker mounting plate into
the vice. Do not remove the protective film at
this time (Fig. 2).
3. Rotate both sides of the vacuum breaker
assembly in opposite directions. This will
tighten the fittings on both ends of the 1¾”
nipple (Fig. 3).
TOOLS
Vice
Soft jaw adapters
Fig. 1
Fig. 2
Fig. 3
1075903
101918
1000452
B100100-10
1000452
1000450
1001917
105119
1000492
B100100-10

Page | 59
MATERIALS
1001917 – 3/8” NPT nipple1¾” long
106347 – Escutcheon (2 needed)
PROCEDURES
1. Make sure both sides of the vacuum breaker
assembly fits through the holes in the plate. If
they do not fit, you may need to loosen or
tighten the 1¾” fittings (Fig. 1).
2. Slide the 2 escutcheons over both ends of the
assembly (Fig. 2).
3. Thread 1 brass nut onto each side of the
assembly and tighten until they are even with
the bottom of the escutcheon (Fig. 3).
TOOLS
Vice
Soft jaw adapters
Fig. 1
Fig. 2
Fig. 3
1000452
101918
B100100-10
101918
106347
1000452
106347
1075903
1000452
101918

Page | 60
MATERIALS
1001917 – 3/8” NPT nipple1¾” long
106349 – Escutcheon (2 needed)
PROCEDURES
1. Lock the vacuum breaker assembly into
the vice with the vacuum breaker down
and just outside the vice jaws (Fig. 1).
2. Remove the protective film from the
mounting plate and slide the plate over
the 2¾” nipples on each side of the
assembly (Fig. 2).
3. Make sure the plate is even when resting
on the brass nuts. If necessary, adjust the
nuts until the plate is even (Fig. 3).
TOOLS
Vice
Soft jaw adapters
Fig. 1
Fig. 2
Fig. 3
1000452
106347
1000492
105119
101918
106347
1000452
B100100-10
1000492
B100100-10
1075903

Page | 61
MATERIALS
Vacuum breaker assembly
B1002926 – Coupling (2 needed)
Loctite 290
PROCEDURES
1. Attach the remaining 2 brass nuts to the
nipples and tighten with an adjustable
wrench (Fig. 1).
2. Wrap Teflon tape to the end of each
nipple. Wrap clockwise 4 complete turns
(Fig. 2).
3. Apply Loctite to each female end of a
coupling, and thread it onto each taped
nipple (Fig. 3).
TOOLS
Vice
Soft jaw adapters
Fig. 1
Fig. 3
Fig. 2
B100100-10
1075903
1075903
1075903
B100100-10
1300712
101918
B100100-10
B1002926

Page | 62
MATERIALS
B1002926 – Coupling (2 needed)
109289 – Hose bard with hose gasket (2 needed)
Loctite 290
PROCEDURES
1. Apply Teflon tape, 4 complete turns
wrapped clockwise, to the threads on the 2
barbed fittings and attach the barbs to the
couplings (Fig. 1).
2. Tighten the fittings using a deep well
socket (Fig. 2).
3. Slide the yellow hose gasket, with the lip
facing up, onto each barb (Fig. 3).
TOOLS
Vice
Soft jaw adapters
½” ratchet
11/16” socket
Fig. 1
Fig. 2
Fig. 3
B1002926
B1002926
109289
109289
B1002926
109289

Page | 63
MATERIALS
1001243 – Hose end swivel (2 needed)
104233 – Reducer (2 needed)
109289 – Hose barb with hose gasket (2 needed)
1300712 = Teflon tape
PROCEDURES
You will need to assembly 2 hose end swivel
connector assemblies; one attaches to the hose end
used on the vacuum breaker, the other attaches to a
separate hot water hose that connects to the back of
the unit.
1. Wrap Teflon tape 4 times, clockwise, onto the treads of
a reducer and attach it to a hose end swivel connector
(Fig. 1).
2. Wrap Teflon tape to the male threads on a hose bard.
Wrap 4 times, clockwise, and attach it to a reducer
(Fig. 2).
3. Remove the soft jaw adapters from the vice, lock in the
hose end assembly, and tighten the fittings (Fig. 3).
TOOLS
Fig. 1
Fig. 2
Fig. 3
104233 1001243
104233
1001243109289
1001243
104233
109289

Page | 64
MATERIALS
B1005214 – Filter washer
1001243 – Hose end swivel
104233 – Reducer
109289 – Hose barb with hose gasket
PROCEDURES
Assembling the vacuum breaker
(continued)
1. Place a filter washer inside the hose
end swivel and straighten it so it lies flat
(Fig. 1).
2. Slide a yellow barb gasket, lip side up,
onto the barb (Fig. 2).
3. Spray silicone lubricant into both ends
of the 110” hose section and in 1 end on
the 53” hose section you cut during an
earlier procedure (Fig. 3).
TOOLS
Fig. 1
Fig. 2
Fig. 3
1001243
B1005214
1001243
109289
104233
1075554

Page | 65
MATERIALS
PROCEDURES
1. With the vacuum breaker lying flat, work the
110” hose section onto the barb on the vacuum
breaker side of the assembly. Work the
lubricated end of the 55” section over the barb
on the elbow side of the assembly (Fig. 1).
2. Work the open end of the vacuum breaker 110”
hose section onto a barb with a hose end swivel
connection (Fig. 2).
3. Position the vacuum breaker so it will be closest
to the edge of the Gross Star unit and feed the
2 hoses from the vacuum breaker assembly
through the open panel at the top of the unit
(Fig. 3)
TOOLS
Fig. 1
Fig. 2
Fig. 3
Vacuum
breaker hose
Elbow
hose
1075554
1075554

Page | 66
MATERIALS
108115 – 10-32 x 3/8” screws
PROCEDURES
1. Fit the vacuum breaker cover plate over
the opening and secure it with 4 screws
(Fig. 1).
2. Spray silicone lubricant through the open
end of the 55” elbow hose (Fig. 2).
3. Work the elbow hose end onto the lower
barb at the back of the unit (Fig. 3).
TOOLS
Fig. 1
Fig. 2
Fig. 3
Vacuum breaker
assembly
1075554
1075554

Page | 67
MATERIALS
PROCEDURES
Assembling and connecting the hot water
hose
1. Spray silicone lubricant into both ends of
the 66” hose section you cut during an
earlier procedure (Fig. 1).
2. Work 1 end of the 66” hose onto the barb
on a second hose end swivel connection
(Fig. 2).
3. Work the open end of the 66” hose onto
the upper barb for the hot side on the back
of the unit, just above the 55” elbow hose
connection (Fig. 3).
TOOLS
Fig. 1
Fig. 2
Fig. 3
1075554
1075554
1075554

Page | 68
MATERIALS
B10067 – Plumbing service cover
1001113 – Cabinet handle
B108355 – 8-32 x 3/8” screws
PROCEDURES
Finishing the Gross Star assembly
1. Pull both the 110” cold vacuum breaker hose
and the 66” hot hose from the back of the unit to
verify they are both approximately the same
length. If necessary shorten one or the other
hose. Once verified roll both hoses and store
them in the back of the unit (Fig. 1).
2. Remove the protective film and install the
plumbing service cover to the plumbing side of
the unit (Fig. 2).
3. Snap the 2 handles into the slots on the front of
the unit (Fig. 3).
TOOLS
Phillips head screwdriver
Fig. 1
Fig. 2
Fig. 3
1075554
1001113
B10067

Page | 69
MATERIALS
Hot and Cold foot pedals
PROCEDURES
Setting up the Gross Star unit
1. Remove the plug stored in the back of the
unit and insert it into an electrical outlet
(Fig. 1 and Fig. 2).
2. Connect the Hot and Cold water foot
pedals to their slots at the bottom of the
unit (Fig. 3).
TOOLS
Power supply
Fig. 1
Fig. 2
Fig. 3

Page | 70
MATERIALS
PROCEDURES
(continued)
1. Use a laptop to setup the Gross Star
unit (Fig. 1).
2. Open the unit’s cabinet doors and turn
on the 2 switches on the electrical
cabinet door. The center panel will light
(Fig. 2).
3. Using a flat head screwdriver turn the 3
screwdriver slots to unlock the electrical
cabinet door. Open the panel (Fig 3).
TOOLS
Laptop computer
Connecting cord
Flat head screwdriver
Fig. 1
Fig. 2
Fig. 3

Page | 71
MATERIALS
PROCEDURES
(continued)
1. Attach the laptop to the control board inside
the unit (Fig. 1).
2. Using the Gross Star setup sheet as a guide,
the laptop will walk you through the complete
setup procedure (Fig. 2).
3. Once setup is complete, reach inside the unit
and slide the switch on the control board from
PROG to RUN (Fig 3).
4. With the control board set on run, disconnect
the laptop from the control board. Also unplug
the unit from the power supply and store plug
in the back of the unit (Fig. 4).
TOOLS
Laptop computer
Connecting cable
Fig. 1
Fig. 2
Fig. 3
Fig. 3
Slide switch from
PROG to RUN
Cable from
laptop
Laptop
connection
Laptop
connection

Page | 72
MATERIALS
Flexible drain hose
PROCEDURES
Leak testing the Gross Star unit
1. To water test the unit, connect the 66” hot
hose to the hot water valve and the 110 “
vacuum breaker hose to the cold water
valve (Fig. 1).
2. Attach a drain hose to the drain in the unit
and to a floor drain (Fig. 2).
3. Open the valves for the hot and cold water
(Fig. 3).
TOOLS
Hot and cold water supply
Fig. 1
Fig. 2
Fig. 3
1075554
Drain
hose
Water valve

Page | 73
MATERIALS
Hot and Cold foot pedals
PROCEDURES
(continued)
1. After plugging the unit into a power outlet,
verify that the hot and cold water foot pedals
work properly. Step on both pedals. You will
hear an audible click as the water flows. Verify
there is hot water with the Hot pedal and cold
water with the Cold pedal. Step on each pedal
again to shut off the water (Fig. 1).
2. Check each faucet and hand spray to verify
hot and cold water (Fig. 2).
3. Turn on the star handle check valve to verify
all the spray nozzles work (Fig. 3).
TOOLS
Fig. 1
Fig. 2
Fig. 3
Hot and Cold
foot pedals

Page | 74
MATERIALS
B10063 – Rinse bar bracket — right
B10064 – Rinse bar bracket — left
C1000300 – 5/16” nyloc nuts (2 needed)
PROCEDURES
(continued)
1. Verify, too, that the water from the spray
nozzles is aimed toward the creases in the
back and front of the sink and not the sink
wall (Fig. 1).
2. If necessary, adjust the rinse bar to aim
the nozzles properly (Fig. 2).
3. Let the water run through the hole at the
end of the rinse bars for a few minutes.
This will flush out any metal shavings or
other debris inside the rinse bar (Fig. 3).
TOOLS
Water supply
Fig. 1
Fig. 2
Fig. 3
B10037
C1001428
B10037
B10037
C1001428
B10063
C1000300

Page | 75
MATERIALS
B10077 – Stainless 1” pipe — 4¾” long
PROCEDURES
(continued)
1. If the unit is equipped with waste or
fresh formulin plumbing, verify that they
are operating properly and that the
carboyd waste and carboyd fresh
formulin are working (Fig. 1 and Fig. 2).
2. With the water still flowing, check the
plumbing inside the cabinet for leaks
(Fig. 3).
TOOLS
Water supply
Flexible drain hose
Fig. 1
Fig. 2
Fig. 3
B10077
B1001088

Page | 76
MATERIALS
1075061 – ¼”-20 x ½ bolt
PROCEDURES
(continued)
1. Once the rinse bars are flushed, turn off
the water and add a Teflon-taped bolt (4
complete turns, clockwise) to the end of
each bar (Fig. 1).
2. Tighten the bolts until snug (Fig. 2).
3. If necessary, tighten any leaking or loose
fittings or connections and leak test
again (Fig. 3).
TOOLS
Ratchet
11M socket
Adjustable crescent wrenches
Fig. 1
Fig. 2
Fig. 3
B10037
1075061
B10037
1075061

Page | 77
MATERIALS
PROCEDURES
(continued)
1. With the system leak tested, close the hot
and cold water valves at the main supply
and open the hot, cold, and star handled
check valve on the sink top (Fig. 1).
2. Open compressed air valves for both the
hot and cold to flush out any residual water
from the hot and cold lines. This also helps
to dry the sink (Fig. 2 and Fig. 3).
3. Once the unit is dry and completely tested,
complete any final prep work to prepare it
for shipping.
TOOLS
Water supply
Compressed air supply
Fig. 1
Fig. 2
Fig. 3
Compressed
air valve

Gross Star

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