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Aussie 6805 Gas Grill User Manual

1. 40 Register your grill and retain your receipt Remove Grill and all the packaging from carton and place on floor Make sure there are no loose parts NOTE Before using your grill read the instructions and your manual For easier set up and assembly follow instructions of each step in the order they are written as you look at the dia grams If accessories mentioned in certain assembly steps do not come with your model skip that step and proceed to the next step that applies to your model If you have any questions or need help contact Customer Service at 1 800 251 7558 or go to www aussiegrills com Be sure to have the grill model number and serial number printed on the black label located inside the left door of the cabinet If you need replacement parts look in the Parts List Section to find the exact parts you need If you need a replacement part under warranty a proof of purchase will be necessary You will be asked to forward your proof of purchase via e mail or to fax your proof of purchase to 423 639 1055 and reference your model and serial number It is important to register your grill and retain your receipt Packing List Model 6804 Box Description Cabinet Bottom Panel Bottom Panel 2 Cabinet Side Panel Right Cabinet Side Panel Left Warming Rack 3 Left Side Shelf with Side Burner Right Side Shelf Door Drawer handle 2 pcs Large Door handle Locking Caster 2 pcs Fixed Casters 2 p
2. 9 Step 6B Cylinder Blocking Wire Assembly 9 Step7 Door Handle Assembly 9 Step8 Drawer Track Assembly 10 Step 9 Drawer 10 Step 9B Drawer 10 Step 10 Door Assembly 11 Step 11 Hood Body To Cart Assembly 11 Step 12 Side Table Assembly 12 Step 13 Side Burner Valve Assembly 13 Step 14 Side Burner Valve Connection Model 6805 13 Step 15 Side Burner Igniter Wire Connection 14 Step 16A Side Burner Control Knob Assembly 14 Step 16B Side Burner Grid Assembly 14 Step 17A Bottom Body Panel Assembly 15 Step 17B Foil Pan Grease Pan Assembly 15 Step 18 Warming Rack Assembly 15 Step 19 Flame Diffuser Cooking Grid Assembly 16 Step 20 Battery in Igniter Installation 16 Connecting Disconnecting the Gas BEC RETE TUUM 17 Gas Cylinder op crisnoasnocsincrsianshoriecseecinensecenteiennewiesss 17 LP Hose amp 18 Connecting LP Gas Cylinder 18 Disconnecting LP G
3. Turn LP Gas Cylinder valve counterclockwise Fig 7 Left Main Burner Control Knob Fig 9 Igniter Button Right Main Burner Control Knob 4 Push far left Main Burner Control Knob in on Control Panel and turn counterclockwise to the High position Figs 7 and 9 5 Push the Igniter Button in until the Burner is lit Listen for the spark ignition and look to make sure the Burner is lit If no spark see Troubleshooting Section on page 34 3 16 gap p Gas Collector Box If no spark pinch together or open Gas Collector Box to adjust 3 16 gap between electrode tip and V notch Fig 10 6 From the Off position light all other Burners from left to right making sure each Burner is lit before lighting the next Your grill has a Crossover Ignition System that allows the Burners to light successively off one another Confirm each Burner is lit before lighting another Burner 7 If the Burner fails to light repeat Step 5 If it still does not light try the next Burner from left to right If a Burner goes out during operation turn all Control Knobs to the Off position and close the LP Gas Cylinder valve to dissipate any accumulated gas Open Hood and wait five minutes before attempting to relight the grill If any or all Burners fail to light after three to four attempts following Steps 4 7 turn all Control Knobs to the Off posi tion and close the LP Gas Cylinder valve to dis
4. Parts Illustrations Model 6805 If you need replacement parts refer to the Parts Illustra tions to find the exact parts you need If you have any 22 questions or need help contact Customer Service at a 1 800 251 7558 or go to www aussiegrills com Be gt 23 sure to have the grill model number and serial number acm printed on the black label located inside the left door of 2 the cabinet If you need replacement part under fs ex 24 warranty a proof of purchase will be necessary uem You will be asked to forward your proof of purchase via SSS 25 e mail or to fax your proof of purchase to 423 639 1055 7 ue and reference your model and serial number It is im portant to register your grill and retain your receipt ae Caution If it is necessary to replace thermocouple safety m 4d Cu d 27 sensors Key 55 56 or 57 use only Meco supplied parts T BM 4 i PA ios at 2 s S o Y pg T et pe 10 5 6 7 8 9 10 11 L 12 6c 7 j Limited Warranty MECO CORPORATION LIMITED WARRANTY This product is warranted to the original consumer purchaser against defects in material and workmanship under normal outdoor household use and correct assembly if assembled by the consumer purchaser Burners are warranted for a period of two 2 years from the date of purchase Stainless steel parts are warranted for
5. from your local grocer or retail store or ordered online at www AussieGrills com Grill Body and Cabinet Do not mistake the accumulation of grease and smoke residue for peeling or flaking paint Remove excess grease and or fat with a soft plastic or wooden scraper Do not use steel wool or other abrasive cleaners that can scratch painted porcelain coated or stainless steel surfaces It is not necessary to remove all the grease from the body Wipe it down with paper towels or soft damp cloth Warming Rack Clean if necessary Cooking Grid Flame Diffusers Clean the residue off with a baking soda and water solution For stubborn stains use a non abrasive scouring powder Do not use steel wool or other abrasive cleaners that can scratch the stainless steel or porcelain coated surfaces This can cause foods to stick on the Cooking Grids All other Cleaning For further cleaning use hot soapy water and a cloth or nylon bristled brush only Do not immerse the Gas Controls or Manifold in water Avoid getting water in the Burner holes Burners Burning off the residue after cooking will keep the Burners clean with normal usage provided the Burners are op erating correctly Clean the Burners annually or whenever heavy build up is found to ensure that there are no signs of blockage debris insects in the Burner portholes the primary air inlet or the neck of the Burners See How to Clean the Burners After cleaning replace all
6. grilling perfection SSI Inspired design Vantage LP Gas Grill Assembly and Use Manual For Outdoor Household Use Only Not for Commercial Use Need Help Need to Register Your Grill Looking for Aussie Parts amp Accessories Visit us online at www AussieGrills com Or call Aussie Customer Service at 1 800 251 7558 Failure to follow these intructions could result in If you smell gas fire or explosion which could cause death serious 1 Shut off gas to the appliance personal injury or property damage 2 Extinquish any open flame Read and follow instructions carefully before as 3 Open lid sembly or use 4 If odor continues keep away from the appli Do not use this product for any other purpose than ance and immediately call your gas supplier or which it is intended your fire department These instructions must be kept with the user SAVE THESE INSTRUCTIONS Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance An LP cylinder not connected for use shall not be stored in the vicinity of this or any other appliance NOTICE Meco Corporation strives to be a quality supplier of consumer products If we omitted any parts needed for assembly or you need troubleshooting information please contact us using our toll free number or visit our website It is important to register your grill and retain your receipt 1 800 251 7558 Consumer Service Department
7. Make sure Side Burner Control Knob is turned Off first 3 Turn the LP Gas Cylinder valve open counterclockwise until it stops Fig 8 4 Push Side Burner Control Knob in and turn counterclockwise to the High position 5 Hold lit Match near Burner 6 If the Burner fails to light repeat Steps 3 4 If the burner fails to light after three or four attempts following Steps 3 6 turn the Side Burner Control Knob to the Off position and close the LP Gas Cylinder valve to dissipate an accumulated gas Wait five minutes then repeat the lighting procedure NOTE If the Burners still fail to light refer to Troubleshooting Section Am v Fig 14 Side Burner Control Knob Lighting the Side Burner Sear Burner or Rotisserie Burner Bl UC 3 EJ NOTE Do not operate the Sear burner and Rotisserie burner at the same time Do not use the Rotisserie burner when main burners are in use Remove the Warming Rack when using the Rotisserie Burner to prevent damage to the Warm ing Rack 1 Open lid during lighting 2 Make sure the Side Burner Knob Sear knob or Rotisserie knob is in the Off position 3 Turn on LP Gas Cylinder 4 Push in and turn the Side Sear or Rotisserie knob to the High position and hold in for 3 4 seconds While holding the knob in push the starter button until the Burner is lit Release the Starter Button but continue to hold the knob in for another 10 seconds to allow the complete heating of the safety se
8. See How to Clean Burners section Troubleshooting Problem Possible Cause Solution Burners will not light using the ignitor See re assembly after cleaning in Care and Maintenance Burners not assembled correctly When lighting the first LEFT MOST Burner push Control Knob in and turn counterclockwise to the High position Depress the Igniter Button until the Burner lights Not holding ignitor switch long enough for pulse spark No spark electrode cracked 1 Make sure all the wires are connected and to the right broken or loose terminals 2 If Electronic check the battery Make sure it is pushed in the holder 3 Gas collector tab is bent making too large or small of a gap between the Electrode and tab By hand bend gas collector tab back within a maximum of 3 16 gap to Electrode Page 23 4 Tighten Electrode mounting screws 5 Replace damaged Electrodes LP gas cylinder is empty Take LP Gas Cylinder to licensed LP gas supplier to be refilled Troubleshooting Problem IR side burner will not stay lit IR side burner will not light using ignitor or match Burners will not light using a match Low flame or low heat Possible Cause Regulator coupling nut is not fully connected to LP cylinder LP Excess flow valve tripped in regulator Vapor lock in connections Obstructions in Burners Wet Electrodes and Burners Wire loose or disconnected Wire shorting sparking between Igni
9. leakage exces should be noted on cylinder sive rust or other forms of visual external damage it 3 Must be constructed and marked in accordance with may be hazardous and should be checked by a liquid Specifications for LP Gas Cylinders of the U S De propane supplier Do not use an LP Gas Cylinder with a partment of Transportation DOT or the National damaged valve Standard of Canada 339 Cylinders Do not store a spare LP Gas Cylinder under or near the LP gas grill When grill is not in use turn off all grill Control Knobs LP Gas Cylinder valve and disconnect LP Gas Cylinder Never fill the LP Gas Cylinder more than 80 of cylinder Spheres and Tubes for Transportation of Dangerous Goods and Commission as applicable See collar for marking 4 Must have collar to protect LP Gas Cylinder valve volume 20 Ib maximum Do not ask the propane 5 Must be marked PROPANE supplier to over fill the Cylinder If you obtain LP gas through a cylinder exchange dealer 6 Must be provided with a cylinder connection device make sure you get a safe and adequate cylinder Use only that is compatible with the grill s connection a licensed LP Gas Cylinder dealer LP Hose and Regulator To reduce the risk of serious bodily injury or death from fire or explosion Clean and inspect the gas hose regulator before each use of the outdoor cooking gas appliance The gas hose regulator must be replaced prior to being
10. FINGER TIGHT Finally turn nut 1 4 turn more with sup plied wrench DO NOT OVER TIGHTEN Underside view of Side Table Side Burner Thermocouple wire not shown for clarity To avoid possible damage to grill DO NOT ATTEMPT LIFT GRILL BY THE SIDE TABLES Step 15 Side Burner Igniter Wire Connection The Side Burner Igniter Wire is pre installed and connected to the Ignition Box Attach the wire to the Side Burner elec trode by sliding the wire connector onto the electrode terminal Underside view of Side Table Side Burner Note Shown without Regulator Hose for clarity Step 16 A Side Burner Control Knob Assembly Align the flat keyed hole in the Control Knob with the keyed stem of the Side Burner Valve Push the Control Knob onto the Side Burner Valve stem B Side Burner Grid Assembly Place the Side Burner Grid onto Side Burner Table allowing the three protruded ends to fall into the three holes around the Side Burner Step 17 A Bottom Body Panel Assembly Slide the Bottom Body Panel into the guides of the Body assembly Secure Bottom Body Panel to Body assembly with one 5 32 x 31 Bolt on each side B Foil Pan Grease Pan Assembly Insert the Foil Pan into the Grease Pan Slide the Grease Pan into the guides under the Bottom Body Panel 5 32 31 Bolt 2 pc To reduce the risk of a laceration hazard Wear protective gloves when installing warming rack
11. Model 6804 Parts List Model 6805 9 Manifold Assembly Key Description Quantity Key Description Quantity 1 Side Burner Cover 1 Side Burner Cover 1 2 Side Burner Cooking Grid 2 Main Burner 4 3 Left Side Table 3 Side Burner Cooking 1 4 Side Burner Valve 4 Left Side Table 1 5 Side Burner Knob Bezel 5 Side Burner Valve 1 6 Control Knob 6 Side Burner Knob Bezel 1 7 Side Burner 7 Control Knob 7 8 1 8 Infrared Side Burner 1 gnon ox 1 1 i 5 9 Main Knob Bezel 4 6 lum He 10 Front Crossbar 1 n 11 Cylinder Wire guard 1 12 Main Kaob Bezel 12 Cabinet Side LEFT 1 13 Front Crossbar i 13 _____ Upright 1 14 Cylinder Wire guard 14 _____Cylinder Retainer Bolt 1 15 Cabinet Side Panel LEFT 1 15 Cabinet Bottom Panel 1 16 Cabinet Upright 1 16 Cabinet Door LEFT 17 Cylinder Retainer Bolt 17 Drawer Front 1 18 Cabinet Bottom Panel 1 18 Drawer Box 19 Cabinet Door LEFT 19 Cabinet Door RIGHT 20 Cabinet Door RIGHT 1 20 Handle Large Door 21 Handle Door Drawer 3 21 Handle Small Door Drawer 2 22 Hood Handle 1 22 Hood Handle 1 23 Thermometer 1 23 Thermometer 1 24 Hood Bumper 2 24 Hood Bumper 2 25 Hood 25 Hood 1 26 Warming Rack 26 Wearmina hack 1 27 Main Cooking Grid 3 27 Main Cooking Grid 3 28 Hame Diffuser 4 _ 28 Flame Diffuser 4 29 Rotisserie Burner 30 Sear Burner 1 29 Main Burner 4 31 Right Side Tabl
12. a period of one 1 year for rust through only from the date of purchase All other parts are warranted for a period of one 1 year from the date of purchase MECO CORPORATION DOES NOT warrant in any way the propane cylinder see label on cylinder for cylinder manufacturer s warranty The LP Cylinder manufacturer is responsible for the materials workmanship and performance of the cylinder If the cylinder has a defect malfunctions or you have a question regarding the cylinder call the cylinder manufacturer s customer service center The phone number is on the cylinder If the cylinder manufacturer has not resolved the issue to your satisfaction then call MECO CORPORATION at the customer service number listed below MECO CORPORATION requires proof of purchase and we suggest that you keep your receipt Damages caused by commercial or institutional use accidental or intentional damage repairs made or attempted by unauthorized persons or misuse are not covered by this warranty If defective the part or product will be repaired or replaced at the option of MECO CORPORATION without charge This warranty does not include the cost of any inconvenience or property damage due to failure of the product and does not cover damage due to misuse abuse accident damage arising out of transportation of the product damage incurred through commercial use or failure to perform normal and routine maintenance LIABILITY FOR CONSEQUENTIAL PROPERTY OR COMMERCI
13. the cleaned parts Re tighten Bottom Panel bolts To reduce the risk of death or serious injury from an explosion or a fire beneath the grill Inspect and clean Burner Venturi Tubes for insects or insect nests Spiders or small insects can build nests webs and lay eggs in the grill s Venturi Tubes Fig 15 obstructing the flow of gas to the Burner The backed up gas can ignite behind the Control Panel and cause a fire beneath the grill posing the risk of death or serious bodily injury This is known as a flashback Be sure Burners are re installed properly before using grill Should you notice that your Burner s are getting hard to light or the flame is not as hot as it once was refer to the How to Clean your Burners section to remove any possible obstructions In order to prevent flashbacks the Burner s should be removed from the grill and cleaned periodically especially if the grill has been stored for an extended period of time Control Knob Burner Spider webs or nest inside Venturi Tube Fig 15 Venturi Tube How to Clean the Burners 1 Make sure the Control Knobs are turned Off and the grill is completely cooled 2 Carefully remove Cooking Grids and Flame Diffusers 3 To remove each Main Burner first remove the nut amp bolt that fastens the burner flange to back wall Fig 16 Leave Side Burner in place 4 Slide each Main Burner toward the grill front to disengage tab at rear of burn
14. 8 am 5 pm E S T Monday Friday MECO CORPORATION 1 423 639 1171 Telephone 1500 Industrial Road 1 423 639 2570 Fax Greenville TN 37745 USA www aussiegrills com CARBON MONOXIDE HAZARD This appliance can produce carbon monoxide which has no odor Using it in an enclosed space can kill you Never use this appliance in an enclosed space such as a camper tent car or home To reduce the risk of serious bodily injury or death from fire or explosion Never use alcohol prescription or non prescription drugs while assembling or safely operating this appliance Do not connect LP Gas Cylinder until assembly is complete To reduce the risk of a laceration hazard wear protective gloves when handling parts that have sharp edges Tools Required for Assembly Supplied with Grill Phillips Screwdriver 6804 amp 6805 Wrench 6805 Contents Preparation for 3 Packing Lists Model 6804 4 Model OBOS E DU URN OPERI 5 Assembly Instructions Step 1 Caster 6 Step 2 Cabinet Bottom Assembly 6 Step 3 Side Panel Assembly 7 Step 4 Front Crossbar Assembly 8 Step 5 Cabinet Upright Assembly 8 Step Cylinder Guard Assembly
15. AL DAMAGES ARE EXPRESSLY EXCLUDED BY THIS WARRANTY ANY APPLICABLE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS ARE LIMITED IN DURATION TO THE PERIOD COVERAGE OF THIS EXPRESS WRITTEN LIMITED WARRANTY Some states do not allow limitation on how long an implied warranty lasts so this limitation may not apply to you Deterioration or damage due to severe weather conditions such as hail hurricanes earthquakes or tornados discoloration due to exposure to chemicals either directly or in the atmosphere is not covered by this limited warranty No returns will be accepted without prior authorization from MECO CORPORATION Authorization for return may be obtained by calling 1 800 251 7558 Handling and transportation costs for returning the product are not covered by this warranty and will be paid for by the purchaser Please send your correspondence to MECO CORPORATION Attn Customer Service 1500 Industrial Road Greeneville TN 37745 For reference and correspondence Serial No record your Serial number here Please use this number in registering your warranty and any See nameplate on side of grill correspondance with MECO CORPORATION P N 03 6907 09 Rev 20090114
16. Drawer Front with two 5 32 x 22 Bolts Note 1 extra screw provided Attach Drawer Front to Drawer Body with 5 32 x 31 Bolts into threaded holes in inside of Drawer Front 5 32 x 22 Bolt set 2 pc N UA 5 32 x 31 Bolt set Model 6804 6 pcs Model 6805 7 pcs B Drawer Positioning Slide Drawer Assembly over the Drawer Tracks to position the Drawer Step 10 Door Assembly Install LEFT Door Drop bottom door pin into Cabinet Bottom Panel hole Swing top of door toward hole in top of Left Side Panel Depress spring loaded pin with thumb while sliding pin into Left Side Panel hole until it snaps into place Right Door assembly is similar Fixed pin is under drawer and inserts into hole in door and spring loaded pin is in the BOTTOM of small door and functions the same Depress Left Door shown Right Door under drawer Step 11 Hood Body To Cart Assembly Lift the Hood Body Assembly over the cart assembly and set it down until it rests on the inside top flanges of the cart Align the holes in the side of the Hood Body with the holes in the Side Panel brackets Insert four 1 4 20 x 50 Bolts through the holes in cabinet flanges and into threaded inserts in firebox and tighten after all are installed Right side 1 4 20 x 50 Bolt set 4 pc NOTE Model 6805 Carefully route gas and electrical lines when placing hood body assembly on car
17. Hood and Bowl edges could be sharp Step 18 Warming Rack Assembly Insert Warming Rack leg ends into holes on top edge of firebox Seat securely Step 19 Flame Diffuser Cooking Grid Assembly A Lay a Flame Diffuser from back to front over each Burner on the lower Body ridges Place each Flame Diffuser in the individual guides to keep from sliding B Place the Cooking Grids over the Burner Diffusers on the upper Body ridges he Jr c 79 y M sg C a d To a aJ E SES tI c E f A lm 52 7 a flame diffuser cooking grid Step 20 Battery in Igniter Installation u u Unscrew lgniter Cover and insert AA Battery with the negative end going in first Replace the cover and tighten securely A A NY Battery AA 1 5v Alkaline 1 pc This Completes the Grill Assembly Connecting Disconnecting the Gas Using Gas Carbon Monoxide Hazard This appliance can produce carbon monoxide which has no odor Using it in an enclosed space can kill you Never use this appliance indoors on recreational vehicles or boats To reduce the risk of serious bodily injury or death from fire or explosion Use only propane gas with this LP gas grill Do not attempt to convert an LP unit to natural gas Always use a gas appliance outdoors in an open area with good ventilation to avoid breathing tox
18. IME USE LEAK TEST Detach the Control Panel from the Grill Body Firebox by removing the two 5 32 Bolts from each end Fig 1 Gently pull the Control Panel away from the Body until Valves disengage from the Tubular burner ends Fig 2 Support the Control Panel to keep tension off of the igniter wire leads or detach the wire leads from the Starter Button module Tubular Burner Ends Check for leaks at Cylinder Valve and Regulator Connection and Fittings Fig 3 Fig 3a To reduce the risk of a laceration hazard Wear protective gloves when removing or replacing Control panel which could have sharp edges 21 6 Check for leaks by brushing the soap solution on all gas valves hose connections and fittings Shown by the heavy arrows in Fig 3a 4 5 and 6 Make sure you generously brush the locations with the soap solution completely surrounding the connections and fittings NOTE After checking the connections and fittings in Figure 4 replace the control panel in the same manner as it was removed Take special care to be sure the valve ends are inserted into the openings in the burner ends as shown in Figure 4a If all valve ends do not immediately align with the burner end openings starting at one end grasp the tube burner inside the firebox and gently move it until the valve seats in the open end Also note that the end caps of the control panel skin fit to the outside of the flanges on the firebox as sho
19. alve stem out through the hole in the bezel and fascia on the front of the side table Next flex the tube of the burner down and insert the nozzle into the opening in the burner tube B Install two 5 32 x 31 Bolts through the Control Knob Bezel and front of Side Table and into the threaded Valve bracket holes Install the top bolt first by twisting the valve bracket to align only the top holes Do not tighten completely Next twist the valve bracket to align the bottom holes and install the second bolt Tighten both x f 5 32 x 31 Bolt 2 pc Top First Step 14 8 Side Burner Valve Connection Install the Side Burner Valve from underneath the LEFT Side Table First insert the valve stem out through the hole in the bezel and fascia on the front of the side table Next install two 5 32 x 31 Bolts through the Control Knob Bezel and front of Side Table and into the threaded Valve bracket holes B Remove nut from the unattached end of the corrugated hose that is connected to the Side Burner valve Place the end of the hose through the hole in the Side Burner bracket Replace the nut on the other side of the bracket C Attach Thermocouple fitting to valve Carefully align and insert end of sensor extending from brass nut on copper tubing into threaded opening in side burner valve as shown below Gently flex copper tubing to insure brass nut is not cross threaded Tighten brass nut BY HAND FIRST
20. an and Grease Pan after each cooking session so excessive grease does not accumulate Never light the LP gas grill without the Foil Pan Grease Pan and Bottom Panel in place 1 After each cooking session close the Hood and turn the Burners to the High position and burn for five minutes This will burn off some cooking residue thus making cleaning easier Side Burner not affected 2 When you have finished using your grill turn the Control Knobs clockwise to the Off position 3 Turn off the gas at the LP Gas Cylinder valve by turning the handle clockwise until it stops 4 Wait until the grill is cool before closing the Hood cleaning or putting on a grill cover 5 Be sure to close the Side Burner Lid when not in use 6 Regularly clean your LP gas grill between uses and after extended storage periods To maintain the condition and extend the life of your grill we strongly recommend that the unit be covered when stored outside for any Care and Maintenance To reduce the risk of a laceration hazard wear protective gloves when handling parts that have sharp edges Cleaning the Grill Bottom Panel Grease Pan Foil Pan Remove the two bolts on the sides securing the Bottom Panel Step 19 page 18 Scrape away food and fat residue from the Bottom Panel Empty and wash the Foil Pan and Grease Pan with hot soapy water and a cloth The Foil Pan can be replaced with a standard size foil pan approx 5 1 2 W x 8 1 2 L x 1 1 8
21. as Cylinder 18 Preparation for Assembly Before Using Your Grill Installation 19 Selecting a Location 19 How to Perform a Leak 19 Lighting Grill Using the Pulse Spark Ignitor 20 Manually Lighting the Grill sues 24 Lighting the Side Burner 25 Check the Flame 25 Manually Lighting the Side Burner 26 Lighting Sear and Rotisserie Burners on Model 6805 26 Cooking on the Gas Grill Grill Cooking Direct 27 Roasting Indirect 28 Warming ROCK RIEN T TE 29 End of Cooking 5 51 29 Care and Maintenance Cleaning the 11 30 How to Clean the Burners 31 SICKOGE MR 33 MN 34 Troubleshooting sesecesesecesesecocecococococsesesececececoeo 34 Important Notice LP Cylinder with OPD 36 Parts Illustrations Model 6804 37 Fae S 38 Model 6805 I ePi 39 Limited
22. cs Side Burner Cooking Grid Flame Diffuser 4 pcs Hardware Package Cylinder Wire guard Cylinder Retainer Bolt Side Burner Control Knob Grease Pan Foil Pan Cylinder Blocking Wire 4 Cabinet Door Left Cabinet Door Right Drawer Front 5 Cabinet Back Panel Front Crossbar Cabinet Upright Back Panel Brace Drawer Tracks 2 pcs 6 Cooking Grid 3 pcs 7 Drawer Body 8 Hood Body Detailed Parts List and Illustrations may be found on pages 37 amp 38 Packing List Model 6805 Box Description Cabinet Bottom Panel Bottom Panel 2 Cabinet Side Panel Right Cabinet Side Panel Left Warming Rack 3 Left Side Shefl with Side Burner Right Side Shelf Door Drawer handle 3 pcs Locking Caster 2 pcs Fixed Casters 2 pcs Side Burner Cooking Grid Flame Diffuser 4 pcs Hardware Package Cylinder Wire quard Cylinder Retainer Bolt Side Burner Control Knob Grease Pan Foil Pan Cylinder Blocking Wire 4 Cabinet Door Left Cabinet Door Right Drawer Front 5 Cabinet Back Panel Front Crossbar Cabinet Upright Back Panel Brace Drawer Tracks 2 pcs Cooking Grid 3 pcs 7 Drawer Body 8 Hood Body Detailed Parts List and Illustrations may be found on pages 38 amp 39 Assembly Instructions Step 1 Caster Assembly Lay Cabinet Bottom Panel upside down so that the flat surface is on the floor Assemble Fixed Casters t
23. d the door opening for proper vapor withdrawl Lock the LP Cylinder in place by tightening wing bolt on the outside rear of the cabinet base so that it seats against the ring base of the LP Cylinder 3 Remove the protective cap from the LP Gas Cylinder valve Save cap for re capping Hold Regulator in a straight line with LP Gas Cylinder valve so the connection does not cross thread Insert Regulator Nipple into the LP Gas Cylinder valve Hand tighten coupling nut in clockwise direction DO NOT USE TOOLS Wing Bolt on outside rear of cabinet base Cylinder nozzle faces out toward door Disconnecting LP Gas Cylinder Hand tighten coupling nut in clockwise direction 1 Turn all Control Knobs to the Off position and turn the handle on the LP Gas Cylinder clockwise until it stops 2 Turn coupling nut on regulator counterclockwise until regulator is released from the threaded LP Gas Cylinder nozzle 3 Place the protective cap over LP Gas Cylinder nozzle Before Using Your LP Gas Grill Installation Codes To reduce the risk of serious bodily injury or death from fire or explosion This installation must conform with local codes or in the absence of local codes with either the National Fuel Gas Code ANSI Z223 1 NFPA 54 Natural Gas and Propane Installation Code CSA B149 1 or Propane Storage and Handling Code B149 2 or the Standard for Recreational Vehicles ANSI A 119 2 NFPA 1192 and CSA Z240 RV Series recreatio
24. d turn Off the Burner s directly below the food Close the hood and cook indirectly Monitor the temperature in the Hood Gauge If the heat gets too high turn the Burner to the Low position Avoid lifting the Hood frequently as heat is lost and the cooking time is extended For longer cooking times add water to the Roasting Pan to keep drippings from burning The drippings can be used to make gravies or sauces Warming Rack To reduce the risk of fire or flare up from grease drippings When cooking food on the warming rack make sure no Burners are on directly under the Drip Pan Clean grease drippings away from grill after each use Warming Racks are a convenient way to cook food keep cooked food warm or to warm items such as bread or rolls To keep foods warm set the Burners on Low or turn off all that are not needed When cooking food on the Warming Rack follow procedures for Roasting Indirect Cooking Be sure to place a pan or drip tray under the food When opening the Hood be alert of dripping fat from the Warming Rack that could drip onto the back of the grill Always check that your Warming Rack is properly fitted before use Wipe away any dripping grease End of Cooking Session To reduce the risk of serious bodily injury or death from fire or burn hazard Allow grill and the grease in the Foil Pan to completely cool before emptying handling parts cleaning moving or storage Empty the Foil P
25. device to prevent overfilling your LP Gas Cylinder The proper methods for the filling of your LP Gas Cylinder are by weight or volume as described in NFPA 58 Please make sure your filling station fills your LP Gas Cylinder by weight or volume Ask your filling station to read purging and filling instructions on the LP Gas Cylinder before attempting to fill Do not exchange the LP Gas Cylinder unless the exchange LP Gas Cylinder is equipped with an OPD Otherwise you will lose the OPD Overfill Prevention Device feature If there is not an LP Gas Cylinder available for exchange equipped with an OPD we recommend that you have your LP Gas Cylinder filled at an authorized LP gas dealer by a qualified attendant Parts Illustration Model 6804 If you need replacement parts refer to the Parts Illustra tions to find the exact parts you need If you have any questions or need help contact Customer Service at 1 800 251 7558 or go to www aussiegrills com Be sure to have the grill model number and serial number printed on the black label located inside the left door of the cabinet If you need a replacement part under war ranty a proof of purchase will be necessary You will be asked to forward your proof of purchase via e mail or to fax your proof of purchase to 423 639 1055 and refer ence your model and serial number It is important to register your grill and retain your receipt 38 Parts List
26. e 1 30 ___Right Side Table 1 amp 32 Main Electrode Assembly 2 31 ___ Tool Hooks 20 33 Tool Hooks 3 32 Electrode Assembly 2 34 Bottom Panel 1 34 Control Panel 36 Grease Pan 1 35 Bottom Panel 1 37 Cabinet Back Panel 1 36 Cabinet Back Panel 38 Drawer Tracks 2 37 Foil Pan 39 Cylinder Blocking Wire 1 38 Grease Pan 1 40 CabinetSidePanel RIGHT 39 Cabinet Side Panel RIGHT 1 A1 _MatchHolder Chain 1 40 Cylinder Blocking Wire 42 DrawerBody 1 J 41 Match Holder Chain 1 43 Drawer Front 1 42 Caster Fixed 2 44 Caster Fixed 2 43 Caster Locking Swivel 2 45 ____ Caster Locking Swivel 2 44 Manifold to SB valve Hose 1 46 _____Regulator 2 31 45 Reaulator 1 47 Center Wheel 1 46 Pim Wheel A8 1 4 20 x 50 S S Bolt 28 47 Drawer Tracks 2 49 1 4 20 S S Hex Nut 10 T T 50 1 4 20 x 60 S S Bolt 16 48 ___1 4 20 x 50 5 5 Bot 27 51 5 32 x 47 S S Bolt 4 49 _____1 4 20 5 5 Hex Nut__9 amp 52 5 32 x 31 S S Bolt 29 50 1 4 20 x 60 S S Bot amp l amp 53 5 32 x 22 S S Bolt 9 51 ___5 32 47 5 5 14 54 5 32 S S Hex Nut 1 52 5 32x 3 1 S SBot 28 55 Thermocouple Side Burner 1 no pic 53 1 5 32x 22 5 5 Bot 19 56 Thermocouple Sear Burner 1 no pic 54 5 32 S S Hex Nut 1 57 Thermocouple Rotisserie 1 no pic 55 Side Burner Electrode 1 no pic 58 Side Burner Electrode 1 no pic 59 Sear Burner Electrode 1 no pic 60 Rotisserie Electrode 1 no
27. eak test a minimum of once a season Perform a leak test after a prolonged period of storage or non use Perform a leak test if the regulator flow limiting device has been activated Perform a leak test on the propane cylinder and exposed connections every time the propane cylinder is refilled or exchanged Perform leak tests in a well ventilated area Never use an open flame to test for gas leaks Never smoke near the grill during a leak test Do not perform a leak test on a grill while it is hot or in use Do not use the gas grill if you detect a gas leak that cannot be corrected by using the leak test procedures Before using your gas grill perform a leak test on the Control Valves Hose Regulator Connections Fittings and LP Gas Cylinder How to Perform A Leak Test FIRST TIME USE and as required Supplies Needed for a Leak Test Clean paint brush Water Dish washing liquid 1 Use an LP Gas Cylinder equipped with an OPD Overfill Prevention Device and have it filled at an authorized LP gas dealer by a qualified attendant 2 Make sure all grill Control Panel Knobs are turned to the Off position and verify that the LP Gas Cylinder valve is closed by turning the knob on the LP Gas Cylinder clockwise until it stops 3 Mix one part of water with one part of dish washing liquid 4 Figures 1 2 4 and 4a show the grill at assembly step 11 prior to attaching the Side Tables and illustrate the initial steps in the FIRST T
28. ed Turn Control Knobs to Off position and turn LP Gas Cyl inder handle clockwise until it stops Wait five minutes Relight LP gas grill If flame continues to be low turn off gas at LP Gas Cylinder and grill Disconnect the regulator from the LP Gas Cylinder Reconnect the regulator to the LP Gas Cylinder This will reset the excess flow valve Perform a leak test Relight grill Tighten Regulator Coupling nut by hand about one half to three quarters additional turn Do not use tools See How to Clean Burners in Care and Maintenance Check LP Gas Cylinder Refill if necessary Turn Control Knobs to Off position and turn LP Gas Cyl inder handle clockwise until it stops Wait five minutes Relight LP gas grill If flame continues to be low turn off gas at LP Gas Cylinder and grill Disconnect the regulator from the LP Gas Cylinder Reconnect the regulator to the LP Gas Cylinder This will reset the excess flow valve Perform a leak test Relight grill Problem Possible Cause Solution Flare up Grease build up Clean grill Excessive fat in meat Trim fat from meat before grilling Persistent grease fire Grease trapped around burner Turn Control Knobs Off and turn handle of LP Gas Cylinder system clockwise until it stops Open Hood carefully and let fire burn out After the grill cools remove and clean all parts Unable to fill LP tank Some dealers have older fill The worn nozzles do not have enough bite to engage the nozzl
29. er from slot in back wall of bowl Gently lift the rear of the Burner Fig 17 Slide the Burner towards the grill back to move the Venturi Hole off of the Valve nozzle Fig 18 Lift each Main Burner from the grill Remove nuts and bolts Lift Burner up and out View from inside front body d Valve nozzle V P Burner Venturi Hole fits centrally Fig 18 around Valve nozzle 5 Use a pipe cleaner to clear insect nests from the inlet hole of Main Burner Fig 19 and Side Burner tube Fig 20 6 Open up the Main Burner holes Fig 19 and the Side Burner holes Fig 21 with a small nail or wire Use a non metallic brush to remove food particles and corrosion from the Burner surfaces 7 7 Open up A EP 7 Fa gt 2 holes with a 4 small nail or we wire JF dos E Non metallic Wire Brush D AA Fig 20 Side Burner tube Fig 19 Pipe Cleaner Make sure the screw holding the electrode underneath is tight so 3 16 gap between electrode tip and side burner is maintained Fig 21 Open up Burner holes with a small nail or wire 7 Check the Side Burner Electrode to see if it is loose If so tighten the screw holding the Electrode to maintain 3 16 gap between Electrode tip and Side Burner NOTE Before next step you may wish to clean the rest of the grill See Grill Body and Cabinet 8 After cleaning refit the Burners NOTE When re
30. es with worn threads valve Try another licensed LP dealer Humming or whistling from Outside temperature humid Although this sound may be alarming this is NOT danger regulator ity barometric pressure and ousas long as it is not accompanied by the smell of gas the gas level within the tank Simply adjust the Burner settings and usually the sound may cause the rubber dia will subside If the humming sound persists a change in phragm inside the regulator atmospheric conditions will eventually stop the vibration to vibrate making a humming or whistling sound Cabinet doors do not close Doors magnets loose Tighten Door Magnet bolts and nuts Doors not aligned 1 Loosen bolts and bottom door brackets Align doors 2 Loosen bottom side panel bolts inside cabinet Apply pressure to one side until doors are aligned Retighten bolts Flames blow out High or gusting winds Turn front of grill away from wind or increase flame height Gas in LP cylinder is low Check LP Gas Cylinder Refill if necessary See Low flame problem above If your problem is not resolved from the information provided above please call Customer Service at 1 800 251 7558 If you need a replacement part under warranty a proof of purchase will be necessary IMPORTANT NOTICE The Gas Grill is setup to operate with a LP Gas Cylinder equipped with an OPD Overfill Prevention Device Rises up while filling then stops when full This is a secondary
31. fitting the Burners be sure each Burner is positioned correctly The valves should protrude inside the Venturi ends of the Burner Fig 18 Replace the Bolts and Nuts that fasten the Burner Flange to Back Wall 9 f the grill is to be stored wrap Burners in a protective cover to keep insects out 10 Check Burner operation after re assembly 11 Replace Flame Diffusers and Cooking Grids NOTE The sear burner and IR side burner in the 6805 do not require manual cleaning Do not scrape the ceramic with any sort of tool Remove any large pieces of food after grill has cooled If small amounts of food or grease fall on the ceramic turn the burner on high for 2 to 5 minutes until the food or grease has turned to dust and disappeared from the ceramic Storage To reduce the risk of serious bodily injury or death Store your LP gas grill in a cool dry place Do not store an LP Gas Cylinder in a space greater than 125 degrees Fahrenheit Never store a connected LP Gas Cylinder in a building garage or any enclosed area Store LP Gas Cylinders outdoors out of reach of children Never store an LP Gas Cylinder indoors empty or filled unless it is disconnected from the gas grill and the cylinder s Gas Supply is turned OFF Never leave an LP Gas Cylinder inside a vehicle that can become overheated by the sun Even though your LP Gas Cylinder may appear to be empty gas may still be present and the LP Gas Cylinder should be transported and sto
32. hback Fire in or around Venturi tubes Possible Cause Damaged hose Mechanical failure due to rust or mishandling Failure of valve from mishan dling or mechanical malfunc tion Improper installation con nection not tight failure of seal on LP Gas Cylinder valve Fire in or around Venturi tube section of Burner Too much grease build up in Burner section Clogged or blocked Venturi tube Emergencies Solution Turn off gas at the LP Gas Cylinder Replace valve hose regulator before continuing use Replace LP Gas Cylinder Turn off LP Gas Cylinder valve Return Cylinder to gas supplier Turn off LP Gas Cylinder valve Re install correctly or tighten coupling nut Replace Cylinder if seal is dam aged See Leak Test and Connecting Regulator to LP Gas Cylinder sections If you can safely reach the Control Panel turn off Control Knobs then close the LP Gas Cylinder valve Once fire is out and grill has cooled off remove Burner s and inspect for blockage from spider webs insect nests or rust See How to Clean Burners section Replace any damaged parts Turn off Control Knobs and LP Gas Cylinder valve Once fire is out and grill has cooled off Clean residual food particles and excess grease from inside firebox area grease cup and other surfaces If you can safely reach the Control Panel turn Control Knobs to Off then close the LP Gas Cylinder valve Clean Burner and Venturi tubes
33. ic fumes from leaking gas explosion or fire As with all conventional fuels the burning process consumes oxygen and produces toxic gases including carbon monoxide In addition the combustion products of such fuels including liquefied pe troleum LP contain chemicals known to the state of California and other authorities to cause cancer birth defects and other reproductive harm Any use or alteration of this unit not intended could be unsafe and will void your warranty LP Gas Cylinder RNIN SC AWARNING f you see smell or hear the hiss of LP gas escap ing from the cylinder To reduce the risk of serious bodily injury from fire or explosion Read and follow all warnings on LP Gas Cylinder Do not operate the LP gas grill without the LP Gas Cylin der secured to the cart and oriented as shown in Assem bly Instructions for Connecting the LP Gas Cylinder Never connect or disconnect LP Gas Cylinder or fittings The LP Gas Cylinder for use with this LP gas grill while grill is in use or is hot must meet the following requirements When the LP Gas Cylinder is connected keep the grill outside in a well ventilated space Do not use an LP Gas Cylinder if it shows signs of dents 1 Do not attempt to light appliance 2 Extinguish any open flame 3 Disconnect from fuel supply 1 12 diameter x 18 tall 20 lb maximum capacity 2 Overfill Prevention Device OPD safety feature gouges bulges fire damage corrosion
34. nal Vehicle Code as applicable f an external electrical source is utilized the outdoor cooking appliance when installed must be electrically grounded in accordance with local codes or in the absence of local codes with the National Electrical Codes ANSI NFPA 70 or the Canadian Electrical Code CSA C22 1 Keep any electrical supply cord and the fuel supply hose away from any heated surfaces Selecting a Location To reduce the risk of serious bodily injury or death from fire or explosion This outdoor cooking appliance must be used only outdoors and shall not be used in a building garage breezeway carport porch or in any enclosed area Locate outdoor cooking appliance in an area with good ventilation on a level stable surface clear of combustible and flammable material Locate your LP gas grill at least 10 feet away from your house or any building Maintain minimum clearances of 36 from back and sides of grill to any combustible construction Do not locate this appliance under overhead unprotected combustible construction This outdoor cooking appliance is not intended to be used in or on boats or installed in or on recreational ve hicles Never use gas grill as a space heater Performing A Leak Test To reduce the risk of serious bodily injury or death from fire or explosion Perform a leak test before lighting your grill for the first time Perform a leak test if any gas component is changed Perform a l
35. nsor 5 If ignition does not occur in 5 seconds turn the burner knob to the Off position and wait 5 minutes before repeating the lighting procedure Cooking On the Gas Grill To reduce the risk of serious bodily injury or death from fire explosion or burn hazard Never use charcoal or lighter fluid in your gas grill Keep this outdoor cooking appliance clear and free from combustible materials gasoline and other flammable vapors and liquids Keep any electrical supply cord and regulator hose away from any heated surfaces Make sure there are no gas leaks or obstructions to the flow of combustion and ventilation air before each use Keep the ventilation openings of the LP Gas Cylinder enclosure free and clear from debris Always open the Hood before lighting the LP gas grill Do not attempt to extinguish a grease fire with water or other liquids Have a BC fire extinguisher accessible Never douse or spray the grill or cooking surfaces with water when hot Burns from grease or water splatters could occur If your gas grill catches on fire If the fire is in the grill portion and you can safely reach the Control Knobs on the Control Panel then turn them to the Off position f the fire is in one of the hoses and you can safely reach the LP Gas Cylinder valve then shut the valve off f the fire involves the LP Gas Cylinder leave it alone evacuate the area and call the Fire Department f there is any type of fire that
36. o reduce the risk of serious bodily injury or death from fire or explosion Do not cover more than half 5096 the cooking area if using griddle plates Full coverage of cooking area will cause overheating below the plates Always make sure the Foil Pan Grease Pan and Bottom Panel are empty and are properly installed under the Bowl before each cooking Do not leave any utensils or cookware on a hot Cooking Grid Grill Cooking Direct Method Direct Cooking on the Grids Food is cooked directly over the heat source The Burners heat up the Flame Diffusers under the Cooking Grids which in turn heat the food on the grill The natural food juices from cooking fall onto the hot Flame Diffusers below and vaporize Rising smoke bastes the food giving it that unique barbecued flavor Use the Direct Cooking method for foods that take less than 25 minutes to cook steaks chops kabobs sausages and more These foods should be turned once halfway through the grilling time To sear meats place them over Direct High heat for 2 to 5 minutes per side Smaller pieces require less searing time Hamburgers steaks chops chicken breasts and larger cuts of meat all benefit from searing Usually after searing you finish cooking the food at a lower temperature For Direct Cooking preheat the grill with the Main Burners on High Place food on the Cooking Grate and then adjust all Burners to the temperature required Close the Hood and lif
37. o the LEFT Side the side closest to the cutouts of Cabinet Bottom Panel and Swivel Lock Casters to the RIGHT Side of Cabinet Bottom Panel Insert 1 4 20 x 60 Bolts through the caster bracket holes into the threaded holes in the Cabinet Bottom Panel Tighten the bolts Push the lever on the two Locking Casters to lock so the caster wheels do not roll Fixed Casters 1 4 20 x 60 Bolt set 16 pc Step 2 Cabinet Bottom Assembly With Back Panel on floor place Cabinet Bottom Panel against Back Panel edge and align the holes Install three 1 4 20 x 50 Bolts through the holes and secure with three 1 4 20 Nuts 1 4 20 x 50 Bolt set Model 6804 3 pcs Model 6805 4 pcs Step 3 Side Panel Assembly Attach Left Side Panel and Right Side Panel to Cabinet Bottom Panel with six 1 4 20 x 50 Bolts and 1 4 20 Nuts 6 pc 4 pc o Step 4 Front Crossbar Assembly Turn cart assembly up on casters Attach Front Crossbar with the triangle braces facing down and the flat surface to the front to Side Panels with six 1 4 20 x 50 Bolts into the threaded holes in the top inside ends of Side Panels 1 4 20 x 50 Bolt set 6 pc Step 5 Cabinet Upright Assembly Attach Cabinet Upright to Cabinet Bottom and Front Crossbar with four 5 32 x 31 Bolts Orient Upright so that Match holder Chain is closest to top of cabinet Front Crossbar E Os 5 32 x 31 Bolt set 4 pc To reduce
38. o the Troubleshooting Section 7 After ignition turn the Control Knobs to High for 3 5 minutes and close the Hood to preheat the grill Preheat the grill before every cooking session If a Burner goes out during operation turn all Control Knobs to the Off position and close the LP Gas Cylinder valve to dissipate any accumulated gas Open Hood and wait five minutes before attempting to relight the grill Lighting the Side Burner To reduce the risk of serious bodily injury or death from fire or explosion Open Side Burner Lid before lighting the grill to prevent an explosion from gas build up 1 Open the Side Burner Lid Fig 13 NOTE Side Burner Lid is to remain open while the Side Burner is on or hot 2 IMPORTANT Make sure the Side Burner Control Knob is turned Off first Fig 7 p 22 3 Turn the LP Gas Cylinder valve open counterclockwise until it stops Fig 8 p 22 4 Push Side Burner Control Knob in and turn counterclockwise to the High position Fig 7 p 22 For IR Side Burner on 6805 hold knob in while pushing the igniter button as explained in step 5 After releasing the Igniter Button continue to hold the knob in for another 10 seconds to allow the complete heating of the safety sensor 5 Push the Igniter Button on the Main Control Panel in until the Burner is lit Listen for the spark ignition and look to make sure the Burner is lit If no spark see Troubleshooting Section 6 If the Burner fails to ligh
39. or serious injury from an explosion or a fire beneath the grill Inspect and clean Burner Venturi Tubes for insects or insect nests Spiders or small insects can build nests webs and lay eggs in the grill s Venturi Tubes Fig 15 page 31 obstructing the flow of gas to the Burner The backed up gas can ignite behind the Control Panel and cause a fire beneath the grill posing the risk of death or serious bodily injury This is known as a flashback Be sure Burners are re installed properly before using grill Should you notice that your Burner s are getting hard to light or the flame is not as hot as it once was refer to the How to Clean your Burners section on page 31 to remove any possible obstructions To reduce the risk of serious bodily injury or death from fire or explosion Open Hood before lighting the grill to prevent an explosion from gas build up During failed lighting attempts or if the Burners go out during operation turn Control Knobs Off to dissipate any accumulation of gas Wait five minutes before repeating lighting procedure Light each burner from the left before lighting the next burning to prevent gas from accumulating 1 Open the Hood 2 IMPORTANT Make sure Control Knobs are turned Off Fig 7 3 Turn the LP Gas Cylinder valve open counterclockwise until it stops Fig 8 Control Knob in High Control Knob in position large flame Off position symbol
40. red accordingly Never store a spare LP Gas Cylinder under or near the LP gas grill Always turn off the LP Gas Cylinder at the LP Gas Cylinder valve when the gas grill is not in use 1 Disconnect LP Gas Cylinder from grill and store outside in a dry well ventilated area away from any sources of heat or ignition Re cap LP Gas Cylinder valve with the Safety Cap 2 Remove Burners and wrap with aluminum foil to prevent insects from entering the Burner holes Store wrapped Burners on top of Cooking Grid 3 You may wrap the Cooking Grid and Flame Diffusers in aluminum foil and place inside the Hood or store inside your dwelling 4 Place a grill cover over the grill and store outdoors if possible It may be stored indoors only if the LP Gas Cylinder is disconnected from the gas grill and stored outside 5 Before next use remove aluminum foil and reinstall Burners Flame Diffusers and Cooking Grids 6 Before using the grill after periods of storage or non use i e over winter check your LP gas grill for gas leaks deterioration proper assembly and Burner obstructions 7 Periodically check and tighten all nuts bolts and screws Problem Gas leaking from cracked cut burned hose Gas leaking from LP Gas Cylinder Gas leaking from LP Gas Cylinder valve Gas leaking between LP Gas Cylinder and regula tor connection Fire coming through Control Panel Grease fire or excessive flames above cooking surface Flas
41. sipate any accumulated gas Wait five minutes then repeat the lighting procedures Lighting the Side Burner Sear Burner or Rotisserie Burner NOTE Do not operate the Sear burner and Rotisserie burner at the same time Do not use the Rotisserie burner when main burners are in use Remove the Warming Rack when using the Rotisserie Burner to prevent damage to the Warm ing Rack 1 Open lid during lighting 2 Make sure the Side Burner Knob Sear knob or Rotisserie knob is in the Off position 3 Turn on LP Gas Cylinder 4 Push in and turn the Side Sear or Rotisserie knob to the High position and hold in for 3 4 seconds While holding the knob in push the starter button until the Burner is lit Release the Starter Button but continue to hold the knob in for another 10 seconds to allow the complete heating of the safety sensor 5 If ignition does not occur in 5 seconds turn the burner knob to the Off position and wait 5 minutes before repeating the lighting procedure NOTE If the Burners still fail to light refer to the Troubleshooting Section on page 34 The Burner can also be lit manually see Manual Lighting of the Grill on page 24 Manually Lighting the Grill To reduce the risk of serious bodily injury or death from fire or explosion Open Hood before lighting the grill to prevent an explosion from gas build up 1 Open the Hood 2 IMPORTANT Make sure Control Knobs are turned Off Fig 7 3 Turn the LP Gas C
42. t Be sure no lines are pinched between hood body assembly and cart Prior to performing any further assembly PERFORM FIRST TIME USE LEAK TEST as detailed on pages 20 21 If the grill is fully assembled before performing the First Time Use leak test the side tables will need to be removed in order to perform the leak test on the valves behind the knobs inside the control panel Step 12 Side Table Assembly A Screw two 1 4 20 x 50 Bolts into the two bottom threaded inserts on the outside of the Bowl Do not screw Bolts all the way Leave 1 8 of each Bolt exposed Align the bottom two holes keyhole slots in detail on the inner side of the LEFT Side Table with the two bolts thread ed partly into the inserts in the Side of the Bowl then slide the Side Burner Table over the Bolts B Holding the Side Burner Table in place install two 1 4 20 x 50 Bolts from the inside of the Bowl into the two top threaded holes in the Side Table C From under the Side Table install one 5 32 x 31 bolt through the Side Table end into the side of the Bowl Repeat this assembly for the RIGHT Side Table Tighten all bolts 1 4 20 x 50 Bolt set 8 pc 5 32 31 Bolt set 2 pc Step 13 TETTE Side Burner Valve Assembly NOTE Side Burner Valve is already attached to the regulator hose Install the Side Burner Valve from underneath the LEFT Side Table First insert the v
43. t repeat Step 3 If the Burner fails to light after three or four attempts following Steps 3 6 turn the Side Burner Control Knob to the Off position and close the LP Gas Cylinder valve to dissipate any accumulated gas Wait five minutes then repeat the lighting procedures NOTE If the Burners still fail to light refer to Troubleshooting Section The Burner can be lit manually see Manually Lighting the Side Burner Open Lid Fig 13 Side Burner Control Knob Check The Flame The Burners have been preset by the manufacturer for optimal flame performance A blue flame possibly with a small yellow tip is the result of the optimal air and gas mixture Check the flame before each cooking session and throughout the grilling season Check the flame especially after long periods of storing the grill If the flame is significantly yellow in color the appropriate amount of LP gas in the air LP gas mixture is not correct This could be due to a blocked Burner from grease drippings or from insects building a nest inside the Burner or Burner opening See How to Clean the Burners Yellow Tip Primarily Blue Flame Manually Lighting the Side Burner To reduce the risk of serious bodily injury or death from fire explosion or burn hazard Open Side Burner Lid before lighting the grill to prevent an explosion from gas build up When manually lighting Side Burner use Matchlight Holder 1 Open the Side Burner Lid 2 IMPORTANT
44. t it only to turn food or to test for doneness at the end of the recommended cooking time Cooking on Griddle Plates allows cooking of smaller items that otherwise would fall through the grill The Burners heat the Griddle Plates directly which cooks the food on contact The Griddle Plates sear thin cuts of meat or cook food like eggs that can not be cooked on a grill They can also be used to heat pans CAUTION Do not preheat Cooking Grids over 5 minutes The cooking surface coatings could be destroyed Use only long handled heat resistant plastic or wooden utensils to avoid scratching the non stick surface Roasting Indirect Method To reduce the risk of burns from the hot air and steam trapped inside Open the Hood carefully when roasting on grill Indirect Cooking Roasting Food is cooked like in an oven under lower heat and or longer cooking times These foods require more than 25 minutes grilling time and some are so delicate that Direct Cooking would dry them out or scorch them Use the Indirect Cooking Method to cook whole meats such as roasts ribs chickens turkeys and other large cuts of meat as well as delicate fish fillets Place the food to bake or roast on the center of the cooking grids inside a metal baking tray or a disposable heavy gauge foil pan or on a roasting rack Preheat the grill with the Main Burners on High Then adjust the Burners lower on each side of the food to the cor rect temperature an
45. ter and Electrode Thermocouple is not properly attached to side burner valve Safety sensor is not completely heated IR side Burner has filled with water Burners not assembled correctly LP Gas Cylinder is empty LP Excess flow valve tripped in regulator Regulator Coupling nut is not fully connected to LP Gas Cylinder Obstructions in Burners LP gas in LP Gas Cylinder is low Excess flow valve tripped in regulator Solution Tighten coupling nut by hand about one half to three quar ters additional turn Do not use tools Turn Control Knobs to Off position and turn LP Gas Cyl inder handle clockwise until it stops Wait five minutes Relight LP gas grill If flame continues to be low turn off gas at LP Gas Cylinder and grill Disconnect the regulator from the LP Gas Cylinder Reconnect the regulator to the LP Gas Cylinder This will reset the excess flow valve Perform a leak test Relight grill Clean the Burners See How to Clean Burners in Care and Maintenance Dry Electrode with clean cloth Air dry or use blow dryer Reconnect the wire Replace Igniter Wire Electrode assembly Call the Customer Service Department See Step 14C Page 13 Follow lighting proceedure but hold control knob IN for at least 10 seconds Blow water out of ceramic center of burner Close lid when not in use See re assembly after cleaning in Care and Maintenance Take LP Gas Cylinder to licensed LP gas supplier to be refill
46. the risk of serious bodily injury or death from fire or explosion Never remove guards or devices to prevent storage of spare or oversize LP Gas Cylinders not recommended for this grill Step 6 A Cylinder Guard Assembly Attach Wire Guard to Front Crossbar and Back Panel with two 5 32 x 47 Bolts B Cylinder Blocking Wire Assembly Attach Cylinder Blocking Wire to Right Side Panel with one 5 32 x 47 Bolt and nut Attach to Bottom Panel with one 5 32 x 47 Bolt 5 32 x 47 Bolt set 4 pc 5 32 Nut pc Step 6C Step 7 Center Wheel Assembly Model 6804 Door Handle Assembly Remove screws from Cabinet Bottom Panel Assemble Handle to Left Door using two 5 32 x 22 Bolts Locate Center Wheel as shown and fasten in place to Repeat with Right Door Cabinet Bottom Panel with screws that were just removed Note 2 extra screws provided m 5 32 x 22 Bolt set 4 pc D Step 8 Drawer Track Assembly and Cylinder Retaining Bolt Installation for Model 6805 A Attach one Drawer Track to Back Panel and Cabinet Upright using four 5 32 x 31 Bolts Attach other Drawer Track to Back Panel and Right Side Panel using four 5 32 x 31 Bolts B Install the Cylinder Retainer Bolt through the hole in the back of the Bottom Shelf into the nut welded underneath gt a Sf a 5 32 x 31 Bolt set 8 pc Step 9 Cylinder Retainer Bolt L A Drawer Assembly Assemble Handle to
47. threatens either personal safety or endangers property call the Fire Depart ment Do not use the grill without Bottom Panel and Grease Pan in place Check the Foil Pan and Grease Pan for build up Empty excess grease to avoid a grease fire in the pan If you notice grease or other hot material dripping from the grill onto the valve hose or regulator turn off the gas supply immediately After the grill has cooled determine the cause and correct it After cleaning the valve hose and regulator assembly perform a leak test before continuing use See Performing a Leak Test Do not operate a gas grill if you have knowledge of or suspect a gas leak Do not wear loose clothing example hanging shirt tails clothing with frills etc around a gas grill while in use or hot Do not lean your body over the gas grill when lighting it or while it is in use or hot Do not touch hot surfaces Use heat resistant gloves long handled tongs or cooking mitts at all times since the grill will become very hot Open the Hood carefully when cooking to avoid burns from the hot air and steam trapped inside Do not allow children to operate or play near a gas grill Keep children animals and bystanders out of the grill area Do not leave grill unattended Do not move an LP gas grill when in use or hot When grill is not in use turn off all grill Control Knobs LP Gas Cylinder valve and disconnect the LP Gas Cylinder Grill Cooking Direct Method T
48. used if there is evidence of excessive abra sion or wear or if the hose is cut or leaks Use only the gas hose regulator assembly that has been supplied with this gas grill Do not use hose regulator from another manufacturer Replacement gas hose regulator assembly must be specified by this grill s manufactuer before using Always check for gas leaks when you connect and disconnect the hose regulator to the LP Gas Cylinder especially after a period of storage for example over winter Make sure there are no sharp bends in the hose Make sure the hose regulator does not contact any heated surfaces Connecting LP Gas Cylinder 1 Fill empty LP Gas Cylinder at your local gas supplier NOTE If the hose regulator assembly is not working properly and you need a replacement contact Customer Service at 1 800 251 7558 or go to www aussiegrills com Be sure to have the grill model number and serial number printed on the black label located inside the left door of the cabinet If you need a replacement part under warranty a proof of purchase will be necessary You will be asked to forward your proof of purchase via e mail or to fax your proof of purchase to 423 639 1055 and reference your model and serial number It is important to register your grill and retain your receipt 2 Place the LP Gas Cylinder in the large hole in the Bottom Panel inside the cabinet Rotate the LP Gas Cylinder so the Cylinder nozzle is towar
49. wn in Figure 4a Fig 5 Model 6804 Model 6805 7 If growing bubbles appear on any of the connection points you have detected a gas leak Immediately close the LP Gas Cylinder valve by turning handle clockwise a If leak appears at either end of hose and regulator assembly retighten the connection at the leak but do not over tighten NOTE Only hand tighten at coupling nut in Fig 3 shown on previous page Repeat Leak Test b If the leak is coming from the Gas Cylinder from the valves at the Control Knobs or if the leak cannot be stopped do not use the grill Call Customer Service at 1 800 251 7558 Be sure to have the grill model number and serial number printed on the black label located inside the left door of the cabinet If you need a replacement part under warranty a proof of purchase will be necessary 8 Upon completion of leak test turn all Control Knobs to the Off position Turn the handle on the LP Gas Cylinder clockwise until it stops Disconnect LP Gas Cylinder by turning coupling nut on regulator in a counterclockwise direction until regulator is released from threaded LP Gas Cylinder nozzle 9 Place the protective cap over LP Gas Cylinder nozzle 10 Re attach the wire leads to the Igniter button Replace Control Panel around flanges at Bowl ends and align bolt holes on each side Replace and retighten all bolts Fig 1 Lighting the Grill Using the Pulse Spark Ignitor To reduce the risk of death
50. ylinder valve open counterclockwise until it stops Fig 8 4 Locate either the left or right match lighting hole you intend to use underneath the Grill Bowl Push in and turn either the far left or far right Main Burner Control Knob near the match lighting hole counterclockwise to the High position 5 Insert a lit match through the match lighting hole using the match holder Fig 11 and 11a OR through the cooking grates Fig 12 View from underneath Insert lit match through matchlighting hole under the left side burner table using the 27 match light holder Fig 11 View of match through hole from top side of burner Shown without Flavor Activators and cooking grids Fig lla View of inserting lit match through the cooking grids Each burner may be lit in succession in this method if necessary Fig 12 6 From the Off position light all other Burners from left or right making sure each Burner is lit before lighting the next Your grill has a Crossover Ignition System that allows the Burners to light successively off one another Confirm each Burner is lit before lighting another Burner If any or all Burners fail to light after three or four attempts following Steps 3 4 turn all Control Knobs to the Off po sition and close the LP Gas Cylinder valve to dissipate any accumulated gas Wait five minutes then repeat the lighting procedures NOTE If the Burner still fails to light refer t

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