LP Gas Grill Assembly and Use Manual
6804
6805
For Outdoor Household Use Only. Not for Commercial Use.
Need Help? Need to Register Your Grill? Looking for Aussie Parts & Accessories?
Visit us online at www.AussieGrills.com Or call Aussie Customer Service at 1-800-251-7558
!
WARNING
• Failure to follow these intructions could result in
fire or explosion which could cause death, serious
personal injury, or property damage.
• Read and follow instructions carefully before assembly or use.
• Do not use this product for any other purpose than
which it is intended.
• These instructions must be kept with the user.
SAVE THESE INSTRUCTIONS.
!
WARNING
• 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.
!
DANGE R
If you smell gas:
1. Shut off gas to the appliance.
2. Extinquish any open flame.
3. Open lid.
4. If odor continues, keep away from the appliance and immediately call your gas supplier or
your fire department.
2
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
8 am - 5 pm E.S.T. Monday - Friday
1-423-639-1171
(Telephone)
1-423-639-2570
(Fax)
Consumer Service Department
MECO CORPORATION
1500 Industrial Road
Greenville, TN 37745 USA
www.aussiegrills.com
!
DANGE R
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.
!
WARNING
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.
!
CAUTION
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 & 6805)
Wrench (6805)
3
Contents
Preparation for Assembly.............................................. 3
Packing Lists
Model 6804 ................................................................. 4
Model 6805 ................................................................. 5
Assembly Instructions
Step 1 Caster Assembly ............................................ 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 6A Cylinder Guard Assembly .............................. 9
Step 6B Cylinder Blocking Wire Assembly ................... 9
Step 7 Door Handle Assembly .................................. 9
Step 8 Drawer Track Assembly................................ 10
Step 9A Drawer Assembly......................................... 10
Step 9B Drawer Positioning....................................... 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
Using Gas .................................................................. 17
LP Gas Cylinder .......................................................... 17
LP Hose & Regulator ................................................... 18
Connecting LP Gas Cylinder ................................... 18
Disconnecting LP Gas Cylinder ............................... 18
Before Using Your Grill
Installation Codes ....................................................... 19
Selecting a Location ................................................... 19
How to Perform a Leak Test ........................................ 19
Lighting Grill Using the Pulse-Spark Ignitor ................ 20
Manually Lighting the Grill ......................................... 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 Method)..................................... 27
Roasting (Indirect Method) .......................................... 28
Warming Rack ............................................................ 29
End of Cooking Session .............................................. 29
Care and Maintenance
Cleaning the Grill .......................................................30
How to Clean the Burners .......................................... 31
Storage ....................................................................33
Emergencies ............................................................34
Troubleshooting.......................................................34
Important Notice- LP Cylinder with OPD ...............36
Parts Illustrations
Model 6804 ............................................................... 37
Parts List ...........................................................................38
Model 6805 ...............................................................39
Limited Warranty.......................................................40
Register your grill and retain your receipt.
Preparation for Assembly
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 diagrams. 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.
4
Packing List- Model 6804
Box
1
2
3
4
5
6
7
8
Description
Cabinet Bottom Panel
Bottom Panel
Cabinet Side Panel- Right
Cabinet Side Panel- Left
Warming Rack
Left Side Shelf with Side Burner
Right Side Shelf
Door/Drawer handle, 2 pcs.
Large Door handle
Locking Caster, 2 pcs.
Fixed Casters, 2 pcs.
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
Cabinet Door- Left
Cabinet Door- Right
Drawer Front
Cabinet Back Panel
Front Crossbar
Cabinet Upright
Back Panel Brace
Drawer Tracks, 2 pcs.
Cooking Grid, 3 pcs.
Drawer Body
Hood/Body
2
6
3
3
8
3
3
1
5
3
3
5
3
5
2
Detailed Parts List and Illustrations
may be found on pages 37 & 38.
3
1
3
2
7
4
3
4
3
3
3
4
3
5
Packing List- Model 6805
Box
1
2
3
4
5
6
7
8
Description
Cabinet Bottom Panel
Bottom Panel
Cabinet Side Panel- Right
Cabinet Side Panel- Left
Warming Rack
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 guard
Cylinder Retainer Bolt
Side Burner Control Knob
Grease Pan
Foil Pan
Cylinder Blocking Wire
Cabinet Door- Left
Cabinet Door- Right
Drawer Front
Cabinet Back Panel
Front Crossbar
Cabinet Upright
Back Panel Brace
Drawer Tracks, 2 pcs.
Cooking Grid, 3 pcs.
Drawer Body
Hood/Body
2
6
3
3
3
3
3
8
3
1
3
5
5
2
5
3
3
Detailed Parts List and Illustrations
may be found on pages 38 & 39
5
5
3
1
7
4
3
3
3
3
3
4
2
3
3
3
3
6
Assembly Instructions
Step 1
Caster Assembly
Lay Cabinet Bottom Panel upside down, so that the flat surface is on the floor. Assemble Fixed Casters to 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
Swivel Lock Casters
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
7
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.
1/4-20 x .50” Bolt set
6 pc
Secure Left and Right Side Panels to Back Panel with four 5/32 x .31” Bolts through the inside of the Back Panel.
5/32 x .31” Bolt set
4 pc
8
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.
front crossbar
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 Matchholder/Chain is closest to top of cabinet (Front Crossbar).
5/32 x .31” Bolt set
4 pc
9
!
WARNING
To reduce 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.
B
A
5/32 x .47” Bolt set
4 pc
nut
5/32 Nut
1 pc
Step 6C
Center Wheel Assembly (Model 6804)
Step 7
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.
5/32 x .22” Bolt set
4 pc
10
Step 8 Model 6805 & 6804 with drawer
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.
A
5/32 x .31” Bolt set
8 pc
B
Cylinder Retainer Bolt
Step 9 Model 6805 & 6804 with drawer
A. Drawer Assembly
Assemble Handle to 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
A
drawer
front
5/32 x .31” Bolt set
Model 6804- 6 pcs
Model 6805- 7 pcs
B
B. Drawer Positioning
Slide Drawer Assembly over the Drawer Tracks to position the Drawer.
11
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.
!
CAUTION
To reduce the risk of bodily injury from lifting, the following assembly steps #s 11 and 12 will require two people.
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
view
1/4-20 x .50” Bolt set
4 pc
NOTE:
Model 6805: Carefully route gas and electrical lines
when placing hood/body assembly on cart. Be sure no
lines are pinched between hood/body assembly and cart.
12
!
CAUTION
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 threaded 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.
A
Keyhole Slots
1/4-20 x .50” Bolt set
8 pc
5/32 x .31” Bolt set
2 pc
B
C
5/32 x .31” Bolt
13
Step 13 Model 6804
Side Burner Valve Assembly
NOTE: Side Burner Valve is already attached to the regulator hose.
A. 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, 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.
A
5/32 x .31” Bolt
2 pc
Top First
Valve
B
Bottom Second
Step 14 Model 6805
Side Burner Valve Connection
A. 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, FINGER TIGHT. Finally, turn nut 1/4 turn more with supplied wrench. DO NOT OVER TIGHTEN.
Underside view of
Side Table/Side Burner
Thermocouple wire not
shown for clarity
A
B
C
Brass Thremocouple Nut
DO NOT OVER TIGHTEN
Side Burner Valve
14
!
CAUTION
To avoid possible damage to grill, DO NOT ATTEMPT TO 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 electrode 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.
A
B
15
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 x .31” Bolt
2 pc
A
B
!
CAUTION
To reduce the risk of a laceration hazard:
• Wear protective gloves when installing warming rack. 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.
16
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.
A
flame diffuser
B
cooking grid
Step 20
Battery in Igniter Installation
Unscrew Igniter Cover and insert AA Battery with the negative “-“ end going in first. Replace the cover and tighten
securely.
Battery
AA 1.5v Alkaline
1 pc
+
-
This Completes the Grill Assembly.
17
Connecting/Disconnecting the Gas
Using Gas
!
DANGE R
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.
!
WARNING
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 toxic 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 petroleum (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
!
DANGE R
• If you see, smell, or hear the hiss of LP gas escaping from the cylinder:
1. Do not attempt to light appliance.
2. Extinguish any open flame.
3. Disconnect from fuel supply.
The LP Gas Cylinder, for use with this LP gas grill,
must meet the following requirements:
1. 12” diameter x 18” tall, 20 lb. maximum capacity
2. Overfill Prevention Device (OPD) safety feature
(should be noted on cylinder)
3. Must be constructed and marked in accordance with
Specifications for LP Gas Cylinders of the U.S. Department of Transportation (DOT) or the National
Standard of Canada, CAN\CSA-B339, Cylinders,
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.
5. Must be marked “PROPANE.”
6. Must be provided with a cylinder connection device
that is compatible with the grill’s connection.
!
WARNING
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 Cylinder secured to the cart and oriented as shown in Assembly Instructions for Connecting the LP Gas Cylinder.
• Never connect or disconnect LP Gas Cylinder or fittings
while grill is in use or is hot.
• 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,
gouges, bulges, fire damage, corrosion, leakage, excessive rust, or other forms of visual external damage; it
may be hazardous and should be checked by a liquid
propane supplier. Do not use an LP Gas Cylinder with a
damaged valve.
• 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
volume. (20 lb. maximum) Do not ask the propane
supplier to over-fill the Cylinder.
• If you obtain LP gas through a cylinder exchange dealer,
make sure you get a safe and adequate cylinder. Use only
a licensed LP Gas Cylinder dealer.
18
LP Hose and Regulator
!
WARNING
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 used, if there is evidence of excessive abrasion 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.
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.
Connecting LP Gas Cylinder
1. Fill empty OPD LP Gas Cylinder at your local gas supplier.
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 toward 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.
19
Before Using Your LP Gas Grill
Installation Codes
!
WARNING
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, recreational Vehicle Code, as applicable.
• If 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
!
WARNING
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 vehicles.
• Never use gas grill as a space heater.
Performing A Leak Test
!
WARNING
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 leak 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.
20
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 TIME 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
Fig. 2
Fig. 1
5. With the regulator hose connected to the LP Gas Cylinder, turn the knob on the Cylinder counterclockwise. (Fig. 3)
Coupling Nut
Check for leaks at
Cylinder Valve and
Regulator Connection
and Fittings
Fig. 3
Fig. 3a
!
CAUTION
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.
Fig. 4
Fig. 4a
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 shown in Figure 4a.
Fig. 6
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)
22
Lighting the Grill Using the Pulse-Spark Ignitor
!
WARNING
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 - 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.
!
WARNING
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
Off position
Control Knob in High
position (large flame
symbol)
Fig. 8
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)
23
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
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” position and close the LP Gas Cylinder valve to dissipate any accumulated gas. Wait five minutes; then repeat the lighting
procedures.
Lighting the Side Burner Sear Burner or Rotisserie Burner Model 6805
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 Warming 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.
24
Manually Lighting the Grill
!
WARNING
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 Cylinder 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
match light holder
Fig. 11
View of match through hole
from top side of burner.
Shown without Flavor
Activators and
cooking grids.
Fig. 11a
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” position 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 to 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.
25
Lighting the Side Burner
!
WARNING
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 light, 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
26
Manually Lighting the Side Burner
!
WARNING
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: 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.
Hold lit match
near Burner
Fig. 14
Side Burner Control Knob
Lighting the Side Burner Sear Burner or Rotisserie Burner Model 6805
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 Warming 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.
27
Cooking On the Gas Grill
!
WARNING
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.
- If the fire is in one of the hoses, and you can safely reach the LP Gas Cylinder valve, then shut the valve off.
- If the fire involves the LP Gas Cylinder, leave it alone, evacuate the area, and call the Fire Department.
- If there is any type of fire that threatens either personal safety or endangers property, call the Fire Department.
• 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)
!
WARNING
To reduce the risk of serious bodily injury or death from fire or explosion:
• Do not cover more than half (50%) 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.
28
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 lift 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)
!
WARNING
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 correct temperature and 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.
29
Warming Rack
!
WARNING
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
!
WARNING
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 Pan 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
30
Care and Maintenance
!
CAUTION
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” H) 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 operating 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 the cleaned parts. Re-tighten Bottom Panel bolts.
!
WARNING
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.
31
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.
Valve
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 & 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 burner 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.
Fig. 16
Fig. 17
Lift Burner up and out.
View from inside
front body
Valve nozzle
Fig. 18
Burner Venturi Hole fits centrally
around Valve nozzle.
32
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 nonmetallic brush to remove food particles and corrosion from the Burner surfaces.
Open up
Main Burner
holes with a
small nail or
wire.
Non-metallic
Wire Brush
Fig. 20
Fig. 19
Side Burner tube
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 refitting 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. If 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.
33
Storage
!
WARNING
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 stored 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.
34
Emergencies
Problem
Possible Cause
Solution
Gas leaking from
cracked/cut/burned hose
Damaged hose
Turn off gas at the LP Gas Cylinder. Replace valve/hose
regulator before continuing use.
Gas leaking from
LP Gas Cylinder
Mechanical failure due to rust
or mishandling
Replace LP Gas Cylinder.
Gas leaking from LP Gas
Cylinder valve
Failure of valve from mishandling or mechanical malfunction
Turn off LP Gas Cylinder valve. Return Cylinder to
gas supplier.
Gas leaking between
LP Gas Cylinder and regulator connection
Fire coming through Control
Panel
Improper installation, connection not tight, failure of
seal on LP Gas Cylinder valve
Fire in or around Venturi tube
section of Burner
Grease fire or excessive
flames above cooking surface Too much grease build-up in
Burner section
Flashback (Fire in or around
Venturi tubes)
Clogged or blocked Venturi
tube
Turn off LP Gas Cylinder valve. Re-install correctly or
tighten coupling nut. Replace Cylinder if seal is damaged. 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. See “How to Clean
Burners” section.
Troubleshooting
Problem
Possible Cause
Solution
Burners will not light using
the ignitor
Burners not assembled correctly
See re-assembly after cleaning in
“Care and Maintenance.”
Not holding ignitor switch long
enough for pulse spark
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.
No spark, electrode cracked,
broken or loose.
1. Make sure all the wires are connected and to the right
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.
35
Troubleshooting
Problem
Possible Cause
Solution
Regulator coupling nut is not
fully connected to LP cylinder
Tighten coupling nut by hand about one-half to three quarters additional turn. Do not use tools.
LP-Excess flow valve tripped in
regulator
Turn Control Knobs to “Off” position and turn LP Gas Cylinder 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.
Vapor lock in connections
Obstructions in Burners
Clean the Burners. See “How to Clean Burners” in Care
and Maintenance.
Wet Electrodes and Burners
Dry Electrode with clean cloth. Air dry or use blow dryer.
Wire loose or disconnected
Reconnect the wire.
Wire shorting (sparking
between Igniter and Electrode)
Replace Igniter Wire/Electrode assembly.
(Call the Customer Service Department)
Thermocouple is not properly
attached to side burner valve.
Safety sensor is not completely
heated
See Step 14C Page 13
IR side burner will not
light using ignitor or
match
IR side Burner has filled with
water
Blow water out of ceramic center of burner.
Close lid when not in use.
Burners will not light
using a match
Burners not assembled correctly
See re-assembly after cleaning in Care and Maintenance.
LP Gas Cylinder is empty
Take LP Gas Cylinder to licensed LP gas supplier to be refilled.
IR side burner will not
stay lit
LP-Excess flow valve tripped in
regulator
Follow lighting proceedure but hold control knob IN for at least
10 seconds.
Turn Control Knobs to “Off” position and turn LP Gas Cylinder 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.
Regulator Coupling nut is
not fully connected to LP Gas
Cylinder
Tighten Regulator Coupling nut by hand about one-half to
three quarters additional turn. Do not use tools.
Obstructions in Burners
See “How to Clean Burners” in Care and Maintenance.
Low flame or low heat LP-gas in LP Gas Cylinder is low
Excess flow valve tripped in
regulator
Check LP Gas Cylinder. Refill if necessary.
Turn Control Knobs to “Off” position and turn LP Gas Cylinder 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.
36
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
nozzles with worn threads
The worn nozzles do not have enough “bite” to engage the
valve. Try another licensed LP dealer.
Humming or whistling from
regulator
Outside temperature, humidity, barometric pressure, and
the gas level within the tank
may cause the rubber diaphragm inside the regulator
to vibrate, making a humming
or whistling sound.
Although this sound may be alarming, this is NOT dangerous as long as it is not accompanied by the smell of gas.
Simply adjust the Burner settings, and usually the sound
will subside. If the humming sound persists, a change in
atmospheric conditions will eventually stop the vibration.
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.
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.
Flames blow out
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).
This is a secondary 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.
!
Rises up while filling,
then stops when full.
WARNING
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.
37
Parts Illustration- Model 6804
If you need replacement parts, refer to the Parts Illustrations 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 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.
22
23
24
25
26
27
1
28
2
29
3
4
5
30
6
7
8
9
10
11
12
13
14
15
31
32
33
34
35
6
36
37
38
39
40
16
41
17
18
19
20
21
42
43
44
45
46
47
38
Parts List- Model 6804
Key
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
Description
Quantity
Side Burner Cover
1
Side Burner Cooking Grid 1
Left Side Table
1
Side Burner Valve
1
Side Burner Knob Bezel
1
Control Knob
5
Side Burner
1
Ignition Box
1
Main Knob Bezel
4
Front Crossbar
1
Cylinder Wire guard
1
Cabinet Side Panel- LEFT
1
Cabinet Upright
1
Cylinder Retainer Bolt
1
Cabinet Bottom Panel
1
Cabinet Door- LEFT
1
Drawer Front
1
Drawer Box
1
Cabinet Door- RIGHT
1
Handle-Large Door
1
Handle-Small Door/Drawer 2
Hood Handle
1
Thermometer
1
Hood Bumper
2
Hood
1
Warming Rack
1
Main Cooking Grid
3
Flame Diffuser
4
Main Burner
4
Right Side Table
1
Tool Hooks
3
Electrode Assembly
2
Manifold Assembly
1
Control Panel
1
Bottom Panel
1
Cabinet Back Panel
1
Foil Pan
1
Grease Pan
1
Cabinet Side Panel- RIGHT 1
Cylinder Blocking Wire
1
Match Holder/Chain
1
Caster, Fixed
2
Caster, Locking Swivel
2
Manifold to SB valve Hose 1
Regulator
1
Center Wheel
1
Drawer Tracks
2
1/4-20 x .50” S/S Bolt
27
1/4-20 S/S Hex Nut
9
1/4-20 x .60” S/S Bolt
16
5/32 x .47” S/S Bolt
4
5/32 x .31” S/S Bolt
28
5/32 x .22” S/S Bolt
9
5/32 S/S Hex Nut
1
Side Burner Electrode
1 (no pic)
Parts List- Model 6805
Key
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
Description
Quantity
Side Burner Cover
1
Main Burner
4
Side Burner Cooking Grid 1
Left Side Table
1
Side Burner Valve
1
Side Burner Knob Bezel
1
Control Knob
7
Infrared Side Burner
1
Manifold Assembly
1
Ignition Box
1
Control Panel
1
Main Knob Bezel
6
Front Crossbar
1
Cylinder Wire guard
1
Cabinet Side Panel- LEFT 1
Cabinet Upright
1
Cylinder Retainer Bolt
1
Cabinet Bottom Panel
1
Cabinet Door- LEFT
1
Cabinet Door- RIGHT
1
Handle, Door/Drawer
3
Hood Handle
1
Thermometer
1
Hood Bumper
2
Hood
1
Warming Rack
1
Main Cooking Grid
3
Flame Diffuser
4
Rotisserie Burner
1
Sear Burner
1
Right Side Table
1
Main Electrode Assembly 2
Tool Hooks
3
Bottom Panel
1
Foil Pan
1
Grease Pan
1
Cabinet Back Panel
1
Drawer Tracks
2
Cylinder Blocking Wire
1
Cabinet Side Panel- RIGHT 1
Match Holder/Chain
1
Drawer Body
1
Drawer Front
1
Caster, Fixed
2
Caster, Locking Swivel
2
Regulator
1
Center Wheel
1
1/4-20 x .50” S/S Bolt
28
1/4-20 S/S Hex Nut
10
1/4-20 x .60” S/S Bolt
16
5/32 x .47” S/S Bolt
4
5/32 x .31” S/S Bolt
29
5/32 x .22” S/S Bolt
9
5/32 S/S Hex Nut
1
Thermocouple -Side Burner 1 (no pic)
Thermocouple -Sear Burner 1 (no pic)
Thermocouple - Rotisserie 1 (no pic)
Side Burner Electrode
1 (no pic)
Sear Burner Electrode
1 (no pic)
Rotisserie Electrode
1 (no pic)
39
Parts Illustrations- Model 6805
If you need replacement parts, refer to the Parts Illustrations 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
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.
Caution: If it is necessary to replace thermocouple/safety
sensors (Key 55, 56 or 57),use only Meco supplied parts.
22
23
24
25
26
27
1
28
2
29
3
4
5
6
7
8
9
10
11
12
7
30
31
32
33
34
35
36
13
37
14
15
38
16
17
39
40
18
19
20
21
41
42
43
44
45
46
47
40
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 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 COMMERCIAL
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