Aussie Bonza Deluxe, Bonza, Kanga User Manual

Aussie

LP Gas Grill

Assembly and Use Manual

Bonza

©Aussie™ Grill Company 2001

For Customer Service, call

1-800-251-7558

www.aussiegrill.com

•READ AND FOLLOW INSTRUCTIONS CAREFULLY BEFORE ASSEMBLY OR USE. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DEATH, SERIOUS BODILY INJURY, AND/OR PROPERTY LOSS.

•FOR OUTDOOR HOUSEHOLD USE ONLY. NOT FOR COMMERCIAL USE.

•SOME PARTS MAY CONTAIN SHARP EDGES - ESPECIALLY WHERE NOTED IN THIS MANUAL! WEAR PROTECTIVE GLOVES IF NECESSARY.

•THESE INSTRUCTIONS MUST BE KEPT WITH THE CONSUMER AND RETAINED FOR FUTURE USE.

•PORCELAIN COATING CAN CHIP DURING ASSEMBLY. WEAR SAFETY GLASSES WHILE ASSEMBLING GRILL.

FOR YOUR SAFETY

If you smell gas:

1. Shut off gas to the appliance.

2. Extinquish any open flame.

3. Open Lid.

4. If odor continues, immediately call your gas supplier or your fire department.

This owners manual is intended for the following models:

Bonza Deluxe

Kanga

7462, 7402, 7362, 7302, 7262, 7202

FOR YOUR SAFETY

1. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

2. An LP cylinder not connected for use shall not be stored in the vicinity of this or any other appliance.

I. IMPORTANT SAFEGUARDS.....................................2

II. Parts lists and Assembly Instructions...........................5

Parts List..........................................................................5

Step 1 - Wheel Leg/Side Table assembly....................9

Step 2 - Fixed Leg/Side Table assembly...................10

Step 3 - Legbrace assembly......................................11

Step 4 - Bottom Shelf/Leg & Caster assembly..........12

Step 5 - Wheel/LP Cylinder Bracket assembly..........13

Step 6 - Grill Body/Cart assembly (Kanga model).....14

Step 7 - Grill Body/Cart assembly (Bonza model).....16

Step 8 - Attach Decorative Privacy Panel to Cart......18

Step 9 - Install Burners...............................................18

Step 10- Install Bottom Body Panel/Grease Tray........20

Step 11- Install Ceramic Briquette Trays & Grids........20

Step 12- Attach Handle to Lid (Kanga lid)...................21

Step 13- Attach Handle & Heat Indicator (Bonza).......22

Step 14- Attach LP Cylinder to Grill.............................23

Step 15- Leak testing (all models)...............................24

III. Operating and Maintaining Your LP Gas Grill...........25

A) Gas, Cylinder, Hose and Regulator Info...............25

1) LP Hose & Regulator Assembly........................25

2) LP Gas Cylinder................................................25

3) Connect/Disconnect LP Gas Cylinder...............25

B) Before Using Your Grill..........................................26

1) Selecting a Location..........................................26

2) Precautions...............................................26

3) Leak Testing..............................................27

C) Operating the LP Gas Grill...........................27

1) Preparation Before Cooking.....................28

2) Lighting Using Integra Spark Ignition.......28

3) Manual Lighting of the Grill......................29

4) Check Your Flame....................................30

4) Grill Cooking.............................................29

5) Roasting....................................................30

6) End of Cooking Session...........................30

7) Turning Off Your LP Gas Grill...................30

D) Care and Maintenance.................................30

1) Porcelain Coated Cooking Surfaces.........31

2) Burner Maintenance..................................31

3) Ceramic Briquettes...................................32

4) Bottom Body Panel...................................32

5) Cleaning the Grill Body.............................32

6) Caring for the Wood Cart..........................32

7) Preventive Maintenance............................32

8) Storage......................................................32

IV. Troubleshooting................................................33

V. Important Notice - LP Cylinder with OPD.........35

VI. Limited Warranty..............................................36

IMPORTANT SAFEGUARDS

FAILURE TO FOLLOW THESE SAFEGUARDS COULD RESULT IN DEATH, SERIOUS BODILY INJURY, AND/OR PROPERTY LOSS. READ AND FOLLOW ALL INSTRUCTIONS CAREFULLY BEFORE ASSEMBLY OR USE OF THE LP GAS GRILL.

1. WARNING! Read and follow all instructions.

2. For Household Outdoor Use Only Do Not Use Indoors or on recreational vehicles or boats. Never use as a space heater. Not for commerical use.

3. WARNING! To reduce the risk of serious or fatal injury from breathing toxic fumes and from explosion and fire as a result of leaking gas, use only outdoors in an open area with good ventilation. 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.

4. Place your Liquefied Petroleum (LP) gas grill on a firm, level surface. Grill should be setup away from high traffic areas and combustible materials.

5. Locate your LP gas grill at least 10 feet away from your house or any building. Do not use the grill in a garage, breezeway, carport, porch, or in any enclosed area. Do not locate this appliance under overhead unprotected combustible surfaces.

6. Have an ABC fire extinguisher accessible. Never attempt to extinguish a grease fire with water or other liquids.

©Aussie Grill Company 2001

7. WARNING! If your grill catches on fire:

• If the fire is in the grill portion and you can safely reach the control knobs, then turn them off by turning knobs clockwise. If you cannot safely reach the control knobs, call the fire department.

• If the fire involves one of the hoses, and you can

safely reach the propane cylinder valve, shut the valve off by turning LP cylinder valve handle clockwise to a full stop.

• If the fire involves the 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.

17. Check the LP gas grill for gas leaks and burner obstructions before each use.

WARNING! Do not use a flame to check for gas

leaks. See Before Using Your LP Gas Grill section of

this manual for correct leak test procedures. A clogged

burner tube can lead to a fire beneath grill.

18. DANGER! If you see, smell, or hear the hiss of

escaping gas from the LP cylinder:

A. Get away from the cylinder. B. Do not attempt to correct the problem yourself. C. Call your local fire department.

8. Check the Bottom Body Panel for grease buildup. Remove excess grease to avoid a grease fire in the pan.

Never use the grill without Bottom Body Panel and Grease Tray in place.

9. WARNING! If you notice grease or other hot material dripping from the grill onto valve, hose, or regulator, turn off gas supply immediately. After the grill has cooled,

determine the cause and correct it. After cleaning the valve, hose and regulator, perform a leak test before continuing use. See Before Using Your LP Gas Grill section of this manual for correct leak test procedures.

10. This installation must conform with local codes or, in the absence of local codes, with either the National Fuel Gas Code, ANSI Z223.1, or CAN/CGA-B149.2, Propane

Installation Code.

11. 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.

12. Keep any electrical supply cord and the fuel supply hose away from any heated surfaces. Electric cords should be placed away from walkways to avoid a tripping hazard.

19. WARNING! Do not operate an LP gas grill if you

have knowledge of or suspect a gas leak.

20. Always inspect the gas hose and regulator assembly before each use. Always turn the LP cylinder to the “Off” position before inspecting parts. If the hose is cut, damaged, or showing signs of excessive abrasion or wear, do not use the LP gas grill. Contact the manufacturer, as the hose must be replaced with an assembly specified by the manufacturer prior to further use of the LP gas grill.

21. WARNING! Before lighting the LP gas grill, open the lid or hood to prevent an explosion from gas build-up. The lid (KangaTM series only) must never cover the

cooking surface while the grill is in use or hot. See Operation of Your LP Gas Grill section

22. If any burner does not light, turn off all gas control knobs. Leave the grill lid or hood open and wait five minutes before attempting to light.

23. If any burner goes out during operation, turn off all gas control knobs. Open the hood (on Bonza™) and wait five minutes before attempting to light.

24. Excercise reasonable care when using this LP gas grill. Never leave grill unattended during use or cleaning.

13. Combustible materials should never be within 36 in. of the back or sides of your LP gas grill.

14. Never apply polyurethane to the wood cart while the grill

is in use or hot. Allow polyurethane to completely dry before using.

15. The Vinyl grill cover must be removed and placed at

least 36 inches from LP gas grill while in use. The grill cover is made of a flammable material. The grill must be cooled before putting the cover back on the grill.

16. WARNING! Always Store Lp Cylinders upright

and where temperatures do not exceed 125 degrees Fahrenheit. Never store a spare or disconnected LP

cylinder under or near this LP gas grill.

25. Never allow children to operate or play near an LP gas grill. Keep animals and bystanders out of the grill area.

26. Always turn off the LP gas cylinder at the cylinder valve when not in use. Allow grill to cool before handling parts or cleaning.

27. WARNING! Do not move an LP gas grill when in

use or hot.

28. WARNING! Never touch hot surfaces. Use heat resistant gloves, long-handled tongs, or cooking mitts at all times. The grill will become very hot. Open the hood carefully when cooking to avoid burns from the hot air and steam trapped inside.

30. Use of this LP gas grill other than for the intended use, or alteration of this LP gas grill in any way may not be safe and will void any warranty.

37. Never store an LP gas cylinder indoors (empty or filled). If storing the gas grill indoors, disconnect LP gas cylinder and store it outdoors out of the reach of children.

31. Never attempt to repair the LP gas grill or cylinder yourself. Contact the manufacturer for information regarding repairs to your grill.

32. LP gas is not natural gas. The conversion or attempted use of natural gas in an LP unit or LP gas in a natural gas unit is dangerous and will void your warranty.

33. Do not use charcoal in an LP gas grill. Do not use aerosols or store flammable liquids or materials near this LP gas grill.

34. WARNING! Do not wear loose clothing (for example: hanging shirt tails, clothing with frills, etc.) around an LP gas grill while in use or hot.

35. Never use an LP 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

Liquefied Petroleum supplier. Do not use an LP cylinder

with a damaged valve.

36. Even though your LP cylinder may appear to be empty, gas may still be present and the cylinder should be transported and stored accordingly.

38. Never leave an LP cylinder inside a vehicle which may become overheated by the sun.

39. Never lean your body over the LP gas grill when lighting it or while it is in use or hot.

40. Do not attempt to disconnect, move or alter any gas fittings while your LP gas grill is in operation.

41. Your LP gas grill should be cleaned on a regular basis. Refer to Care and Maintenance section in this manual.

42. This LP gas grill is not designed to be used with more

than 50% of the cooking area as a solid plate (griddle). Full coverage of plates will cause excessive heat and could damage the grill.

43. Never douse the grill with water when its surfaces are

hot because it may cause grease to splatter or the porcelain cooking grids and hood to break.

44. When not in use, the LP cylinder valve must be

turned to “Off” position.

— NOTICE —

AUSSIE GRILL COMPANY STRIVES TO BE A QUALITY SUPPLIER OF CONSUMER PRODUCTS. IF WE INADVERTENTLY

OMITTED ANY PARTS NEEDED FOR ASSEMBLY, OR YOU NEED TROUBLESHOOTING INFORMATION, PLEASE CONTACT US USING OUR TOLL FREE NUMBER. THANK YOU FOR PURCHASING AN AUSSIE GRILL COMPANY PRODUCT.

1-(800)-251-7558 8 am - 5 pm E.S.T Mon. - Fri. 1-(423)-639-1171 (TELEPHONE) 1-(423)-639-2570 (FAX)

CONSUMER SERVICE DEPARTMENT AUSSIE GRILL COMPANY 1500 INDUSTRIAL ROAD GREENEVILLE, TN. 37745 USA

www.aussiegrill.com

ASSEMBLY INSTRUCTIONS for KANGA, BONZA, and BONZA DELUXE MODELS

PREPARATION FOR ASSEMBLY: Removing parts from carton and some assembly will require two people. Before starting assembly, read the instructions and your manual.

This manual covers several Aussie Grill models. Use only the steps that pertain to your model. Remove all the parts from the carton and lay them on a smooth, clean surface. (You may cut the carton, spread it out, and use it as a pad to protect part finishes.) Look in the Parts List below under your model number to find the exact parts you need. Do not throw away any packaging until you have located all the parts.

Follow instructions of each step in the order they are written as you look at the diagrams. This will allow little confusion and easier assembly. If you have any questions which require help, contact Customer Service at 1-800-251-7558 and be sure to mention the model number of your grill.

BONZA

PART/DESCRIPTION

Square Side

Table

PART#

*See Bottom

Page Note

QTY.

2 2

KANGA

Birch

Kempas

BONZA

Birch

Kempas

DELUXE

Left TearDrop Side

Table

Right TearDrop Side

Table

Deluxe Side Table

Rear Wheel Leg - Wood

Front Wheel Leg - Wood

Rear Wheel Leg - Metal Tubing

Front Wheel Leg - Metal Tubing

*See Bottom

Page Note

*See Bottom

Page Note

03.6087.00

03.6087.01

03.6087.02

*See Bottom

Page Note

*See Bottom

Page Note

03.6088.03

03.6089.03

1 1

2 2 2

Birch

Kempas

Birch

Kempas

Birch

Kempas

Birch

Kempas

Birch

Kempas

Birch

Kempas

Birch

Kempas

Birch

Kempas

Chocolate

Birch

Kempas

Sterling

Bolt 1/4” x 1”

Bolt 1/4” x 1 3/8”

*Note: Call Customer Service for correct part # and color for your Model.

03.4062.00

03.6090.00

All Models

PART/ DESCRIPTION

Part#

QTY.

KANGA

BONZA

DELUXE

Rear Fixed Leg - Wood

Front Fixed Leg - Wood

Rear Fixed Leg - Metal Tubing

Front Fixed Leg - Metal Tubing

Legbrace

Bottom Shelf

Axle

*See Bottom

Page Note

*See Bottom

Page Note

03.6091.03

03.6092.03

*See Bottom

Page Note

*See Bottom

Page Note

03.5989.00

1 1

Birch

Kempas

Birch

Kempas

2 2

1 1

Birch

Kempas

Birch

Kempas

Birch

Kempas

Birch

Kempas

Birch

Kempas

Birch

Kempas

Sterling

Birch

Kempas

Chocolate

All Models

Deluxe Axle

Caster Bracket

Caster

Caster Locknut

Bolt 1/4” x 2”

Wheel Pin Spring

Wheel Pin

03.6093.00

03.5042.00

03.5043.00

03.6279.00

03.5990.00

03.5991.00

03.5992.00

03.5993.00

All Models

Wheel

03.5994.00

All Models

*Note: Call Customer Service for correct part # and color for your Model.

All Models

PART/ DESCRIPTON

PART#

QTY.

KANGA

BONZA

DELUXE

Cylinder Bracket

Grill Body Kanga

Spacer

Bolt, 1/4” x 1/2”

Bottom Body Panel

Bolt, 6mm x 110mm

Wing Nut 6mm

03.6094.00

03.5996.00

03.5997.00

03.5998.00

03.5999.00

*See Bottom

Page Note

03.4074.00

03.4066.00

03.6003.00

All Models

1 1

All Models

1 1

2-Burner 3-Burner 4-Burner

All Models

Grill Body Bonza

Privacy Panel

Burner

Cotter Pin

Screw #8 x 1/2”

Foil Pan

Grease Tray

*See Bottom

Page Note

*See Bottom

Page Note

03.6039.00

03.5012.00

03.6010.00

03.6011.00

03.6012.00

1 1 1

2 3 4

2-Burner 3-Burner 4-Burner

All Models

2-Burner 3-Burner 4-Burner

All Models

2-Burner 3-Burner

All Models

Ceramic Tray

03.6095.02

03.6095.03

03.6095.04

2 2 2

2-Burner 3-Burner 4-Burner

*Note: Call Customer Service for correct part # and color for your Model.

2-Burner 3-Burner 4-Burner

2-Burner 3-Burner

PART/ DESCRIPTION

PART#

QTY.

KANGA

BONZA

DELUXE

Cooking Grid

Screw #10 x 3/8”

Handle, Weather Cover

Bolt, 6mm x 90mm

Hood Handle

Handle Spacer

Locknut 6mm

03.6015.00

03.5023.00

03.6016.00

03.6017.00

03.5024.00

03.6020.00

*See Bottom

Page Note

03.6023.00

03.4070.00

2 2 2

1 1 1

2-Burner 3-Burner 4-Burner

All Models

2-Burner 3-Burner 4-Burner

All Models

2-Burner 3-Burner 4-Burner

All Models

2-Burner 3-Burner

All Models

2-Burner 3-Burner

All Models

Heat Indicator

Lockwasher

10-24 Hex Nut

LP Cylinder

Hose and Regulator

Warming Rack

Control Knob

03.5033.00

03.5034.00

03.5035.00

03.5866.00

03.5854.00

03.5854.02

03.6026.00

03.5031.00

03.6027.00

03.5918.00

(Not provided with all models)

1 1

1 1 1

2, 3,

or 4

All Models

(Not provided with all models)

All Models

2-Burner 3-Burner 4-Burner

All Models

(Not provided with all models)

All Models

2-Burner 3-Burner

All Models

Grill Cover

2-Burner 3-Burner 4-Burner

1 1 1

03.6028.00

03.5048.00

03.6029.00

*Note: Call Customer Service for correct part # and color for your Model.

03.6030.00

03.5053.00

03.6031.00

03.6030.00

03.5053.00

STEP 1- WHEEL LEG/ SIDE TABLE ASSEMBLY

TOOLS:

(ITEM 10) ACTUAL SIZE

(ITEM 1, 2, or 4) SIDE TABLE

(ITEM 6) FRONT WHEEL LEG - WOOD

(ITEM 5) REAR WHEEL LEG - WOOD

•Note: There are three side table designs used depending on the model: Square SideTables (Item 1) which can be used on either side, Left and Right Teardrop Side Tables (Item 2 & 3), or Deluxe Side Tables (Item 4).

•Lay Left Side Table (depending on your model you have either 1, 2, or 4) upside down on flat surface as shown. Locate the two Wheel Legs which are the shorter legs with a large axle hole at one end.

•On models with wooden legs, place Rear Wheel Leg so four large recessed holes face away from Side Table (Fig. A) and two threaded holes in edge of leg point outward. (Fig. B)

• Insert four 1/4” x 1” (1/4” x 1 3/8” for Metal legs) Bolts through the leg into the threaded holes of Side Table. (Fig. A) Do not tighten bolts completely.

• Attach Front Wheel Leg to Left Side Table in the same way. On models with wooden legs make sure the two threaded holes on the edge of each leg face outward. Make sure the three velcro patches face inside on all

models.

1/4” X 1 3/8” BOLT 8pcs

(ITEM 8) FRONT WHEEL LEG - METAL TUBING

(ITEM7) REAR WHEEL LEG - METAL TUBING

AXLE HOLES (WHEEL LEGS)

FRONT WHEEL LEG - THREE VELCRO PATCHES FACE INSIDE

SIDE TABLE (TEARDROP TABLE SHOWN)

(ITEM 9) ACTUAL SIZE 1/4” x 1” BOLT 8 pcs

REAR WHEEL LEG

KANGA, BONZA - WOOD

BONZA DELUXE - METAL

FIG. A

FIG. B

THREADED HOLES IN LEGS (Deluxed Models with Metal legs do not have these threaded holes and

can be oriented either way.)

FOUR LARGE RECESSED HOLES (Wooden Legs Only)

1/4” x 1” BOLT (1/4” X 1 3/8” Deluxe Models)

STEP 2- FIXED LEG/SIDE TABLE ASSEMBLY TOOLS:

(ITEM 1, 3, OR 4) SIDE TABLE

(ITEM 12) FRONT FIXED LEG - WOOD

(ITEM 11) REAR FIXED LEG - WOOD

•In the same way, attach the Front and Rear Fixed Legs to the remaining Side Table using 1/4” x 1” Bolts (1/4” x 1 3/8” for Metal Legs.)

•On models with wooden legs, be sure to position Fixed Legs with the four large recessed holes facing away from Side Table (Fig. C) and the two threaded holes in edge of each leg pointing outward. (Fig. D) Do not tighten bolts completely. (Metal Tubing Legs can be oriented either way.)

FRONT FIXED LEG

KANGA, BONZA - WOOD

BONZA DELUXE - METAL

SIDE TABLE (Tear Drop Table Shown)

REAR FIXED LEG

KANGA, BONZA - WOOD

BONZA DELUXE - METAL

(ITEM 10) 8 pcs

1/4” x 1 3/8” BOLT

(ITEM 14) FRONT FIXED LEG - METAL

(ITEM 13) REAR FIXED LEG - METAL

FRONT FIXED LEG THREE VELCRO PATCHES FACE INSIDE

(ITEM 9) 8 pcs

1/4” x 1” BOLT

FIG. C

FOUR LARGE RECESSED HOLES (Wooden Legs Only)

1/4” x 1” BOLT (1/4” x 1 3/8” Deluxe Models)

FIG. D

THREADED HOLES IN LEGS (Deluxed Models with Metal legs do not have these threaded holes.)

STEP 3- LEGBRACE ASSEMBLY

Tools:

NOTE: Bonza Deluxe Model with metal legs does not use the legbrace.

(ITEM 9 ) ACTUAL SIZE

1/4” x 1” BOLT

8 pcs

(ITEM 15 ) LEGBRACE

2 pcs

•Attach Legbraces onto each Side Table assembly using 1/4” x 1” Bolts. Do not tighten bolts completely.

AXLE HOLES

VELCRO PATCHES FACE INSIDE

1/4” X 1” BOLT

WHEEL LEG SIDE TABLE ASSEMBLY

1/4” X 1” BOLT

FIXED LEG SIDE TABLE ASSEMBLY

+ 25 hidden pages

Aussie Bonza Deluxe, Bonza, Kanga User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual