Page 1
Aussie
Bushman™ LP Gas Grill
Assembly and Use Manual for:
Bushman™, Deluxe, & Elite Models
FOR YOUR SAFETY
If you smell gas:
1. Shut off gas to the appliance.
2. Extinguish any open flame.
3. Open Lid.
4. If odor continues, immediately call your gas
supplier or your fire department.
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.
•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 Customer Service, call
1-800-251-7558
www.aussiegrill.com
This owners manual is intended for the following models:
Bushman™, Bushman™ Deluxe, & Bushman™ Elite
TM
©Aussie™ Grill Company 2001
Bushman™
Bushman™ DDeluxe
Bushman™ EElite
Page 2
2
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
commercial 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.
I. IMPORTANT SAFEGUARDS...........................................2
II. Parts Diagram, lists, and Assembly Instructions................5
Parts List................................................................................6
Step 1 - Cylinder Support/ Retain Clip Assembly............10
Step 2 - Legs to Bottom Shelf Assembly.........................11
Step 3 - Wheel Assembly.................................................12
Step 4 - Attach Rear Support Bar....................................13
Step 5 - Attach Drip Cup Holder......................................13
Step 6 - Attach Burner.....................................................14
Step 7 - Attach Heat Shield.............................................15
Step 8 - Mount Igniter/ Flavor Activator Stud...................16
Step 9 - Mount Grill Bowl on Legs...................................17
Step 10- Leak Test/ Attach Control Panel.........................18
Step 11- Attach Igniter Wire..............................................19
Step 12- Attach Hood/ Bowl Hinges.................................20
Step 13- Mounting Hood...................................................21
Step 14- Attach Hood Handle...........................................22
Step 15- Insert Drip Cup...................................................22
Step 16- Attach Side Tables.............................................23
Step 17- Right Side Burner Assembly..............................24
Step 18- Attach Flavor Activator™...................................25
Step 19-Attach Privacy Panel...........................................25
Step 20-Insert Warming Rack...........................................26
Step 21- Insert Cooking Grid............................................26
Step 22- Attach LP Cylinder.............................................27
III. Operating and Maintaining Your LP Gas Grill................28
A) Gas, Cylinder, Hose and Regulator Info....................28
1) LP Hose & Regulator Assembly............................28
2) LP Gas Cylinder....................................................28
3) Connect/Disconnect LP Gas Cylinder...................28
B) Before Using Your Grill.............................................29
1) Selecting a Location..............................................29
2) Precautions............................................................29
3) Leak Testing...........................................................30
C) Operating the LP Gas Grill........................................30
1) Preparation Before Cooking..................................31
2) Lighting with Igniter................................................31
3) Lighting the Side Burner........................................32
3) Manual Lighting of the Grill....................................33
4) Check Your Flame.................................................34
5) Grill Cooking..........................................................34
6) Roasting................................................................34
7) End of Cooking Session........................................34
8) Turning Off Your LP Gas Grill................................34
D) Care and Maintenance..............................................35
1) Porcelain Coated Cooking Surfaces......................35
2) Burner Maintenance...............................................35
3) Flavor Activator......................................................36
4) Drip Cup.................................................................36
5) Cleaning the Grill Body..........................................36
6) Preventive Maintenance.........................................36
7) Storage...................................................................36
IV. Troubleshooting.............................................................37
V. Important Notice - LP Cylinder with OPD.....................39
VI. Limited Warranty...........................................................40
©Aussie Grill Company 2001
Page 3
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.
8. Check the Grease Cup for grease buildup. Remove
excess grease to avoid a grease fire in the pan. Never
use the grill without Grease Cup 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 (page 29) 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.
13. Combustible materials should never be within
36 in. of the back or sides of your LP gas grill.
14. 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.
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.
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 hood to prevent an explosion from gas build-up.
See Operation of Your LP Gas Grill section
22. If burner does not light, turn off all gas control knobs.
Leave the grill hood open and wait five minutes
before attempting to light.
23. If burner goes out during operation, turn off all gas
control knobs. Open the hood and wait five minutes
before attempting to light.
24. Exercise reasonable care when using this LP gas grill.
Never leave grill unattended during use or cleaning.
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.
29. Use only the hose and regulator assembly
that is supplied with your LP gas grill and/or
specified by the manufacturer.
3
Page 4
— 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
30. Use of this LP gas grill other than for the intended use,
or alteration of LP gas grill in any way may not be safe
and will void any warranty.
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.
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.
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 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.
4
Page 5
Parts Diagram - Some small parts may not be depicted
3/4
5
6
7
10/ 11
14
15
17
18
20
21
22
24
25
8, 9, 30, 31, 33, 34, 35
32
36
38
39
39
40
40
40
42 43 44 45 46 47 48 49 50
41
51
54
55/ 56
5
28
Page 6
ASSEMBLY INSTRUCTIONS for BUSHMAN, DELUXE, & ELITE 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 Bushman 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 and be sure to mention the
model number of your grill.
1
2
3
4
5
6
7
8
9
10
PART#
End Caps - Oval
End Caps - Round
Legs, Fixed Oval
Legs, Fixed - Tubular
Clip, Cylinder Retainer
Bottom Shelf
Cylinder Support
Bolt, M6 x 15
Nut, M6
Legs, Wheel - Oval
03.6201.00
03.6202.00
03.6203.00
03.6204.00
03.6205.00
03.6206.00
03.6207.00
03.6208.00
03.6209.00
03.6210.00
BUSHMAN
2
1
1
1
1
11
39
BUSHMAN
DELUXE
2
1
1
1
1
11
39
1
BUSHMAN
ELITE
2
1
1
1
1
11
39
1
PART/ DESCRIPTION
6
Page 7
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Part#
Legs, Wheel - Tubular
Bolt, M6 x 50
Bolt, M6 x 45
Wheel
Axle
Nut, M8
Wheel Cover
Rear Support Brace
Bolt, M6 x 35
Drip Cup Holder
Bowl
Burner
Screw ST4.8 x 10
Heat Shield
Igniter
03.6211.00
03.6212.00
03.6213.00
03.6214.00
03.6215.00
03.6216.00
03.6217.00
03.6218.00
03.6219.00
03.6220.00
03.6221.00
03.6222.00
03.6223.00
03.6224.00
03.6225.00
BUSHMAN
DELUXE
12
12
2
1
2
2
1
4
1
1
1
4
1
1
BUSHMAN
ELITE
12
12
2
1
2
2
1
4
1
1
1
4
1
1
BUSHMAN
1
24
2
1
2
2
1
4
1
1
1
4
1
1
7
PART/ DESCRIPTION
Page 8
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
PART#
Bowl Bolt spacer
Washer, 6M
Control Panel
Hose & Regulator
Bowl Hinge
Hinge Pad
Hood
Hood Hinge
Hinge Pin
Cotter Pin
Hood Handle
Bolt, M5 x 10
Drip Cup
Side Table, Bushman
Side Table, Deluxe/ Elite
03.6226.00
03.6227.00
03.6228.00
03.6228.01
03.5854.01
03.6230.00
03.6231.00
03.6232.00
03.6233.00
03.6234.00
03.6235.00
03.6236.00
03.6237.00
03.6238.00
03.6239.00
03.6240.00
BUSHMAN
4
6
1
1
2
8
1
2
2
2
1
2
1
2
BUSHMAN
DELUXE
4
6
1
1
2
8
1
2
2
2
1
2
1
2
BUSHMAN
ELITE
4
6
1
1
2
8
1
2
2
2
1
2
1
1
03.6257.00
8
PART/ DESCRIPTION
41
Privacy Panel
1
1
Page 9
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
PART#
Side Table, Burner
Spacer, Side Table
Side Burner Pan
Side Burner
Side Burner Igniter
Side Burner Igniter Clip
Side Burner Cover
Side Burner Hinge Pin
Side Burner Hinge Pin
Clip
Flavor Activator™
Flavor Activator™
Mounting Stud
Grid, Side Burner
Warming Rack
Cooking Grid, Chrome
Cooking Grid, Porcelain
03.6241.00
03.6242.00
03.6243.00
03.6244.00
03.6245.00
03.6246.00
03.6247.00
03.6248.00
03.6249.00
03.6250.00
03.6251.00
03.6252.00
03.6253.00
03.6254.00
03.6255.00
BUSHMAN
8
1
2
1
1
BUSHMAN
DELUXE
8
1
2
1
1
2
BUSHMAN
ELITE
1
8
1
1
1
1
1
1
2
1
2
1
1
2
9
PART/ DESCRIPTION
57
Grill Cover
03.6256.00
1
Page 10
STEP 1- Cylinder Support/ Retainer Clip Assembly
TOOLS:
10
•Using three 6M x 15 bolts and three 6M nuts, attach the Cylinder Support to the Bottom Shelf as
shown.
•Attach Cylinder Retainer Clip to Bottom Shelf: push ends of clip in and allow to spring outward
through holes in top surface of bottom shelf.
•The Cylinder Support will be on the left of the Bottom Shelf as you face the front of your grill.
(ITEM 6) BOTTOM SHELF
(ITEM 5)
CLIP, CYLINDER
RETAINER
(ITEM 7)
CYLINDER SUPPORT
IMPORTANT: BEFORE ASSEMBLY OF YOUR LP GAS GRILL YOU MUST HAVE AN LP GAS
CYLINDER EQUIPPED WITH AN OPD (OVERFILL PREVENTION DEVICE) AND HAVE IT FILLED
AT AN AUTHORIZED LP GAS DEALER. THE CYLINDER WILL BE USED TO PERFORM LEAK
TESTING DURING ASSEMBLY.
(ITEM 8)
6M X 15 BOLT
3 pcs
(ITEM 9 )
6M NUT
3 pcs
Page 11
STEP 2- Attach Legs to Bottom Shelf
TOOLS:
11
•Attach Legs to Bottom Shelf as shown using M6 x 50mm Bolts (M6 x 45mm for Bushman.) Note that
the Wheel Legs (that have axle holes at the bottom) attach on the same side of the Bottom Shelf as
the Cylinder Support. Position legs so that the velcro patches and/ or the four Bolt holes on the back
leg face to the rear.
(ITEM 10, 11)
WHEEL LEGS
(ITEM 12)
BOLT, M6 X 50
8 pcs
(ITEM 13)
BOLT, M6 X 45
8 pcs
(ITEM 9)
NUT, M6
8 pcs
Velcro patches on
this side.
(ITEM 3 OR 4)
LEGS, FIXED
Velcro
Patches on
back side
of Front
Leg Deluxe
and Elite
Models
only.
Velcro
Patches on
back side
of Front
Leg Deluxe
and Elite
Models
only.
Wheel Leg
Four
Bolt
Holes
here
on
back
leg
Four
Bolt
Holes
here on
back
leg
Wheel
Leg
Axle
holes
Page 12
STEP 3 - Attach Wheels to Cart
Tools:
12
•Screw 8M Nut onto the Axle. Place Wheel on Axle. Note: position Wheel with recessed center
toward Nut.
•Insert Axle through holes in Wheel Legs. Secure other Wheel, using 8M Nut with two pliers.
•Install Wheel Covers : Align Wheel Cover pins into holes on Wheel and snap in place.
(ITEM 14)
WHEEL
2 pcs
(ITEM 15)
AXLE
(ITEM 16)
NUT, M8
2 pcs
(ITEM 17)
WHEEL COVER
2 pcs
2 pliers
Page 13
STEP 4 - Attach Rear Support Bar
13
TOOLS:
•Attach Rear Support Bar on backside of grill legs as shown using four M6 x 35mm Bolts and four 6M
Nuts. Tighten All Bolts.
(ITEM 18)
REAR SUPPORT BRACE
(ITEM 19)
BOLT, M6 X 35
4 pcs
(ITEM 9)
NUT, M6
4 pcs
STEP 5 - Attach Drip Cup Holder
(ITEM 20)
DRIP CUP HOLDER
(ITEM 21)
BOWL
•Attach Drip Cup Holder : From inside grill Bowl, feed end of Cup Holder through center hole (as
shown below) so that it hangs from bottom of Bowl by the eyelet at top.
2 each 6M x 35mm Bolts
Each Side
Page 14
STEP 6 - Attach Burner
14
TOOLS:
•Attach Burner : Insert Burner manifold tubes down through holes in bottom of grill Bowl toward front
of grill. (Photo 1)
•From underside of Bowl, insert screws into holes of Burner and tighten (Photo 2)
(ITEM 22)
BURNER
(ITEM 23)
SCREW ST4.8 X 10
2 pcs
Photo 1
Photo 2
Page 15
STEP 7 - Attach Heat Shield
15
•Thread Drip Cup Holder through center hole of Heat Shield and secure Heat Shield to bottom of grill
bowl as shown, using 2 screws.
(ITEM 24)
HEAT SHIELD
(ITEM 23)
SCREW, ST4.8 X
10
2 pcs
Caution : Some parts may have sharp edges or corners.
Extend Heat Shield toward
left side (tank side) of Bowl
TOOLS:
Page 16
STEP 8 - Mount Igniter/ Flavor Activator Mounting Stud to Grill Bowl
16
TOOLS
•Mount Igniter to Grill Bowl : With Tightening Nut removed, Insert Igniter threaded section down
through Igniter hole ( located in center and next to and in front of Burner) of grill Bowl from inside
until Igniter is resting on bottom of Bowl. NOTE: Do not remove or loosen the adjusting nuts on
Igniter as the correct height has been preset by the factory. (See Photo 1 below)
•Position open side of Igniter Box to face Burner and secure Igniter with Tightening Nut from
underside of grill Bowl. While keeping the Ignitor Box aligned with the edge of the Burner, tighten.
(See Photo 2 below)
•Insert 6M washer onto the threaded end of each Flavor Activator Mounting Studs. Insert Flavor
Activator Mounting Stud into center hole on each side of bowl and secure with 6M nut. (See Photo 3)
(ITEM 25)
IGNITER
(ITEM 52)
FLAVOR ACTIVATOR
MOUNTING STUD
2 pcs
(ITEM 27)
6mm WASHER
2 pcs
(ITEM 9)
NUT, 6M
2 pcs
Flavor
Activator™
Mounting
Stud
Tightening Nut - Comes on
threaded post of Igniter and
should be removed before
mounting on Grill.
Photo 1
Photo 2
Photo 3
3/16”
GAP
Collector Box
Electrode
Fig 1
Page 17
STEP 9 - Mount Grill bowl to Legs
17
•Carefully position grill Bowl over holes in tops of Legs with the Burner manifold tubes facing forward
opposite the Rear Support Bar at the back of cart. (The Cylinder Support Bracket should be on the
left side.)
•Insert a M6 x 45mm Bolt through a 6mm Washer. Carefully align a Bowl Bolt Spacer between Bowl
and Leg underneath one of the four holes in each corner of the bowl. Insert a M6 x 45mm Bolt
through Bowl, Bowl Bolt Spacer and Leg and secure with a 6M Nut. (See Photos 2 & 3) Repeat with
remaining Bolts.
(ITEM 13)
BOLT, M6 X 45
4 pcs
(ITEM 27)
WASHER 6MM
4 pcs
(ITEM 26)
BOWL BOLT SPACER
4 pcs
(ITEM 9)
NUT, 6M
4 pcs
TOOLS:
6M x 45 Bolt
Bowl Bolt
Spacer
6M Nut
*Caution* - DO NOT Overtighten
mounting screws. You could crack
the porcelain Bowl.
Photo 1
Photo 2
Photo 3
Page 18
Step 10 - Leak Test and Attach Control Panel
Supplies Needed for a Leak T
est
Clean paint brush, water, and dishwashing liquid.
How to perform a leak test
WARNING! Never use an open flame to test for gas leaks.
1)Use an LP 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 of the 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)Remove the protective cap from the LP cylinder gas nozzle.
4)Hold regulator in a straight line with LP cylinder gas nozzle so the connection does not cross thread.
5)Insert nipple of regulator into the LP cylinder nozzle opening.
6)Hand tighten coupling nut in a clockwise direction. Do not use tools.
7)Mix one cup of water with one cup of dishwashing liquid.
8) Open the valve on LP gas cylinder (Turn the knob on the LP gas cylinder counter-clockwise.)
9)Check for leaks by brushing the soap solution on all LP gas connections and fittings (such as those shown by the
heavy arrows in the diagram below.) Make sure you generously brush the locations with the soap solution,
completely surrounding the connections and fittings.
10)If “growing” bubbles appear on any of the connection points, then you have detected a gas leak. Immediately close
the LP cylinder valve by turning the handle clockwise.
A) If leak appears at either end of hose and regulator assembly, retighten the connection at the leak, but do not
overtighten. (Note: Only hand tighten at coupling nut) Repeat Leak Test.
B) If the leak is coming from the LP 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.
11)Turn all control knobs to the “off” position and turn the handle on the LP gas cylinder clockwise until it stops.
Disconnect LP gas cylinder by turning coupling nut on regulator in a counter-clockwise direction until regulator is
released from threaded LP cylinder gas nozzle.
12)Place the protective cap over LP cylinder gas nozzle.
•Before attaching control panel a leak test must be performed on the Control Valves, Burner manifold,
and Regulator/ Hose connections.
18
Note: Elite Control
Panel Shown with
Side Burner Valve.
Other models will
not have this addi-
tional valve.
LP Gas Cylinder
Control Valve
Regulator
Coupling Nut
Page 19
Continued: STEP 10 - Attach Control Panel
STEP 11 - Attach Igniter Wire
19
•Attach Control Panel : Insert gas outlet tubes on back of Control Panel into Burner manifold tubes.
(See Photo 1 below) Secure Control Panel to Cart by inserting bolts through holes on outside tops
of front legs. When Control Panel and Burner are correctly aligned, tighten all bolts.
•Attach Igniter Wire : Push electrode connector
at end of Igniter wire onto center tab on rear
of Igniter Button.
•NOTE: Be sure to route electrode wire away
from hot areas of the grill.
BUSHMAN™ ELITE
(ITEM 13)
BOLT, M6 X 45
4 pcs
(ITEM 9)
NUT 6M
4 pcs
TOOLS:
(ITEM 28)
CONTROL PANEL
BUSHMAN™ & BUSHMAN™
DELUXE
OR
Photo 1
Page 20
20
STEP - 12 Mounting Hood/ Bowl Hinges
•Insert M6 x 15mm Bolt through Hood Hinge and Hinge Pad and into hole in back side of Grill Hood
as shown. Secure with 6M Nut. (See Photos 1 & 2 below) Repeat for remaining holes to secure two
Hood Hinges.
•Insert M6 x 15mm Bolt through Bowl Hinge and Hinge Pad and into hole in back side of Grill Bowl
as shown. Secure with 6M Nut. (See Photos 3 & 4 below) Repeat for remaining holes to secure two
Bowl Hinges.
NOTE: DO NOT Overtighten mounting screws. You could crack the porcelain grill coating.
(ITEM 32)
HOOD
(ITEM 30)
BOWL HINGE
2 pcs
(ITEM 31)
HINGE PAD
8 pcs
(ITEM 8)
BOLT, M6 X 15
8 pcs
(ITEM 9)
NUT 6M
8 pcs
(ITEM 33)
HOOD HINGE
2 pcs
TOOLS:
Bowl
Hood
Hinge Pads go
between hinge and
Bowl or Hood
Hood Hinge
Bowl Hinge
Photo 1
Photo 2
Photo 3
Photo 4
Page 21
21
STEP 13 - Mounting Hood
•Align Hood Hinge tabs with Bottom Hinge tabs and insert Hinge Pins from outside. Secure each
Hinge Pin with Cotter Pin as shown.
•Close Hood and check assembly to make sure that the hood and bowl fit properly together. Adjust
hood by loosening the Hinge Bolts and retightening.
TOOLS:
(ITEM 34)
HINGE PIN
2 pcs
(ITEM 35)
COTTER PIN
2 pcs
Page 22
STEP 14 - Attach Hood Handle
22
TOOLS:
•Insert M5 x 10mm bolt through front of Hood into Hood Handle. Repeat for other side of handle.
NOTE: DO NOT Overtighten mounting screws. You could crack the porcelain grill
coating.
STEP 15-Insert Drip Cup
•Insert Drip Cup into hanger clip underneath grill bowl.
(ITEM 36)
HOOD HANDLE
1 pc
(ITEM 37)
BOLT, M5 X 10
2 pcs
TOOLS:
(ITEM 38)
Drip Cup
Page 23
STEP 16 - Attach Side Tables
23
NOTE BEFORE ATTACHING SIDE TABLES:
If you have an Bushman Elite grill with a Side
Burner, you will attach the left Side Table as
shown in this Step then skip to Step 17 for
installation of the Side Burner on the right
side.
•Slide eight Side Table Spacers onto eight M6 x
45mm Bolts.
•Insert M6 x 45mm Bolt and Side Table Spacer
through bottom hole of Side Table Bracket and
through Leg. Secure with M6 Nut and Tighten.
Repeat for other side bottom hole Side Table
Bracket. (See Photo 1)
•Insert 6M Bolt and Side Table Spacer through
top holes of leg. Secure with 6M Nut and
Tighten. Repeat for other side
•Repeat assembly for other Side Table.
(ITEM 39)
SIDE TABLE,
BUSHMAN
(ITEM 40)
SIDE TABLE
BUSHMAN DELUXE or
LEFT SIDE ELITE
(ITEM 42)
SIDE TABLE BURNER
BUSHMAN ELITE
(RIGHT SIDE ONLY AND DOES
NOT FOLD)
(ITEM 9)
NUT, M6
8 pcs
(ITEM 43)
SPACER, SIDE TABLE
8 pcs
(ITEM 13)
BOLT, M6 X 45
8 pcs
TOOLS:
Photo 1
Photo 2
Top Side Table Bolt
and Spacer
Bottom Side Table
Bolt and Spacer
Side Table shown
locked into position
Page 24
STEP 17 - Elite Right Side Burner
(BUSHMAN ELITE MODELS ONLY)
24
•With Left Side Table installed in Step 16, begin installation of the Right Side Burner Table. If you do
not have a Side Burner Table skip to Step 18.
•Insert Side Table Burner Tube onto Side Burner Nozzle as shown below. Using four 6M x 45mm
Bolts, 6M nuts, and Side Table Spacers attach Burner Side Table to Cart. (See Photos 1 & 2 below)
•Connect Igniter Wire to side tab on Igniter Button as shown below. ( See Photo 3)
•Lay Side Table Grid into place using provided holes in top of Side Table. Insert Side Burner Cover
hinges into slots at the back of the Side Burner Table so that the cover swings up and down freely.
(See Photo 4)
(ITEMS 42, 43,
44, 45, 46, & 47)
SIDE BURNER
ASSEMBLY
(ITEM 53 )
SIDE TABLE GRID
TOOLS:
(ITEM 48)
SIDE BURNER
COVER
Connect Igniter Wire to side tab on Igniter
Side Burner Tube
Side Burner
Nozzle
Note: Burner Side Table does
not fold down for storage
Photo 1
Photo 2
Photo 3
Photo 4
Page 25
Step 18 - Attach Flavor Activator™
•Using the holes on each side of the Flavor Activator™, place onto the two Flavor Activator™ mounting studs so that it lays above the burner.
(ITEM 51)
FLAVOR ACTIVATOR™
25
STEP 19 - A
TTACH PRIVACY P
ANEL
•Attach Privacy Panel to the velcro
patches on back side of front legs as
shown. Note: Privacy Panel may be
removed to install LP Cylinder then
reattached.
(ITEM 41)
PRIVACY PANEL
Note: Only the Deluxe and Elite Models use the
Privacy Panel. If your grill does not have the Privacy
Panel please skip to Step 20.
Flavor
Activator™
Mounting
Stud
Flavor
Activator™
Page 26
Step 20 - Insert Warming Rack
•Position Warming Rack as shown. Insert legs 1
and 2 in holes on right side of grill Bowl and Hood
respectively. While holding leg 3, insert leg 4 into
hole on hood. Carefully position leg 3 into hole in
grill Bowl and allow it to spring outward into
position.
Step 21 - Insert Cooking Grid
•Lay Cooking Grill into position above
Flavor Activator™.
(ITEM 54)
WARMING RACK
(ITEM 55, 56)
CHROME OR
PORCELAIN
26
Note: Warming rack is only included on the Deluxe and Elite
Models. If you grill does not have the warming rack, please
skip to Step 21.
1
2
3
4
Page 27
Step 22 - Attach LP Cylinder
•Swing the Cylinder Retainer Clip to outside of the Bottom Shelf. Place the LP Cylinder in circular
recessed area on Bottom Shelf. Position Cylinder Retainer Clip over round shoulder of the LP
Cylinder until it meets the cylinder carrying handle.
•Take the protective cap off the cylinder valve. Hold Regulator in a straight line with LP Cylinder
valve so the connection does not cross thread. Insert nipple of regulator into the LP cylinder nozzle
opening. Hand tighten coupling nut in clockwise direction. Do not use tools.
•Turn all control knobs and LP Cylinder valve to the “Off” position.
You are now ready to use your grill!
27
Hand tighten
coupling nut
in clockwise
direction
Cylinder
Retainer Clip
Caution: When swinging Cylinder
Retainer Clip into position, keep
fingers and hands on corners of
Clip to prevent Pinching.
Page 28
OPERATING AND MAINTAINING YOUR GAS GRILL
GAS, CYLINDER, HOSE AND
REGULATOR INFORMATION
This LP gas grill was designed to use propane gas. Propane
cylinders will supply gas all year round, even on cold winter
days.
LP HOSE AND REGULATOR ASSEMBLY
· Using a hose and regulator assembly that has
not been supplied by the manufacturer of this LP
gas grill, could result in serious bodily injury
or property loss.
· Use only the hose and regulator assembly that has been
furnished with this LP gas grill. If the hose and regulator
assembly is not working properly and you need a
replacement, contact the manufacturer (1-800-251-7558).
· Inspect the hose before each use. If the hose is cut or
damaged or shows 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 the further use of the LP gas grill.
· Read and follow all warnings on LP gas cylinder.
· If you see, smell, or hear the hiss of LP gas
escaping from the cylinder:
1) Evacuate all people from the grilling area.
2) Do not attempt to correct the problem
yourself.
3) Call the local fire department.
· The LP gas cylinder, for use with the Aussie LP gas grills,
must meet the following requirements:
1) 12” diameter x 18” tall, 20 lb maximum capacity
2) Overfill Protection Device (OPD) safety feature (should
be noted on cylinder)
3) Must be constructed and marked in accordance with
the U.S. Department of Transportation (DOT) or the
National Standard of Canada, CAN\CSA-B339. (See
collar for marking)
4) Must have collar to protect LP cylinder valve.
· Never 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.
· The LP gas cylinder should never be filled 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 are getting a safe and adequate O.P.D.
cylinder. Use only a licensed LP gas cylinder dealer.
· Keep children away from LP gas cylinder at all times.
· Do not use, store, or transport the LP gas cylinder where it
would be exposed to high temperatures. The relief valve
may open which will allow a large amount of flammable
gas to escape. Never leave an LP gas cylinder inside a
vehicle which may become overheated by the sun.
· WARNING! Never store an LP cylinder indoors.
Storage of an outdoor cooking gas appliance indoors is
permissible only if the cylinder is disconnected and
removed from the outdoor cooking gas appliance.
Cylinders must be stored outdoors out of the reach of
children and must not be stored in a building, garage, or
any other enclosed area.
· WARNING! Never store a spare LP gas cylinder
under or near the grill. All spare and disconnected LP
gas cylinders must have safety caps installed on the LP
cylinder valve.
· 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.
· Never attempt to repair an LP gas cylinder valve yourself.
See an authorized LP gas cylinder dealer for repairs.
· When transporting an LP gas cylinder, keep it secured in
an upright position with cylinder valve turned to off
position.
· Do not operate the LP gas grill when the LP gas cylinder
is not attached to the cart as shown in the Assembly
Instructions.
· Always check for gas leaks when you disconnect
and reconnect the regulator to the LP gas cylinder,
especially after a period of storage (for example,
over winter).
· Check tubes that lead into the burner for any
blockage from insects, spiders, or food grease
before using.
· Check grill hoses for cracking, brittleness, holes,
or leaks.
· Make sure there are no sharp bends in the hose or
tubing.
· Make sure Regulator Hose does not contact hot
metal surfaces.
28
LP Cylinder
Connecting/ Disconnecting LP
Gas Cylinder to Grill
Page 29
· Never connect or disconnect LP gas cylinder or fittings
while grill is in use or is hot.
· When the LP gas cylinder is connected, the grill must
be kept outside in a well-ventilated space. Turn off all
of the grill control knobs and the LP cylinder valve
when grill is not in use.
· Move gas hose as far away as possible from hot surfaces.
How to Connect your LP gas cylinder
(See STEP 22 of
Assembly Instructions for diagram)
1) Make sure all of the control knobs are turned to the
“off” position and verify that the LP gas cylinder valve is
closed by turning the handle on the LP gas cylinder
valve clockwise until it stops.
2) Remove the protective cap from the LP cylinder gas
nozzle.
3) Hold regulator in a straight line with LP cylinder gas
nozzle so the connection does not cross thread.
4) Insert Regulator nipple into the LP cylinder nozzle opening.
5) Hand tighten coupling nut in a clockwise direction.
Do not use tools.
6) Perform a Leak Test. (See STEP 10 of Assembly
Instructions for Leak Test Instructions)
How to Disconnect your LP gas cylinder
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 in a counter-clockwise
direction until regulator is released from threaded LP
cylinder gas nozzle.
3) Place the protective cap over LP cylinder gas nozzle.
BEFORE USING YOUR
LP GAS GRILL
· Do not use an LP gas grill indoors, on recreational
vehicles, or on a boat.
· This LP gas grill is for outdoor use only and should be
placed on firm, level surface. The grill should be setup in
an open area with good ventilation, away from high traffic
areas and combustible materials.
· Combustible or flammable materials should never be
used or stored within 36 inches of the back or sides of
your LP gas grill.
· 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 under a surface that can
catch fire.
· Carefully read the Important Safeguards section
of this manual (pages 2 through 4). Make sure
you follow and understand all instructions and
warnings. If you have any questions regarding
these pages, call 1-800-251-7558 and ask for a
Customer Service Representative.
· 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.
· 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.
· If any electric appliance or rotisserie is used with the
LP gas grill, do not allow cords to touch or be near hot
surfaces. Electric cords should be placed away from
walkways to avoid a tripping hazard.
· Grill storage cover must be removed and placed at
least 36 inches from the LP gas grill while in use. The
grill cover is made of a flammable material. The grill
must be completely cooled before putting the cover
back on the grill.
· Never store a spare or disconnected LP gas cylinder
under or near this LP gas grill.
· Inspect the hose and regulator assembly before each
use. If the hose is cut or damaged or shows 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 the further use of the LP gas
grill.
· Use only the hose and regulator assembly that is
supplied with your LP gas grill.
· Use of this LP gas grill other than for the intended
use, or alteration of the LP gas grill in any way may
not be safe and will void any warranty.
· LP gas is not natural gas. The conversion or
attempted use of natural gas in an LP unit is
dangerous and will void your warranty.
· Never 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 Liquefied Petroleum supplier. Do not
use an LP cylinder with a damaged valve.
· Never use charcoal in your LP gas grill. Do not use
aerosols or store flammable liquids or materials near
this gas grill.
Selecting a Location
Precautions
29
Page 30
· Always perform a leak test before each use.
· Leak test must be performed in a well ventilated
area.
· Never perform a leak test on a grill while in use or
hot.
· If you detect a gas leak that cannot be corrected
by using the leak test procedures below, do not
use the LP gas grill.
· Never smoke or have an open flame near the grill
during a leak test.
Supplies Needed for a Leak T
est
Clean paint brush, water, and dishwashing liquid.
How to perform a leak test
(See Step 10 of Assembly
Instructions for leak test diagrams.)
WARNING! Never use an open flame to test for gas
leaks.
1)Use an LP 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 of the 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)Remove the protective cap from the LP cylinder gas
nozzle.
4)Hold regulator in a straight line with LP cylinder gas
nozzle so the connection does not cross thread.
5)Insert nipple of regulator into the LP cylinder nozzle
opening.
6)Hand tighten coupling nut in a clockwise direction. Do not
use tools.
7)Mix one cup of water with one cup of dishwashing liquid.
8) Open the valve on LP gas cylinder (Turn the knob on the
LP gas cylinder counter-clockwise.)
9)Check for leaks by brushing the soap solution on all LP
gas connections and fittings (such as those shown by the
heavy arrows in the diagram below.) Make sure you
generously brush the locations with the soap solution,
completely surrounding the connections and fittings.
10)If “growing” bubbles appear on any of the connection
points, then you have detected a gas leak. Immediately
close the LP cylinder valve by turning the handle
clockwise.
A) If leak appears at either end of hose and regulator
assembly, retighten the connection at the leak, but do
not overtighten. (Note: Only hand tighten at coupling
nut) Repeat Leak Test.
B) If the leak is coming from the LP 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.
11)Turn all control knobs to the “off” position and turn the
handle on the LP gas cylinder clockwise until it stops.
Disconnect LP gas cylinder by turning coupling nut on
regulator in a counter-clockwise direction until regulator is
released from threaded LP cylinder gas nozzle.
12)Place the protective cap over LP cylinder gas nozzle.
· Before proceeding, make certain that you
understand the Important Safeguards on pages 2
through 4 of this manual.
· Before lighting the LP gas grill, you must open
the the hood to prevent an explosion from
gas build-up.
· If your LP 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 involves one of the hoses, and you can
safely reach the LP cylinder valve, shut the valve
off.
- 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.
· 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 and hose and regulator assembly,
perform a leak test before continuing use. (See Step
10 of Assembly Instructions)
· Do not operate an LP gas grill if you have knowledge
of or suspect a gas leak.
· Never allow children to operate or play near an LP gas
grill. Do not leave grill unattended.
· Always turn off the LP gas cylinder at the LP cylinder
valve when not in use. Allow grill to cool before
handling parts or cleaning.
· Do not move an LP gas grill when in use or hot.
· Never 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 from the hot air and
steam trapped inside.
· Do not wear loose clothing (example: hanging
shirt tails, clothing with frills, etc.) around a LP
gas grill while in use or hot.
· Never lean your body over the LP gas grill when
lighting it or while it is in use or hot.
·
This LP gas grill is not designed to be used with
a solid plate (griddle.) Full coverage of plates will
cause excessive heat and could damage the grill.
Leak Testing
OPERATING THE LP GAS GRILL
30
Page 31
· Wash the porcelain or chrome coated Cooking Grids
with a mixture of hot water and baking soda.
· Empty the grease cup after each cooking session so
excessive grease does not accumulate.
Failure to remove grease may result in grease
dripping onto the cart and/or a grease fire in the
tray.
How to light your LP gas grill (See diagram below
for illustrations)
1) Open Hood
2) Important: Make sure control knobs are turned
“off” first. Open the LP gas cylinder valve by turning
the valve handle counter-clockwise until it stops.
3) From the “Off” position, push control knob in on the left
side and turn counter-clockwise to the high position.
4) Push the igniter button several times so that it clicks each
time.
5) Check to make sure that the burner is lit.
6) Light the remaining half of the burner by turning the control
knob counter-clockwise. Your grill has a crossover ignition
system that allows the burner to light each side successively.
7) If burners does not light, repeat Step 3. The burner
should light within three or four attempts. If burner still does
not light, try the right side.
WARNING: If both sides of the burner fail to light
after following Steps 3 & 4, turn all knobs to the “off”
position and close the valve on the LP gas cylinder.
Wait five minutes; then repeat all of the above lighting
procedures.
Note:If the burner still fails to light, refer to the
T
roubleshooting page. The burner can be lit manually, see
Manual Lighting of the Grill
.
8) After ignition, preheat the grill by turning the control knobs to
“High” for 3-5 minutes. The grill should be pre-heated before
every cooking session. The hood should be closed during
preheating.
WARNING: If a burner goes out during the cooking
cycle, turn all knobs to the off position and close the
valve on the LP cylinder. Open hood and wait five
minutes before attempting to relight the grill.
Preparation Before Cooking
Lighting the Grill Using Igniter
31
1. Open hood
2. Turn LP cylinder handle counter-clockwise to
open.
3. Push in left or right control knob and turn
counter-clockwise to the “High” position.
4. Push in Igniter to light.
· Open Hood before lighting the grill to prevent an
explosion from gas buildup.
· Always inspect the gas hose and regulator
assembly before each use. If the hose is cut,
damaged, or shows signs of excessive abrasion
or wear, do not use the LP gas grill. Contact the
manufacturer, as the hose and regulator assembly
must be replaced with an assembly specified by
the manufacturer prior to further use of the LP gas
grill.
Page 32
How to light your LP Gas Grill Side Burner (See
diagram below for illustrations)
1) Open Side Burner Lid
2) Important: Make sure Side Burner Control Knob is
turned “off” first. Make sure the LP gas cylinder valve is
open by turning the valve handle counter-clockwise until
it stops.
3) From the “Off” position, push in the Side Burner Control
Knob (right most knob of the control panel) and turn
counter-clockwise to the “high” position.
4) Push the igniter button several times so that it clicks each
time.
5) Check to make sure that the burner is lit.
6) If the side burner does not light, repeat Steps 3 and 4.
The burner should light within three or four attempts.
WARNING: If burner fails to light after following
Steps 3 & 4, turn Side Burner Knob to the “off”
position and close the valve on the LP gas cylinder.
Wait five minutes; then repeat all of the above
lighting procedures.
Note: If the burner still fails to light, refer to the
T
roubleshooting
page.
Lighting the Side Burner (Elite Series Only)
•Open Side Burner Lid before lighting to prevent an
explosion from gas build-up and to prevent burning the
paint.
2. Make sure Side Burner Control Knob
is turned “off” first. Make sure the LP
Gas Cylinder valve is open by turning
the valve counter-clockwise until it
stops.
1. Open Side
Burner Lid.
3. Push the Side Burner Control Knob and
turn counter-clockwise to the high position.
4. Push igniter
button to light.
32
Page 33
· Open Hood before lighting the grill to prevent an
explosion from gas build-up.
· Always inspect the gas hose and regulator
assembly before each use. 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.
How to manually light your LP gas grill
1) Open Hood
2) Important: Make sure Control Knobs are turned “off.”
Open the LP gas cylinder valve by turning counterclockwise until it stops.
3) Insert a lit match through match-lighting hole
underneath the grill bowl on the right side. (See figure
below).
4) Push in and turn the right main burner control knob counterclockwise to the “high” position.
WARNING: If the burner fails to ignite after
following the above procedure, turn control knob to
the off position and close the valve on the LP cylinder.
Wait five minutes and repeat all of the above manual
lighting procedures. If the grill still fails to light, see
the T
roubleshooting
page.
5) Check to make sure that the burner is lit.
6) Light the remaining half of the burner by turning the control
knob counter-clockwise. Your grill has a crossover ignition
system that allows the burner to light each side successively.
7) If burner does not light, repeat Step 3. The burner
should light within three or four attempts.8) After ignition,
preheat the grill by turning the control knobs to “High” for 35 minutes. The grill should be pre-heated before every
cooking session. The hood should be closed during
preheating.
WARNING: If the burner goes out during the cooking
cycle, turn the control knob to the “off” position and
close the valve on the LP cylinder. Wait five minutes
before attempting to relight.
Manual Lighting of the Grill
33
4. Push in right control knob and turn
counter-clockwise to
the “High” position.
3. Match lighting hole in right side of grill body Insert a lit match through the match lighting hole.
2. Turn LP cylinder handle
counter-clockwise until it stops.
1. Open hood
NOTE: Shown with right side
table removed for clarity.
Page 34
Your burner has 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 LP gas mixture. (See diagram below)
The flame should be checked before the initial cooking session and periodically throughout the grilling season, especially after storing the grill over a long period of time. If the
flame is significantly yellow in color, then you are not getting
the appropriate amount of LP gas in the air /LP gas mixture.
This could be a result of a blocked burner from grease drippings or from insects building a nest inside the burner or
burner opening. You should follow the Burner Maintenance
section of this manual for cleaning the burners.
The burner heats up the Flavor Activator™ underneath the
grid, which in turn heats the food on the grill. The natural
food juices produced during cooking fall onto the hot Flavor
Activator™ below and vaporize. The subsequent rising
smoke bastes the food, as it travels upwards, giving it that
unique barbecued flavor.
The grill is equipped with a roasting hood giving the option
of cooking with hood closed to form an ‘oven’ for roasting
food, such as roasts of meat, whole chickens, etc. When
the hood is closed, a large amount of heat is trapped inside
the grill. Thus, it is IMPORTANT to make sure that the
burner is turned to the low position to prevent burning of
the food. Avoid lifting the hood unnecessarily as heat is
lost every time the hood is opened.
After each cooking session, close the hood and turn the
grill burners to the “high” position and burn for five minutes.
This procedure will burn off cooking residue, thus making
cleaning easier.
How to turn off your LP gas grill
1) When you have finished using your grill, turn the grill
Control Knobs clockwise to the “Off” position.
2) Turn off the gas at the LP cylinder valve by turning the
handle clockwise until it stops.
3) Wait until the grill is cool before closing the grill hood
and putting on the cover.
WARNING! 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.
· Always turn “off” the LP gas cylinder at the LP
cylinder valve, when not in use. Allow the grill to
cool before handling parts or cleaning.
· Do not move an LP gas grill when in use or hot.
· Never touch hot surfaces. Use heat resistant
gloves, long-handled tongs, or cooking mitts at all
times since grill will become very hot.
· Do not wear loose clothing (for example: hanging
shirt tails, clothing with frills, etc.) around a LP gas
grill while in use or hot.
· Never lean your body over the LP gas grill when
lighting it or while it is in use or hot.
· 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.
Check Your Flame
Grill Cooking
Roasting Hood Cooking
End of Cooking Session
· Never leave your LP gas grill unattended during use
or cleaning.
Turn off Your LP Gas Grill
CARE AND MAINTENANCE
34
Yellow Tip
Primarily Blue
Flame
Page 35
Regularly clean your LP gas grill between uses and especially after extended periods of storage. Ensure the grill
and its components are cool before cleaning. In order to
extend the life and maintain the condition of your grill, we
strongly recommend that the unit be covered when stored
outside for any length of time, especially during the winter
months.
Most residue on the Cooking Grids can be cleaned with a
baking soda and water solution. For stubborn stains, use a
nonabrasive scouring powder. Do not use steel wool or
other like cleaning products on the porcelain coated surfaces. This will scratch the porcelain coating causing foods
to stick.
Provided that the Burner is operating correctly, in normal
usage, burning off the residue after cooking will keep the
burner clean. The Burner should be removed and cleaned
annually, or whenever heavy build-up is found, to ensure that
there are no signs of blockage (debris, insects) in either the
burner portholes, the primary air inlet, or the neck of the
burner. (See Burner cleaning instructions below)
How to clean the Burner
1) Make sure the LP cylinder and grill control knobs are
turned off, and the grill has completely cooled.
2) Carefully remove Grease Cup, Cooking Grid, and Flavor
Activator™.
3) Remove the Burner, by first removing the Heat Shield
from the bottom of grill Bowl. Remove the two screws
securing the burner (also located underneath the grill
bowl.)
4) Remove Burner from the grill.
5) Use a pipe cleaner to clear obstructions from the Burner
holes and inlet hole. Verify that there are no insects or
insect nests blocking the inlet hole. Normal wear and
corrosion may enlarge some holes, however, if large
cracks or holes are found the Burner should be replaced.
Note: It is normal for surface rust to be present on the
Burner.
6) If grill is to be stored, coat Burner lightly with cooking oil.
and Wrap in a protective cover to keep insects out.
7) After cleaning, reinstall Burner and other parts
removed back into grill. Note: When refitting the Burner,
be careful to check that it is positioned correctly. (Refer
to Step 6 of Assembly
Instructions for reinstallation)
CARE AND MAINTENANCE
(Continued)
Porcelain coated Cooking Surfaces
(Deluxe & Elite Series Only)
· Check the LP gas grill for gas leaks and Burner
obstructions before each use.
· Always turn off the LP gas cylinder at the
LP cylinder valve when not in use. Allow grill to
cool before handling parts or cleaning.
Burner Maintenance
35
Clean all Burner
holes and Burner
tubes with pipe
cleaner or small
wire.
Page 36
Remove and wash the Flavor Activator™ in order to keep it
clean. Burning off the residue after each cooking will make
cleaning easier. Clean with soap and water.
· Always turn the LP gas cylinder valve “Off” when
not in use. Allow grill to cool before handling parts
or cleaning.
· Empty the Grease cup after each cooking session so
excessive grease does not accumulate.
Failure to remove grease may result in grease
dripping onto the cart and/or a grease fire in the cup.
· Never light the LP gas grill without the grease cup in
place.
· Before each use, remove all grease from your Grease Cup.
· Make sure Grease Cup is in place before each grilling
session.
· Failure to remove grease from the Grease Cup may result
in grease dripping onto the cart.
· Always turn off the LP gas cylinder at the LP
cylinder valve when not in use. Allow grill to cool
before handling parts or cleaning.
How to Clean the Grill Body
1) Remove Cooking Grid, Flavor Activator™, and Burner
before full cleaning.
2) Remove excess grease and/or fat from the grill Bowl
with a soft plastic or wooden scraper. Never use steel
wool or other abrasive cleaning product on porcelain
coated surfaces.
3) 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. Make sure all water is
removed from Burner.
4) When finished cleaning, replace Burner, Flavor
Activator™ and Cooking Grid according to Steps 6, 7, 18,
and 21 in the Assembly Instructions
.
5) Check burner operation after reassembly.
· Always turn off the LP gas cylinder at the LP
cylinder valve when not in use. Allow grill to cool
before handling parts or cleaning.
· Do not use aerosols or store flammable liquids or
materials near this gas grill.
Periodically check and tighten all nuts, bolts, and screws.
· Never store an LP gas cylinder indoors (empty or
filled). If storing the gas grill indoors, disconnect
the LP gas cylinder and store it outdoors out of the
reach of children.
· Never leave an LP gas cylinder inside a vehicle
which may become overheated by the sun.
· Never store a spare or disconnected LP gas
cylinder under or near the LP gas grill.
· Always turn off the gas cylinder when not in use.
Allow grill to cool before handling parts or
cleaning.
· Even though your LP gas cylinder may appear to be
empty, gas may still be present and the cylinder
should be transported and stored accordingly.
· Store your LP gas grill in a cool dry place .
· 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 cylinder valve with the Safety Cap.
· Remove Burner and wrap with aluminum foil to prevent
insects from entering the burner holes. Store wrapped
Burner on top of cooking grid.
· Before next use, remove aluminum foil and reinstall
Burner, Flavor Activator, and Cooking Grid according to
Assembly Instructions
.
· Check your LP gas grill for gas leaks, deterioration, proper
assembly, and burner obstructions before using the grill
after periods of storage and/or non-use(i.e. over winter).
Flavor Activator™
Drip Cup
Cleaning the Grill Bowl
Preventive Maintenance
Storage
36
Page 37
TROUBLESHOOTING
Problem
Possible Cause
Solution
Burner will not light
using the ignitor
Burner not assembled correctly
Not pausing long enough
before clicking the Igniter
Button
No spark
LP gas cylinder is empty
Coupling nut is not fully con-
nected to regulator
Excess flow valve tripped in
regulator
Obstructions in burner
Electrode and burner are wet
Wire is loose or disconnected
Wire is shorting (sparking
between ignitor wire and
electrode
Burner not assembled correctly
LP gas cylinder is empty
Excess flow valve tripped in
regulator
Coupling nut is not fully connected to regulator
Obstructions in burner
See Assembly Instructions for installing the Burner.
When lighting the Burner, push-in and turn control panel knob
counter-clockwise to the high position. Pause 4 seconds, then
push in Igniter button several times so that it clicks each time.
Gas collector tab is bent (making too large or small of a gap
between electrode and tab). By hand, bend gas collector tab
back within a maximum of 3/16” gap to electrode. See page 16
Fig. 1 for details.
Take LP gas cylinder to licensed LP gas supplier to be refilled
Tighten coupling nut by hand about one-half to three quarters
additional turn. Do not use tools.
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 remains to be low, turn off gas at cylinder and
grill. Disconnect the regulator from the LP gas cylinder.
Reconnect the regulator to the LP gas cylinder. Perform a leak
test. Relight grill. This will reset the excess flow valve.
Clean burner (See Burner Maintenance in Care and
Maintenance section of this manual)
Dry electrode with clean cloth
Reconnect the wire
Replace ignitor wire/electrode assembly (Call the Customer
Service Department)
See Step 8 - Install Burner page of the Assembly Instructions
Take LP gas cylinder to licensed LP gas supplier to be refilled
Turn control knobs to “off” position and turn LP gas cylinder
handle clockwise until it stops. Wait five minutes. Relight LP
gas grill.
Tighten coupling nut by hand about one-half to three quarters
Clean burner (See Burner Maintenance in Care and
Maintenance section of this manual)
Burner will not light
using a match
37
Page 38
TROUBLESHOOTING
Problem
Flames blow out
Flare up
Persistent grease fire
Unable to fill LP tank
Humming or whistling
from the regulator
Possible Cause
High or gusting winds
Gas in LP cylinder is low
Excess flow valve tripped
Grease build up
Excessive fat in meat
Grease trapped around burner system
Some dealers have older fill
nozzles with worn threads.
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.
Solution
Turn front of grill to face wind or increase flame height.
Check LP gas cylinder. Refill if necessary.
See “Low flame” problem above
Clean grill
Trim fat from meat before grilling
Turn control knobs “off” and turn handle of LP cylinder clockwise until it stops. Open hood carefully and let fire burn out.
After the grill cools, remove and clean all parts.
The worn nozzles don’t have enough “bite” to engage the valve.
Try another licensed LP dealer.
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. Should you smell gas, do not
use the grill and call Customer Service at 1-800-251-7558
If your problem is not resolved from the information provided above, please call Customer Service at
1-800-251-7558.
38
Low flame or low heat
Excess flow valve tripped in
regulator
Gas in LP cylinder is low
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 remains to be low, turn off gas at cylinder and
grill. Disconnect the regulator from the LP gas cylinder.
Reconnect the regulator to the LP gas cylinder. Perform a leak
test. Relight grill. This will reset the excess flow valve.
Check LP gas cylinder. Refill if necessary.
Page 39
IMPORTANT NNOTICE
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 the overfill of 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 cylinder before attempting to fill.
WARNING! Do not exchange the LP Gas cylinder unless the exchange LP
cylinder is equipped with an OPD. Otherwise you will lose the OPD (Overfill
Prevention Device) feature. If there is not an LP cylinder available for exchange
equipped with an OPD, we recommend that you have your cylinder filled at an
authorized LP gas dealer by a qualified attendant.
Rises up while filling
then stops when full.
39
© AUSSIE™ GRILL COMPANY
Page 40
AUSSIE GRILL COMPANY
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). Burner and Cooking Grid are warranted for a period of one (1) year from the date of purchase.
All other parts are warranted for a period of one (1) year from the date of purchase. Aussie Grill
Company 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 Aussie
Grill Company at the customer service number listed below.
Aussie Grill Company may require reasonable proof of purchase and we suggest 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 Aussie Grill Company 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 Aussie Grill Company. 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:
Aussie Grill Company
1500 Industrial Road
Greeneville, TN 37745
40
Serial No.___________________
Please use this number in registering your warranty and any correspondence with Aussie Grill
Company.
For reference and correspondence,
record your Serial number here.
(See nameplate on side of grill.)
P/N 03.6113.00
REV. 10/2001
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