LP Gas Grill Assembly and Use Manual With the NEW Aussie FLAVOR ACTIVATOR SYSTEM (Patent Pending) Provides: - More even heat on the cooking surface - Hotter temperature with the same fuel usage - Longer cooking for the same amount of fuel 68R5A9SSS1 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.
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 web site. 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 Greeneville, TN 37745 USA www.aussiegrills.
Packing List Description Warming Rack Cooking Grid, 3 pcs. Flavor Activators - 4 large, 3 small Grease Pan Foil Pan Left Side Shelf with Side Burner Side Burner Control Knob Hood/Body Right Side Shelf Bottom Body Panel Cabinet Back Panel Front Crossbar Drawer Tracks, 2 pcs. Cabinet Side Panel- Left Back Panel Brace wire Cylinder Retainer Bolt Cabinet Upright Cylinder Blocking Wire Cabinet Side Panel- Right Cabinet Bottom Panel Front Corner Brackets Drawer Body Locking Caster, 2 pcs. Fixed Casters, 2 pcs.
Contents Packing List .................................................................. 3 Preparation for Assembly .......................................... 4 Assembly Instructions Step 1 Caster Assembly ............................................ 5 Step 2 Cabinet Bottom Assembly .............................. 5 Step 3 Side Panel Assembly ...................................... 6 Step 4 Front Crossbar Assembly ............................... 7 Step 5A Cabinet Upright Assembly ..........................
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.
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 .
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 A. Cabinet Upright Assembly Attach Cabinet Upright to Cabinet Bottom and Front Crossbar with four 5/32 x .31” Bolts.
! 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. Back Panel Brace wire Assembly Attach Back Panel Brace wire 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 .
Step 8 Model 6805 & 6804 with drawer Drawer Track Assembly and Cylinder Retaining Bolt Installation 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.
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 Prior to performing any further assembly, PERFORM “FIRST TIME USE” LEAK TEST as detailed on pages 19-20. 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 main burner valves inside the control panel, behind the knobs, . 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.
Step 13 Side Burner Valve Assembly NOTE: Side Burner Valve is already attached to the regulator hose. Hose is not shown in some illustrations for clarity. A. Install the Side Burner Valve from underneath the LEFT Side Table. Remove the screws from the side burner bracket and set aside with bracket. B. Tilt venturi end of burner down and slide rectangular venturi windscreen toward back of grill to expose open end of burner tube. C.
! CAUTION To avoid possible damage to grill, DO NOT ATTEMPT TO LIFT GRILL BY THE SIDE TABLES Step 15 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 Step 16 A.
! CAUTION To reduce the risk of a laceration hazard: • Wear protective gloves when installing warming rack. Hood and Bowl edges could be sharp. Step 17 Warming Rack Assembly Insert Warming Rack leg ends into holes on top edge of firebox. Seat securely. Step 18 Flavor Activator/Cooking Grid Assembly A. Lay a large Flavor Activator over each Tube Burner on the lower body ridges. Lay a small Flavor Activator between each large Flavor Activator.
Step 19 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. 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.
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.
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.
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.
! CAUTION To reduce the risk of a laceration hazard: • Wear protective gloves when removing or replacing Control panel, which could have sharp edges. 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.
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 6a) Make sure you generously brush the locations with the soap solution, completely surrounding the connections and fittings. corrugated rotisserie gas line 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.
8. 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.
Lighting the Grill Using the Pulse-Spark Ignitor (continued) ! 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.
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 33. 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.
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.
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.21) 3. Turn the LP Gas Cylinder valve open counterclockwise until it stops. (Fig. 8 p.21) 4.
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 Match light 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.
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.
Grill Cooking (Direct Method) continued Direct Cooking on the Grids: Food is cooked directly over the heat source. The Burners heat up the Flavor Activators under the Cooking Grids, which in turn heat the food on the grill. The natural food juices from cooking fall onto the hot Flavor Activators below and vaporize. Rising smoke bastes the food, giving it that unique barbecued flavor.
Rotisserie Cooking Rotisserie Cooking: The constant turning of the meat while cooking allows it to self baste with natural juices, making food cooked on the rotisserie exceptionally moist and tender. The best meats for rotisserie cooking are tightly tied, boned or boneless cuts. Cuts with a bone can be cooked on the rotisserie if they are carefully balanced on the spit so that it can turn easily.
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.
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 16A, page 13) 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.
Cleaning the Grill (continued) 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 Flavor Activators. 3.
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.
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.
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.
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.
Parts List- Model 6805 Key 1 2 3 4 5 6 7 8 8A 8B 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 23A 24 25 26 27 28 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 Cast Iron Side Burner 1 Side Burner Bracket 1 Side Burner Wind Shield 1 Manifold Assembly 1 Ignition Box 1 Control Panel 1 Main Knob Bezel 6 Front Crossbar 1 Back Panel Brace wire 1 Cabinet Side Panel- LEFT 1 Cabinet Upright 1 Cylinder
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.
MECO CORPORATION - LIMITED WARRANTY 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.
