Aussie TM Bushman™ LP Gas Grill Assembly and Use Manual for: Bushman™, Deluxe, & Elite Models Bushman™ Deluxe Bushman™ For Customer Service, call 1-800-251-7558 www.aussiegrill.com Bushman™ Elite ©Aussie™ Grill Company 2001 This owners manual is intended for the following models: Bushman™, Bushman™ Deluxe, & Bushman™ Elite •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.
I. IMPORTANT SAFEGUARDS...........................................2 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...........
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.
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. 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. 38.
Parts Diagram - Some small parts may not be depicted 32 55/ 56 36 8, 9, 30, 31, 33, 34, 35 18 54 39 39 51 22 40 40 21 40 25 24 20 38 42 43 44 45 46 47 48 49 50 28 10/ 11 3/4 41 6 17 7 14 5 15 5
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.
BUSHMAN DELUXE BUSHMAN ELITE 12 12 Part# BUSHMAN 11 Legs, Wheel - Tubular 03.6211.00 1 12 Bolt, M6 x 50 03.6212.00 13 Bolt, M6 x 45 03.6213.00 24 12 12 14 Wheel 03.6214.00 2 2 2 15 Axle 03.6215.00 1 1 1 16 Nut, M8 03.6216.00 2 2 2 17 Wheel Cover 03.6217.00 2 2 2 18 Rear Support Brace 03.6218.00 1 1 1 19 Bolt, M6 x 35 03.6219.00 4 4 4 20 Drip Cup Holder 03.6220.00 1 1 1 21 Bowl 03.6221.00 1 1 1 22 Burner 03.6222.00 1 1 1 23 Screw ST4.8 x 10 03.
PART# BUSHMAN BUSHMAN DELUXE BUSHMAN ELITE 26 Bowl Bolt spacer 03.6226.00 4 4 4 27 Washer, 6M 03.6227.00 6 6 6 1 1 PART/ DESCRIPTION 03.6228.00 28 Control Panel 03.6228.01 1 29 Hose & Regulator 03.5854.01 1 1 1 30 Bowl Hinge 03.6230.00 2 2 2 31 Hinge Pad 03.6231.00 8 8 8 32 Hood 03.6232.00 1 1 1 33 Hood Hinge 03.6233.00 2 2 2 34 Hinge Pin 03.6234.00 2 2 2 35 Cotter Pin 03.6235.00 2 2 2 36 Hood Handle 03.6236.00 1 1 1 37 Bolt, M5 x 10 03.6237.
PART/ DESCRIPTION PART# BUSHMAN BUSHMAN DELUXE BUSHMAN ELITE 42 Side Table, Burner 03.6241.00 43 Spacer, Side Table 03.6242.00 44 Side Burner Pan 03.6243.00 1 45 Side Burner 03.6244.00 1 46 Side Burner Igniter 03.6245.00 1 47 Side Burner Igniter Clip 03.6246.00 1 48 Side Burner Cover 03.6247.00 1 49 Side Burner Hinge Pin 03.6248.00 1 50 Side Burner Hinge Pin Clip 03.6249.00 2 51 Flavor Activator™ 03.6250.00 1 1 1 52 Flavor Activator™ Mounting Stud 03.6251.
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.
STEP 2- Attach Legs to Bottom Shelf TOOLS: (ITEM 12) BOLT, M6 X 50 8 pcs (ITEM 3 OR 4) LEGS, FIXED (ITEM 13) BOLT, M6 X 45 8 pcs (ITEM 10, 11) WHEEL LEGS (ITEM 9) NUT, M6 8 pcs •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.
STEP 3 - Attach Wheels to Cart Tools: 2 pliers (ITEM 15) AXLE (ITEM 14) WHEEL 2 pcs (ITEM 17) WHEEL COVER 2 pcs (ITEM 16) NUT, M8 2 pcs •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.
STEP 4 - Attach Rear Support Bar (ITEM 18) REAR SUPPORT BRACE TOOLS: (ITEM 9) NUT, M6 4 pcs (ITEM 19) BOLT, M6 X 35 4 pcs •Attach Rear Support Bar on backside of grill legs as shown using four M6 x 35mm Bolts and four 6M Nuts. Tighten All Bolts.
STEP 6 - Attach Burner TOOLS: (ITEM 22) BURNER (ITEM 23) SCREW ST4.8 X 10 2 pcs •Attach Burner : Insert Burner manifold tubes down through holes in bottom of grill Bowl toward front of grill.
STEP 7 - Attach Heat Shield TOOLS: (ITEM 23) SCREW, ST4.8 X 10 2 pcs (ITEM 24) HEAT SHIELD •Thread Drip Cup Holder through center hole of Heat Shield and secure Heat Shield to bottom of grill bowl as shown, using 2 screws. Caution : Some parts may have sharp edges or corners.
STEP 8 - Mount Igniter/ Flavor Activator Mounting Stud to Grill Bowl TOOLS (ITEM 52) FLAVOR ACTIVATOR MOUNTING STUD 2 pcs (ITEM 25) IGNITER Tightening Nut - Comes on threaded post of Igniter and should be removed before mounting on Grill.
STEP 9 - Mount Grill bowl to Legs (ITEM 13) BOLT, M6 X 45 4 pcs (ITEM 27) WASHER 6MM 4 pcs TOOLS: (ITEM 26) BOWL BOLT SPACER 4 pcs (ITEM 9) NUT, 6M 4 pcs •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.
Step 10 - Leak Test and Attach Control Panel •Before attaching control panel a leak test must be performed on the Control Valves, Burner manifold, and Regulator/ Hose connections. Supplies Needed for a Leak Test 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.
Continued: STEP 10 - Attach Control Panel TOOLS: OR (ITEM 28) CONTROL PANEL BUSHMAN™ ELITE BUSHMAN™ & BUSHMAN™ DELUXE (ITEM 13) BOLT, M6 X 45 4 pcs (ITEM 9) NUT 6M 4 pcs •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.
STEP - 12 Mounting Hood/ Bowl Hinges TOOLS: (ITEM 32) HOOD (ITEM 30) BOWL HINGE 2 pcs (ITEM 33) HOOD HINGE 2 pcs (ITEM 8) BOLT, M6 X 15 8 pcs (ITEM 31) HINGE PAD 8 pcs (ITEM 9) NUT 6M 8 pcs •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.
STEP 13 - Mounting Hood TOOLS: (ITEM 35) COTTER PIN 2 pcs (ITEM 34) HINGE PIN 2 pcs •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: STEP 14 - Attach Hood Handle (ITEM 37) BOLT, M5 X 10 2 pcs (ITEM 36) HOOD HANDLE 1 pc •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 TOOLS: •Insert Drip Cup into hanger clip underneath grill bowl.
STEP 16 - Attach Side Tables TOOLS: (ITEM 39) SIDE TABLE, BUSHMAN (ITEM 13) BOLT, M6 X 45 8 pcs (ITEM 9) NUT, M6 8 pcs (ITEM 40) SIDE TABLE BUSHMAN DELUXE or LEFT SIDE ELITE (ITEM 43) SPACER, SIDE TABLE 8 pcs (ITEM 42) SIDE TABLE BURNER BUSHMAN ELITE (RIGHT SIDE ONLY AND DOES NOT FOLD) 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 si
STEP 17 - Elite Right Side Burner (BUSHMAN ELITE MODELS ONLY) TOOLS: (ITEMS 42, 43, 44, 45, 46, & 47) SIDE BURNER ASSEMBLY (ITEM 53 ) SIDE TABLE GRID (ITEM 48) SIDE BURNER COVER •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.
Step 18 - Attach Flavor Activator™ (ITEM 51) 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. Flavor Activator™ Mounting Stud Flavor Activator™ STEP 19 - ATTACH 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.
Step 20 - Insert Warming Rack 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. (ITEM 54) 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 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.
OPERATING AND MAINTAINING YOUR GAS GRILL GAS, CYLINDER, HOSE AND REGULATOR INFORMATION · 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. This LP gas grill was designed to use propane gas. Propane · Keep children away from LP gas cylinder at all times. cylinders will supply gas all year round, even on cold winter days.
· 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.
Leak Testing OPERATING THE LP GAS GRILL · 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 Test Clean paint brush, water, and dishwashing liquid.
Preparation Before Cooking 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.
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. 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.
Manual Lighting of the Grill · 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.
Check Your Flame 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) Yellow Tip End of Cooking Session · Never leave your LP gas grill unattended during use or cleaning. After each cooking session, close the hood and turn the grill burners to the “high” position and burn for five minutes.
Burner Maintenance CARE AND MAINTENANCE (Continued) 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.
Flavor Activator™ 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. Drip Cup · 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. Preventive Maintenance · Always turn the LP gas cylinder valve “Off” when not in use.
TROUBLESHOOTING Problem Possible Cause Solution Burner will not light using the ignitor Burner not assembled correctly See Assembly Instructions for installing the Burner. Not pausing long enough before clicking the Igniter Button 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.
TROUBLESHOOTING Problem Possible Cause Solution Flames blow out High or gusting winds Turn front of grill to face wind or increase flame height. Gas in LP cylinder is low Check LP gas cylinder. Refill if necessary. Excess flow valve tripped See “Low flame” problem above Grease build up Clean grill Excessive fat in meat Trim fat from meat before grilling Persistent grease fire Grease trapped around burner system Turn control knobs “off” and turn handle of LP cylinder clockwise until it stops.
IMPORTANT NOTICE The gas grill is setup to operate with a LP Gas Cylinder equipped with an OPD (Overfill Prevention Device). This is a secondary device to prevent 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.
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.