Ducane 04 Series Owner's manual

Brand: Ducane

Model: 04 Series

Category: Barbecues & grills

Type: Owner's manual

This manual is also suitable for

Ducane

Owner’s Manual

1605SS

04 and 05 Series

Owner’s

Manual

TABLE OF CONTENTS

IMPORTANT INFORMATION...............2

SPECIAL FEATURES...........................4

SAFETY TIPS...................................10

INSTALLATION

Liquid Propane Gas Grills............11

Natural Gas Grills.......................16

CONNECTION

Liquid Propane Gas Grills............12

Natural Gas Grills.......................17

NORMAL OPERATION .....................20

HELPFUL HINTS .............................23

TROUBLESHOOTING.......................29

MAINTENANCE...............................33

WARRANTY....................................40

INDEX ..........................................42

02/33

IMPORTANT: We urge you to read this manual carefully and to follow the recommendations enclosed. This will

help assure you of the most enjoyable and trouble-free operation of your new Ducane

Gas Grill. We also

advise you to keep this manual for future reference.

WARNING: Your grill has been designed to operate using only the gas specified on the agency’s rating plate

located on the control box. Do not attempt to operate your grill on other gases. Failure to follow this warning

could lead to a fire hazard and bodily harm, and will void your warranty.

CAUTION:

FOR YOUR SAFETY

Do not store any flammable materials in any cabinets beneath the grill burner box or in the vicinity of

your grill.

WARNING:

Be sure to have your LP (propane) tank filled by a reputable propane dealer. An incorrectly filled or

an overfilled LP tank can be dangerous. The overfilled condition combined with the warming of the LP tank (a

hot summer day, tank left in the sun) can cause LP gas to be released by the pressure relief valve on the tank

since the temperature increase causes the propane to expand. LP gas released from the tank is flammable and

can be explosive. Refer to Pages 12-15 for more information concerning filling your LP tank.

Important

INFORMATION FOR YOUR SAFETY

IMPORTANT

ON PAGES:

6, 8, 14, 18, 19, 20

30, 31, 33, 34

WARNING

ON PAGES:

7, 11, 13, 14, 15, 16, 19, 20

21, 22, 23, 25, 30, 36, 37

CAUTION

ON PAGES:

11, 15, 16, 18, 20, 21, 22

25, 26, 27, 30, 34, 36

02/43

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 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.

CALIFORNIA PROPOSITION 65-WARNING: The burning of gas cooking fuel generates some by-products which are

on the list of substances known by the State of California to cause cancer or reproductive harm. California law requires

businesses to warn customers of potential exposure to such substances. To minimize exposure to these substances always

operate this unit according to the use and care manual, ensuring you provide good ventilation when cooking with gas.

Dear New Ducane

Grill Owner,

You’re now the proud owner of a quality American-made gas grill! Your pride

should come from knowing that Ducane

Gas Grills has worked very hard to design a

grill that will bring you and your family years of barbecuing fun with very few

problems. The extensive research and innovative design work that goes into each and

every product has made us a leader in our industry.

Ducane Gas Grill components should last the life of their warranty; however,

there is always the possibility of component failure. If a covered part fails within your

warranty period, a replacement will be provided free of charge.

For your own safety, be certain you are receiving genuine Ducane replacement

parts. Ducane is the only grill manufacturer who fabricates all of their own warranty

parts. Using off-brand replacement parts will void your gas grill’s American Gas

Association certified approval. But more importantly, your family’s safety may be

at risk when you select off-brand replacement parts. For example, the port openings

on a replacement burner may vary slightly, and keep gas from flowing properly which

could cause a flashback or fire.

So for safety’s sake, if you ever need to replace a component on your new Ducane

Gas Grill, request genuine Ducane replacement parts by calling 1-800-308-3360. And

for even more information, visit our website at www.ducane.com.

Happy Grilling!

Ducane Gas Grills, Inc.

02/43

304 Grade Stainless Steel

TOP-PORTED™ Burner(s)

Unlike other grills, Ducane grills employ a TOP-

PORTED™ burner which is protected from drippings

by the LA-VA-GRATE

. This TOP-PORTED

burner

allows the flames to come from the top instead of the

side (See Fig. 1), which also allows the flames to look

directly up at the LA-VA-GRATE

and induce more heat

toward the briquettes. This makes our barbecue grills

very efficient and the burners run cooler, last longer

and save gas. The extreme temperatures of cooking

make the burners on other grills wear out faster.

SOME OTHER GRILLS

Special Features

OF YOUR DUCANE

GRILL

Factory Installed Burner(s)

Each burner has been installed and fire tested in

our factory for proper operation. A quick reminder on

how to install the burner(s) and to check for proper

orifice alignment has been included within the

Maintenance section of this book. (Page 33)

Burner Adjustments

(Factory Adjusted)

The gas burner(s) shutter is pre-adjusted at the

factory for your convenience. The adjustments are

completely open for natural gas and half open for

propane units. If further adjustment to the burner(s)

is required, please see Page 23 for proper method

within the Helpful Hints section.

304 Grade Stainless Steel

Convenient Up-front Control Box

Your grill features a convenient up-front control

box with removable, child-safe burner control knobs.

The ignitor is located on the right side of the

control box. This position allows easy access for

ignition and provides the ignitor additional

protection from the elements. (See Fig. 2)

FIG. 1

DUCANE’S TOP-PORTED

™

BURNER

REMOVABLE, CHILD-SAFE

BURNER CONTROL KNOBS

IGNITOR LOCATED ON

SIDE OF CONTROL BOX

FIG. 2

02/43

Rotary Ignition with VIS-U-GLO

Observation Port

Ducane has added a unique safety feature to our rotary

ignition. An observation port and a glowing wire in the

flame path lets you see that the grill is lit, even in the

brightest sunlight. And you don’t need batteries or

matches. (See Fig. 3) By simply rotating the side-

mounted ignition knob, a hammer is triggered which

impacts a crystal element and produces multiple sparks

to ignite the burners.

It is very important to make sure your grill is covered

when not in use. This will help eliminate moisture

contamination which would render the rotary ignitor

temporarily inoperable. If your grill fails to light, see

Troubleshooting on Page 29.

Ducane Gas Grill Cover

A Ducane full-length cover will protect your grill from

the environment. We strongly recommend that you

use it throughout the year. If you ever need to replace

it, don’t be misled by imitations. Ducane’s cover carries

our trademarked red logo. It is designed specifically for

your grill and it will do the very best job of protecting

your investment!

FIG. 3

VIS-U-GLO

SAFETY FLAME CONFIRMATION

02/43

FIG. 4

ROTIS-A-GRATE

Patented ROTIS-A-GRATE

Ducane has a separate vertical heat source that

rotisses from behind the meat — the real way to rotis!

With Ducane’s patented ROTIS-A-GRATE

you can

put your sauce and seasoning in a pan under the meat

and it will self-baste by vaporization. No mess. No

flare-ups. No grease fires!

ROTIS-A-GRATE

is also much more efficient

because the heat is direct. Your cooking time is reduced

and you still use less than half the gas other rotisseries

use — only 12,500 BTUs. (See Fig. 4)

The ROTIS-A-GRATE

is made of a high-quality

stainless steel. Due to the heat of cooking, a

discoloration of the ROTIS-A-GRATE

is normal and

will not affect the ROTIS-A-GRATE

in any manner.

304 Grade Stainless Steel

SEAR GRID

Ducane grills come with our patented heat-trapping,

2-piece stainless steel SEAR GRID

Our stainless steel SEAR GRID

is unique within

the gas grill industry. This grid has been patented in the

United States and Canada.

The stainless steel SEAR GRID

is a 2-piece die

formed part with domed runners. (See Fig. 5) Each

runner traps and collects the heat of the briquettes

thus making your grill 30% more effective than other

cooking grids. The trapped heat within each runner

produces wide sear marks on the meat, thus sealing

in the meat’s juices.

The SEAR GRID

is made of a high quality stainless

steel. Due to the heat of cooking, a discoloration of the

SEAR GRID

is normal and will not affect the SEAR

GRID

in any manner.

IMPORTANT: Prior to initial use, preheat grill for

twenty minutes with the main burner(s) set on

High in order to assure a clean cooking surface.

The effectiveness of the SEAR GRID

is greatly

diminished by the build up of food deposits.

Keeping your SEAR GRID

clean is the best way of

keeping your SEAR GRID

hot.

FIG. 5

STAINLESS STEEL SEAR GRID

DOMED RUNNERS

02/33

Ducane

Permanent Briquettes

General Information

When placing the briquettes on the LA-VA-GRATE

place the rocks individually by hand. Do not pour them

from their shipping bag. We ask that the briquettes be

placed on the LA-VA-GRATE

by hand to prevent the

dust that settles in shipment from reaching the burner

box and clogging the burner ports. Place the briquettes

evenly across the surface of the LA-VA-GRATE

in a

single layer. The briquettes should be placed similar

to the pattern shown on Page 8; however, the

configuration may be changed to suit individual

preference. Using more than one layer of properly-

spaced briquettes will prevent heat from reaching the

cooking surface and will cause premature deterioration

of internal components. (See Fig. 7)

After installing the briquettes, you may have some

left over. Save any remaining pieces for future use.

WARNING:

Do not use charcoal briquettes or any

flammable material in place of the briquettes

supplied with your grill.

Do not place charcoal, wood chips or any

flammable material on the briquettes supplied with

your grill.

Use of such material other than permanent

briquettes will void your warranty and may lead

to a fire, explosion and bodily harm.

Care & Cleaning

There is very little! Ducane

briquettes will clean

themselves each time you preheat your grill. At most,

when they are cool, you can brush them with a stiff

bristle brush and vacuum them with your household

vacuum cleaner.

304 Grade Stainless Steel Patented

LA-VA-GRATE

All Ducane grills are equipped with a patented, high

temp stainless steel LA-VA-GRATE

. This grate-like

device is installed above the burner(s) and supports

the briquettes. The LA-VA-GRATE

is constructed of

two layers of offset “V”-shaped runners.

When properly installed, the bottom of the

“V”-shaped runners must point toward the burner.

(See Fig. 6)

The function of the LA-VA-GRATE

is to catch

and vaporize the juices which are not absorbed by the

briquettes while grilling, therefore eliminating the need

for a messy and unsightly grease container. For proper

operation, the grid must be level and preheated to

operating temperature. See preheating instructions

under Normal Operation section— Page 20.

FIG. 6

LA-VA-GRATE

BOTTOM OF

V-SHAPED

RUNNERS

ONE LAYER ONLY

LA-VA-GRATE

FIG. 7

02/33

DUCANE

Permanent Briquettes Placement

Instructions

Briquette configuration may be varied to change heat distribution as

required. To increase cooking temperature, simply remove one row of

briquettes, and spread out remaining ones to cover entire surface of LA-VA-

GRATE

Place — do not dump — the briquettes on LA-VA-GRATE

diagonally as

shown in larger picture above. Follow configuration shown for your

model, leaving approximately 1/2" between briquettes. Use the entire

surface of the LA-VA-GRATE

for briquettes.

IMPORTANT: Proper briquette spacing is necessary to establish the

SEAR GRID

temperatures required for grilling. If the briquettes are

touching or too close together, heat will be blocked from reaching

the SEAR GRID

1/2" SPACING

FOR MODEL SERIES 800,

1000, 1200 & 2000,

A MAXIMUM OF 41

PIECES REQUIRED.

FOR MODEL SERIES

1300, A MAXIMUM OF

54 PIECES REQUIRED.

FOR MODEL SERIES

1600, A MAXIMUM OF

70 PIECES REQUIRED.

FOR MODEL SERIES

1500, 4000 & 5000

A MAXIMUM OF 50

PIECES REQUIRED.

FIG. 8

BRIQUETTE CONFIGURATIONS

02/33

QUALITY

Assurance

At Ducane, all grill models must

meet our high quality standards.

All grills are leak tested, burners

are fire tested and component

parts are checked to ensure proper

and exact fits. These high quality

standards are to ensure your safety

and also your grilling enjoyment,

which we feel you should expect

from America’s finest gas grill.

• Keep grill cover clean. This

is your best protection against

mildew which will form on

any dirt or foreign material

allowed to accumulate on

tops or bottoms of fabric.

We recommend Armor All

concentrated cleaner for

safe and effective cleaning.

• Keep all shrubs and vines

away from grill cover as many

plants contain acids which

harm fabrics.

• Have any small tears or

punctures repaired promptly.

• Keep away from pets.

DO NOT

• Store a damp or wet cover.

Dry thoroughly first.

• Use wire or stiff brushes, harsh

detergents,abrasive cleaner or

chlorine on your grill cover.

• Drag cover over abrasive

surfaces, rocks, etc.

• Use high-pressure hoses or

steam to clean.

• Never spray cover with insect

repellents as insecticides can

stain and/or damage fabrics.

• Permit leaves, twigs or other

organic debris to remain

on cover.

• Keep a potted plant or store

anything on top of your grill

cover.

• Cover your grill while grill

is hot.

Ducane

Gas

Grill Cover

Helpful Hints

Care of Cabinets

n order to protect your grill from rust, we advise that you apply car wax

twice a year to all painted surfaces except for the burner box and hood. A light

coat of vegetable oil applied to the burner box and hood will highlight the black

finish. Apply when needed to maintain desired luster. Stainless steel bases can

be cleaned with a quick swipe of WD-40

and a soft rag. Do not apply this to

painted surfaces or internal parts.

Ducane

Utensil Rack/Towel Bar

Your grill comes with one or more chrome-plated utensil racks which

should be mounted on your side shelf frame. Use it for storage of your

cooking utensils or hand towels so everything is handy, but not in your

way while cooking.

Stainless Steel Hardware

(Nuts, Bolts & Screws)

The external hardware used in assembling your Ducane Gas Grill

is made of the finest material available for use in an outdoor environment.

The Great Cover-Up

Your cover will help in protecting your grill from the detrimental effects

of weather and outside pollutants. As with any outdoor product, however,

a cover is only as good as the maintenance given to the grill. Following the

recommended maintenance included in this manual will add greatly to the

life of your grill.

Ducane covers carry a limited 5-year warranty from the manufacturer

against splitting or cracking, but there are some common sense precautions

that a homeowner should take in caring for the vinyl covers. (See Page 9

for more hints.)

02/33

• Never pull your grill; always push it.

• Never move your grill while it is

in operation or still hot.

• Always use a protected hand

when cleaning the grid surface

after the post-heating period and

when closing propane tank valve.

• Use a covered hand during the

grilling period.

• Wait until the bottom casting has

cooled off before reaching under

to turn off the gas.

• Using an uncovered hand to turn

off the LP tank valve without

allowing the grill to cool down

could result in a severe burn.

• Never operate your grill under

overhangs, awnings or any

covered area.

• Never spray any liquid on the

SEAR GRID

area to control flare

ups.

• Never leave a grill unattended to

guard against possible grease fires

getting out of control (See Page

39). Grease fires can be severe

and cause grill damage, property

damage and bodily harm.

• Always turn off the control knob

first, then the propane gas supply

tank.

• Never cover your grill while it is

still warm.

• Position your portable grill away

from direct wind.

• Do not store or use gasoline or

other flammable substances in the

vicinity of your gas grill.

• Never store a propane tank —

whether full or empty — inside

your home or living area.

• Before storing your tank, make

sure that it has been turned to the

“OFF” position.

• Should you store your grill

indoors, be sure to close the tank

valve, disconnect the hose from

the tank, remove the tank from the

grill and store the tank outdoors.

• Make sure the grill hood is fully

open before lighting your grill.

• Do not operate your rotis

burners and main burners

at the same time.

• When connecting or replacing

any gas fittings, all joints must

be sealed with an approved,

leak-proof sealing compound.

• Never use an open flame when

testing for gas leaks.

• When your grill is not in use, it

is recommended that for child

safety, you remove the control

knobs and store them indoors.

• Never drill out the orifice or make

any other field alteration to your

grill without receiving approval

from Ducane

• Do not use charcoal briquettes,

wood chips or any flammable

material on top of or in place

of the briquettes supplied with

your grill.

• Do not store any flammable

materials in any cabinets beneath

the grill burner box or in the

vicinity of your grill.

• Be careful while handling any

parts during assembly. It is

strongly recommended that

you protect your hands with

a pair of work gloves.

Safety Tips

FOR YOUR DUCANE

GAS GRILL

Liquid

Propane Grills

Safety Tips

For liquid propane grills only,

Ducane supplies a cylinder valve

connection with thermo shut-off

feature and flow-limiting device.

In an effort to assure the safety

of the connection to the 20 lb.

propane tank, Ducane supplies a

Type 1 gas grill connection

coupling (See Pages 14-15 for

additional information). This

coupling eliminates the old

method wherein the grill owner

had to use a pipe wrench, or in

some cases an attached hand

wheel wrench, to connect the grill

to the propane tank.

The Type 1 coupling is not

only is much safer, but also

eliminates the possibility of

damaging the delicate fitting

that assures an airtight seal.

• Do not replace the Type 1

connection coupling

with any other style of

connection fitting.

• BE SURE TO HAVE

YOUR LP (PROPANE) TANK

FILLED BY A REPUTABLE

PROPANE DEALER. AN

INCORRECTLY FILLED OR

AN OVERFILLED LP TANK

CAN BE DANGEROUS.

02/33

Locating Your Grill

Your Ducane

Gas Grill is manufactured for use

outdoors only! Any grill, charcoal or gas, produces

carbon monoxide while in operation and this gas

should not be allowed to accumulate in a confined

area. Never operate the grill inside your home or

recreational vehicle or any enclosed area.

When locating your grill, choose a safe outdoor

location away from flammable or combustible surfaces

and out of traffic paths. Ducane strongly recommends a

six (6) foot clearance to combustible surfaces.

CAUTION:

Never operate your grill under

overhangs, awnings or any covered area such

as a gazebo or porch. When possible, adjust

your grill’s position to reduce the likelihood of

wind blowing directly onto it. (See Fig. 9)

CAUTION:

This grill is not intended to be installed

in or attached to a recreational vehicle. It is also

not intended to be installed in or on a boat.

It is very important on patio base and permanent

post installations that proper spacings are used during

the time of installation.

Consult your local codes for possible additional

restrictions on location or operation of your grill.

As your grill uses gas, it requires air to burn properly.

Do not locate your grill in such a manner or as to

obstruct the flow of combustion and ventilation air

around the grill.

WARNING:

For your safety, do not store or use

gasoline or other flammable vapors and liquids in

the vicinity of this or any other appliance. Failure

to follow this warning could lead to a fire,

explosion and bodily harm.

Assembly

Make sure your grill is assembled properly. Detailed

assembly instructions are packed with each grill, giving

specific assembly procedures for each model. Follow

these instructions carefully to ensure the correct and safe

assembly of the grill.

CAUTION: Although we take every effort to ensure

that the assembly process is as easy and as safe as

possible, it is inherent with fabricated steel parts

that corners and edges can cause cuts if improperly

handled during assembly procedures. Be careful

while handling any parts during assembly. IT IS

STRONGLY RECOMMENDED THAT YOU PROTECT

HANDS WITH A PAIR OF WORK GLOVES.

Leveling

It is important for the proper operation of the grill

that it be located on a level surface.

On permanent post and patio base installations, it is

important that the installation instructions detailing

how to level the grill have been followed.

FIG. 9

RECOMMENDED CLEARANCE: 6’ TO ANY

COMBUSTIBLE SURFACE,

MINIMUM 15”

Installation

LIQUID PROPANE GAS GRILLS

02/33

6’

02/43

FIG. 10

Type of Gas

Your LP grill is factory built to operate using liquid

propane only. Never attempt to operate your grill on

gases other than the type specified on the grill rating

plate.

The regulator supplied with your liquid propane

gas grill is set for 11" wc and is for use with propane

gas only. This regulator and the factory-supplied hose

assembly must be used when operating your grill with

a 20 lb. LP gas cylinder. If replacement of the hose

and/or regulator becomes necessary, factory-specified

parts are required.

For safety and design reasons, the conversion of a

Ducane grill from operation using LP gas to operation

using natural gas requires the change out of the entire

gas supply system of the grill. If this becomes necessary,

see your dealer for additional information.

Handling Liquid Propane Gas

Propane gas should be handled and stored with

care. We suggest asking your propane gas dealer, when

having your tank filled, for a short course in handling,

care and storage of propane gas tanks. Most dealers will

be glad to instruct you on how to store and handle

your tank. Make sure your tank is never stored inside!

Keep it outside in a well-ventilated area in an upright

position away from your gas grill.

Portable Installation

Complete portability is afforded to the grill head

when mounted on the portable cart. When so installed,

it is necessary to use a 20 lb. capacity liquid propane

tank. Use no other size. The tank retainer is designed

to accommodate only this size tank.

Type of Liquid Propane Tank

For LP gas grills, the LP gas supply cylinder to be

used must be constructed and marked in accordance

with the specifications for LP Gas Cylinders of the US

Department of Transportation (DOT) or the National

Standard of Canada, CAN/CSA-B339-88 Cylinders,

Spheres and Tubes for the Transportation of Dangerous

Goods. This tank must be provided with a shut-off

valve terminating in a liquid propane gas tank valve

outlet. The valve must be equipped with a Type 1

connection complying with 1.5.5 of the latest edition

of ANSI Z21.58.

The liquid propane tank supply system must:

(1) have a safety relief device having direct com-

munication with the vapor space of the tank;

(2) be arranged for vapor withdrawal;

(3) include a collar on the tank to protect the tank

valve; and

(4) be equipped with an overfill protection device

(OPD). The tank should be 12 inches in

diameter and 18-1/2 inches tall.

Installing Liquid Propane Tank

For console base models, lift the liquid propane

tank until the tank is about halfway into the console.

Slip the RING-TITE tank retainer over the tank and

carefully drop the tank into the center hole of the

console. Lock the retainer in place by slipping the

retainer ears into the slots in the console side panels

and pushing down. (See Fig. 10)

Connection

LIQUID PROPANE GAS GRILLS

HAND

WHEEL

EXTERNAL

THREAD

TYPE 1 VALVE

THERMALLY

SENSITIVE NUT

PROPANE

REGULATOR

Checking Gas

Leaks

Before operating your grill

and after refueling, check

carefully to be certain that all

connections are tight and there

are no gas leaks. The easiest

way to do this is to mix up a little

soapy water, like you would for

washing dishes. Turn on the gas

and brush a little of the mixture

around fittings. If new bubbles

form, you have a leak!

FIG. 11

WARNING:

The Type 1 connective coupling (See Fig. 11)

supplied with your grill must not be replaced with a different

type of grill/tank connection system. Removal will result in loss

of warranty and, if improperly done, will result in gas leakage,

fire and severe bodily harm.

The propane cylinder valve connection provided with this grill

incorporates the three important safeguards listed below.

Hand Assembly

1. Make sure the cylinder valve and all appliance valves are in their

“OFF” positions.

2. When connecting regulator/burner valve assembly to cylinder valve,

turn large plastic nut clockwise until it stops.

3. Gas will not flow unless plastic nut is fully engaged.

4. HAND TIGHTEN ONLY.

Type 1 Connective Coupling

All Ducane liquid propane gas grill regulators are equipped with a

UL-listed tank connection as per section 1.5.5 of the latest edition of

ANSI Z21.58. This will require a liquid propane tank that is similarly

equipped with a Type 1 connection in the tank valve

This Type 1 coupling allows you to make a fast and totally safe

hookup between your gas grill and your liquid propane tank. It

eliminates the chance of leaks due to a POL fitting that is not properly

tightened. Gas will not flow from the tank unless the Type 1 coupling

is fully engaged into the coupling.

02/33

Excess Flow Control

The propane regulator assembly incorporates a flow

limiting device designed to supply the grill with sufficient

gas flow, yet control any excess flow.

Rapid changes in pressure can trigger the flow limiting

device. If the cylinder valve is turned to allow gas flow

while a burner valve is open, the surge of pressure will

cause the device to activate. The device will remain closed

until the pressure is equalized. This should occur within a

5-second time frame. If the flame remains low, shut off

the gas valves, wait five seconds and relight grill one

burner at a time.

To ensure that this does not cause difficulty in lighting

the grill, follow these instructions:

1. Make sure all burner valves are “OFF.”

2. Open cylinder valve and wait 5 seconds.

3. Follow lighting instructions on Page 20.

Temperature-Activated Shut-Off

The large plastic nut on the regulator assembly is

designed in coordination with a check valve in the

cylinder valve to shut off the flow of gas when exposed to

temperatures between 240-300ºF.

In the event of a fire or hose break, one of the

safeguards will function to control or stop the flow of

gas from the propane cylinder. Never attempt to use

damaged equipment.

Gas Leak Checks

Never use a match or flame for leak detection. Use

soapy water or testing solution. Brush the solution

onto connection points and look closely for bubbles

indicating escaping gas. If leaks are detected, shut off

the main gas supply valve and securely retighten

connections, then repeat the leak test.

On cabinet models, perform this operation before

placing the tank into its storage compartment. After

placing the tank in the compartment, recheck the tank

to see if any connections were disturbed.

IMPORTANT: When connecting or replacing any

gas pipe or fittings, all joints must be sealed with

leak-proof sealing compound approved for use

with natural and propane gases.

After making connections, check all joints for

leaks using soapy water and a brush.

WARNING:

Never use an open flame when testing

for gas leaks. Use of an open flame could result in

a fire, explosion and bodily harm.

Liquid Propane Tank Safety Tips

Remember to handle your portable liquid propane

tank carefully when you take it to your dealer for a

refill. Avoid dropping it or bumping it against sharp

objects. Liquid propane tanks are sturdily constructed,

but a series of hard jolts could damage the container.

When transporting the tank to your local propane

gas dealer, make sure the valve is closed tightly and the

protective cover is in place. Prop the tank securely in an

upright position so it can’t roll around your vehicle.

If you plan to make stops for other shopping or

errands, have your liquid propane tank filled at the last

stop before going home. Again, see that the refilled

tank is secure in an upright position, and when you

return home, remove the refilled tank from your

vehicle. Never leave a portable liquid propane tank

inside a vehicle which may become overheated by

the sun.

Your local liquid propane gas dealer will gladly offer

you additional safety tips.

02/33

Store Liquid Propane Tank Safely

Whether you’re between cross-country treks in your

recreational vehicle or looking for a place to keep the

liquid propane tank that provides fuel for your outdoor

grill, keep in mind some basic safety rules about storing

portable liquid propane tanks.

Don’t store the tanks — whether full or empty —

inside your home, the living area of an R.V., a garage,

basement or workshop. It isn’t likely that liquid

propane will leak from the tanks, but if it should, the

fuel could be exposed to sparks from automobiles,

power tools or other appliances. When storing or

transporting your LP tank, it must remain in an upright

position. Never lie your LP tank down on its side

whether it is full or empty. Never store a spare tank

near your grill.

CAUTION:

Never transport or move your grill or

grill tank without first closing the manual valve

on your liquid propane gas tank.

The best place to store a liquid propane tank is in a

shady or protected spot outdoors, behind your home

or garage, or on a screened porch but where it is out of

reach of children. Liquid propane won’t evaporate,

because it’s in a strong, closed container. And it won’t

lose any of its clean-burning heat content, even if left

outside year-round.

WARNING:

When not connected to your grill, any

LP gas tank must be stored in an upright position

in a cool, shady, ventilated, outdoor location away

from your grill or any other heat source. Failure

to follow this warning could lead to tank valve

damage, a fire hazard and personal injury.

Filling a Propane Tank

It is extremely important that your LP tank be

filled properly when you take it to be refilled. Be sure

to use a reputable LP dealer and ask him (and watch, if

possible) how he fills the tank and knows when to stop.

An overfilled LP tank can be dangerous.

The proper way to fill a tank is by weight. The empty

tank should be placed on a scale and the scale weights

readjusted to a weight which would allow up to 80%

of the total weight of propane (LP) to be put into the

tank. When this weight is reached, the filling operation

must be ended. If the tank is not completely empty, the

scale readjustment must be changed to consider

the propane (LP) already in the tank.

WARNING: An LP (propane) tank is overfilled if it

contains more than 80% by weight of its total

capacity of propane (LP).

An incorrectly filled or an overfilled LP (propane)

tank can be dangerous. If a tank is overfilled and

the weather causes the warming of the LP tank,

(a hot day, tank left in sun or stored indoors) internal

pressure is created due to expansion of the propane

which in turn causes the LP gas to be released

through the pressure relief valve on the tank. The

pressure relief valve is a safety device required on

20 lb. propane tanks by the Department of

Transportation to prevent a catastrophic tank failure

due to excessive pressure. LP gas released from the

tank is flammable and can be explosive.

02/33

Installation

NATURAL GAS GRILLS

Locating Your Grill

Your Ducane

Gas Grill is manufactured for outdoor

use only! Any grill, charcoal or gas, produces carbon

monoxide while in operation and this gas should not

be allowed to accumulate in a confined area. Never

operate the grill inside your home or recreational

vehicle or any enclosed area.

When locating your grill, choose a safe outdoor

location away from flammable or combustible

surfaces and out of traffic paths. Selection of site

and proper clearances for permanent installations

are detailed in the assembly instructions. Ducane

strongly recommends a six (6) foot clearance to

combustible surfaces.

CAUTION:

Never operate your grill under

overhangs, awnings or any covered area such

as a gazebo or porch. When possible, adjust

your grill’s position to reduce the likelihood of

wind blowing directly onto it. (See Fig. 12)

It is very important on patio base and permanent

post installations that proper spacings are used

during the time of installation. On permanent post

installations, local soil conditions may warrant a

suitable coating to retard the effects of corrosion

conditions existing in your local area.

Consult your local codes for possible additional

restrictions on location or operation of your grill.

As your grill uses gas, it requires air to burn properly.

Do not locate your grill in such a manner or otherwise

obstruct the flow of combustion and ventilation air

around the grill.

WARNING:

For your safety, do not store or use

gasoline or other flammable vapors and liquids

in the vicinity of this or any other appliance.

Failure to follow this warning could lead to a

fire, explosion and bodily harm.

Assembly

Make sure your grill is assembled properly. Detailed

assembly instructions are packed with each grill giving

specific assembly procedures for each model. Follow

these instructions carefully to ensure the correct and

safe assembly of the grill.

CAUTION: Although we take every effort to ensure

that the assembly process is as easy and as safe

as possible, it is inherent with fabricated steel

parts that corners and edges can cause cuts if

improperly handled during assembly procedures.

Be careful while handling any parts during

assembly. IT IS STRONGLY RECOMMENDED

THAT YOU PROTECT HANDS WITH A PAIR OF

WORK GLOVES.

Leveling

It is important for the proper operation of the grill

that it be located on a level surface.

On permanent post and patio base installations, it is

important that the installation instructions detailing

how to level the grill have been followed.

FIG. 12

RECOMMENDED CLEARANCE

6’ TO ANY

COMBUSTIBLE SURFACE,

MINIMUM 15”

02/33

6’

Connection

NATURAL GAS GRILLS

Type of Gas

Your natural gas grill is factory built to operate using natural gas

only. Never attempt to operate your grill on gases other than the type

specified on the grill rating plates.

The regulator supplied with your natural gas grill is set for 3" wc and

is for use with natural gas only. This regulator and the factory supplied

hose assembly must be used when operating your grill. If replacement

of the hose and/or regulator becomes necessary, factory specified parts

are required. See your local dealer.

For safety and design reasons, the conversion of a Ducane grill from

operation using natural gas to operation using LP gas requires the

change out of the entire gas supply system of the grill. If this becomes

necessary, see your dealer for additional information.

What is Natural Gas?

Natural gas, often called methane, is a safe modern fuel. Natural gas

is supplied by your local utility and should be readily available if your

house is already heated with gas.

Portable Installation

Limited portability can be afforded to the grill head when mounted

on the portable cart. All grill heads mounted on this portable cart and

cabinet model grills so equipped can be moved about 12 feet away

from the main gas supply. Ducane recommends moving the grill at

least six (6) feet from the gas supply and any combustible surfaces.

(See Fig. 12)

After the gas supply has been run and checked for leaks in

accordance to the assembly instructions, you are ready to grill. To

connect the hose to the gas supply, pull back the outer fitting, insert

the hose fitting all of the way, and release the outer fitting. This process

will produce a gas joint. (See Fig. 13)

Follow special storage instructions located in the Helpful Hints

section of this manual (See Page 25) for proper care of your grill and

its gas hose.

Natural Gas

Installer’s

Guide

This guide is a recommend-

ation for natural gas installa-

tions. It advises the installer

as to the size tubing that is

necessary on a natural gas

installation depending on how

far the grill is located from

the house.

Distance Tube Size

1-25 feet 3/8"

26-50 feet 1/2"

51-100 feet 2/3 of

the run 3/4"

down to 1/2"

101 feet

or more 3/4"

All tubing should be anti-

corrosive tin-lined copper

or an AGA-approved alternate.

Operating pressure of the grill is

3" wc. This should be verified

after the installation is complete.

Comparably sized black iron

pipe is also acceptable for

natural gas lines.

02/43

Permanent Installation

The natural gas grill head is compatible for use on

the permanent post mount, or the patio base mount.

This type of installation is used when a fixed piping

system is desired for connection to the main gas

supply. (See Fig. 14)

After installation and leak checks have been

completed in accordance with the instruction manual,

your grill is available for use. The natural gas will

automatically be supplied to your grill every time

you turn on your grill.

IMPORTANT: 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-B149.1; Natural Gas

Installation Code or CAN/CGA-B149.2, Propane

Installation Code.

Gas Leaks Checks

Before operating your grill, check carefully to be

certain that all connections are tight and there are

no gas leaks. Never use a match or flame for leak

detection. Use soapy water or testing solution. Brush

the solution on to connection points and look closely

for bubbles indicating escaping gas. If leaks are

detected, shut off the main gas supply valve and

securely retighten connections, then repeat the leak test.

CAUTION:

The appliance and its individual

shutoff valve must be disconnected from the gas

supply piping system during any pressure testing

of that system at test pressures in excess of 1/2

psig (14" wc).

CAUTION:

The appliance must be isolated

from the gas supply piping system by closing

its individual manual shutoff valve during any

pressure testing of the gas supply piping system

at test pressures equal to or less than 1/2 psig

(14" wc).

MALE CONNECTION

FLARE UNION

SWIVEL

CONNECTION

SHUT OFF

VALVE

WHEN PROPERLY ASSEMBLED THE PLUG CANNOT BE

REMOVED WITHOUT PUSHING THE SLEEVE BACK.

TO DISCONNECT, PUSH SLEEVE BACK AND PULL OUT

PLUG. (THIS AUTOMATICALLY SHUTS OFF GAS.)

FIG. 13

FLOW

PUSH

SLEEVE

BACK

SLEEVE

PLUG

SOCKET

COAT THIS PIPE NIPPLE

WITH GAS RESISTANT

PIPE DOPE.

NATURAL GAS

REGULATOR

INSTALL COVERS

WHEN HOSE IS

DISCONNECTED.

PUSH PLUG UNTIL SLEEVE SNAPS FORWARD

LOCKING PLUG IN SOCKET.

(THIS TURNS ON GAS AUTOMATICALLY.)

02/43

IMPORTANT: When connecting or replacing any

gas pipe or fitting, all joints must be sealed with

leak proof sealing compound approved for use

with natural and propane gases.

After making connections, check all joints for

leaks using soapy water and a brush.

WARNING:

Never use an open flame when testing

for gas leaks! Use of an open flame could result in

a fire, explosion and bodily harm.

PERMANENT POST

REGULATOR/TUBING

CONNECTION

PATIO BASE

REGULATOR/TUBING

CONNECTION

NATURAL GAS

REGULATOR

FLARE CONNECTOR WITH TUBING

FIG. 14

ADAPTER

ELBOW

FLARE CONNECTOR

WITH TUBING

FLARE UNION

SEALING COMPOUND

REQUIRED

DO NOT USE

SEALING COMPOUND

02/33

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Ducane 04 Series Owner's manual

Brand: Ducane

Model: 04 Series

Category: Barbecues & grills

Type: Owner's manual

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