Ducane 04 Series, 05 Series, 1605SS Owner's Manual
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.
2
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.
3
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 TOPPORTED™ 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
4
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
5
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 sidemounted 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
6
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 properlyspaced 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.
7
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
8
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-VAGRATE®.
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.
9
DO
• 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
I
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
10
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
11
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
12
HAND
WHEEL
EXTERNAL
THREAD
TYPE 1 VALVE
THERMALLY
SENSITIVE NUT
PROPANE
REGULATOR
13
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
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