Ducane 455, 545 User Manual

ASSEMBLY GUIDE

455 INCH² 3-BURNER & 545 INCH² 3-BURNER

 DANGER

If you smell gas:

1. Shut off gas to the appliance.

2. Extinguish any open flames.

3. Open lid.

4. If odor continues, keep away from the appliance and immediately call your gas supplier or your fire department. Leaking gas may cause a fire or explosion which can cause serious bodily injury or death, or damage to property.

 WARNING

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.

 WARNING Follow all leak-check procedures carefully

in this manual prior to barbecue operation. Do this even if the barbecue was dealerassembled.

Customer Service: 1-800-382-2637

NOTICE TO INSTALLER These instructions must be left with the owner

and the owner should keep them for future use.

THIS GAS APPLIANCE IS DESIGNED FOR OUTDOOR USE ONLY.

 WARNING Do not try to light this appliance without

reading the “Lighting” Instructions section of this manual.

NOTE: Standard LP, Natural Gas and System LP are designed for use with a Ducane® portable cart.

SAVE THESE INSTRUCTIONS FOR

FUTURE REFERENCE

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Important

This grill head is designed to be mounted only on a Ducane® base cabinet kit. DO NOT attempt to mount on any other type of base cabinet or in any other manner.

Read all instructions before proceeding with any assembly. For an assembly view and veriﬁcation of parts, see the parts list and expanded view of pages 13-15.

Installation

NOTE: Your model may differ from those in the assembly photos.

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 CAUTION: Although we make 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 HANDS BE PROTECTED WITH A PAIR OF WORK GLOVES.

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 WARNING: Care must be taken to ensure that this grill is assembled according to these instructions. Failure to assemble the grill properly could create a ﬁre hazard or cause burns or other bodily harm.

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ASSEMBLY

1. Assemble selected base cabinet kit before proceeding with these instructions.

2. Open the hood and remove the bubble wrapped side shelf package(s), Sear Grid package, and accessory package.

3. With the hood open, remove the hairpin clips from the hinge clevis pins (a). Close the hood and slide clevis pins from the hood hinges (b). Lift the hood from the burner box and place it on a nonabrasive surface.

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3. (a)

3. (b)

4. Using the hex head screws and split lock-washers from the hardware bag, attach the two hood knobs to the outside of the grill hood in the location shown. Tighten screws from the inside rather than turning the knob, to avoid scratching paint.

5. Remove the Rotis-A-Grate® and the La-Va-Grate® from the burner box and position the box on the previously assembled base cabinet kit.

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6. Attach the burner box to the base cabinet using the four (4) 1/4x20x1" pointed

screws and the four (4) 1/4

teﬂon washers from the base cabinet kit (a). The screws with the washers directly underneath go through the four holes in the bottom of the burner box and engage in the caged nuts in the top of the

base cabinet (b). Engage all 4 screws before tightening any of the four (c). In order to get the screws in the mounting holes of some grill models, it may be necessary to carefully rotate the burners out of the way of the holes. Unscrew the burner locking screw to release the burner.

6. (a)

6. (b)

6. (c)

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 CAUTION: The screws used to attach the grill burner box to the base cabinet must be tightened securely but not overly tight. The Teﬂon washers used with these screws are very slippery and could lead to over-tightening these screws. Care should be taken to avoid compressing the washer or cracking the burner box.

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 CAUTION: BE CAREFUL NOT TO PULL THE BURNERS OFF THE ORIFICES OR TO DISCONNECT THE IGNITION WIRES.

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7. Before retightening the burner locking screw (a), (b), be sure the burners are correctly engaged over their respective oriﬁces. This can be done by removing the control box or by viewing the burner/oriﬁce engagement from beneath the control box (c).

Burner Locking Screws

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Important

When connecting or replacing any gas pipe ﬁttings, all joints must be sealed with a joint compound (pipe dope) that is resistant to the action of (LP) gases.

7. (a)

7. (b)

7. (c)

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 WARNING: FAILURE TO CHECK PROPER BURNER ORIFICE ENGAGEMENTS COULD LEAD TO A HAZARDOUS CONDITION AND BODILY HAR

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