ASSEMBLY GUIDE
455 INCH² 3-BURNER & 545 INCH² 3-BURNER
Customer Service: 1-800-382-2637
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 dealer-
assembled.
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.
NOTE: Standard LP, Natural Gas and
System LP are designed for use with a
Ducane® portable cart.
WARNING
Do not try to light this appliance without
reading the “Lighting” Instructions section of
this manual.
SAVE THESE INSTRUCTIONS FOR
FUTURE REFERENCE
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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.
3. (b)
3. (a)
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.
4.
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.
5.
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4
"
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. (b)
6. (a)
6. (c)
____________________________________________________________________
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.
____________________________________________________________________
____________________________________________________________________
CAUTION: BE CAREFUL NOT TO PULL THE BURNERS OFF THE ORIFICES OR
TO DISCONNECT THE IGNITION WIRES.
____________________________________________________________________
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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. 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
7. (a)
7. (b)
7. (c)
____________________________________________________________________
WARNING: FAILURE TO CHECK PROPER BURNER ORIFICE ENGAGEMENTS
COULD LEAD TO A HAZARDOUS CONDITION AND BODILY HARM.
____________________________________________________________________
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8. FOR NATURAL AND SYSTEM LP GRILLS. Install the Natural Gas (or System
LP) regulator/hose assembly on to the grills manifold supply pipe. To make the
connection, pull back the outer sleeve of the socket connector, (at the end of the
regulator/hose assembly), and insert all the way the male plug connection, (on the
grills manifold), and then release the outer sleeve of the socket connector. This will
produce a gas joint. After making gas connections, check all joints for leaks using
soapy water and a brush. See Owner’s Guide for more on Natural Gas (or System
LP) installation.
8.
After making gas connections, check all joints for leaks using soapy water and
a brush.
____________________________________________________________________
WARNING: NEVER USE AN OPEN FLAME TO TEST FOR GAS LEAKS.
____________________________________________________________________
9. Assemble the side shelf frame(s) using four (4) #8 x 1 1/2 Phillip’s flat head screws
(a-c). Depending whether your model has one or two side shelves, attach the side
"
shelf to either or both sides of the burner box, using four (4) 1/4 x 1 1/4 black
screws, 1/4-20 nuts, and stainless steel shelf support washers (oval, with two holes).
The washers should go on the inside of the burner box with the raised rib side
facing away from the surface of the burner box (d). The nuts go on the inside of
the burner box. Tighten all four nuts securely (e).
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9. (a)
9. (c)
9. (e)
9. (b)
9. (d)
____________________________________________________________________
WARNING: FAILURE TO INSTALL THE SIDE SHELF FRAME PROPERLY
COULD CAUSE THE SHELF TO LOOSEN AND FALL, CAUSING BODILY HARM.
____________________________________________________________________
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Side-Order Cooker® installation. If your grill does not have a
Side-Order Cooker® go to step 16.
10. Remove Side-Order Cooker® packaging and remove contents.
10.
11. Facing the front of the barbecue hold the front of the Side-Order Cooker®
(control knobs in front) towards you.
11.
12. Slide the left side flange into the shelf opening, towards the burner box, and
then push the right side of the Side-Order Cooker® down into place. This action
engages the two spring locks on the right side of the Side-Order Cooker®.
12.
12.
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Important
Do this before attaching clip
to side table.
13. To install the provided hose retention clip:
a. Push the female quick disconnect through the retention clip.
NOTE: The orientation of the clip hole. This will be a tight fit, but it is
needed to best secure the hose.
13a.
b. Now attach the hose retention clip to the side table using the screw provided.
13b.
____________________________________________________________________
WARNING: FAILURE TO HAVE THE HOSE IN THE HOSE RETENTION CLIP MAY
RESULT IN AN EXPLOSIVE FLAME-UP, WHICH CAN CAUSE SERIOUS BODILY
INJURY OR DEATH.
____________________________________________________________________
14. To connect the gas line:
a. Pull back collar on the quick disconnect at the end of the gas hose.
14a.
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b,c. Push quick disconnect over plug coming down from Side-Order Cooker® and
slide collar forward locking it into place.
14b.
14c.
15. Remove any white protective coating from the stainless steel surfaces of the
Side-Order Cooker®.
16. Replace the Rotis-A-Grate® at the rear of the burner box by lowering it over the
Rotis burner, and hooking the supports on the back of the Rotis-A-Grate® over the
rear edge of the burner box. Reinstall the La-Va-Grate® into the burner box by first
placing the front edge of the La-Va-Grate® on the lower set of supports on the front
of the burner box. Holding the flange (with the “arrow” shaped cut-out) on the rear
of the La-Va-Grate®, rotate the rear edge down so that it rest on the lower “shelf”
of the Rotis-A-Grate®. The “arrow” on the rear flange should be pointing up.)
16.
17. Carefully put the hood back on the burner box and refasten with the clevis pins
and hairpin clips.
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18. Place the briquettes in a pattern filling the entire La-Va-Grate®. Spacing should
"
"
be 3/8 -1/2 between briquettes.
18a.
18b.
455 Inch² 3-Burner
545 Inch² 3-Burner
19. Attach the Rotis motor mounting bracket to the left side of the burner box, using
the three black #10 truss head screws and acorn nuts. The bracket goes inside the
firebox, with the “U” shaped motor mount facing to the outside of the grill. The
acorn nuts go to the inside of the burner box. Tighten the fasteners finger tight,
then insure that the hood will close without hitting the motor mount. Reposition
the mount as necessary to clear the hood, then tighten all three fasteners securely.
19.
20. Carefully place Sear Grid®(s) onto the upper set of supports on the front of the
burner box and the upper shelf of the Rotis-A-Grate® at the rear.
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21. Assemble the meat hooks and handle to the spit rods as shown. Open the hood,
slide rotis motor over the motor mount and insert the spit rod. Refer to the
Owner’s Manual and the Cookbook for additional information on using the rotis.
21.
____________________________________________________________________
CAUTION: The rotis motor must be stored indoors when not in use. DO NOT
leave it mounted to the grill.
____________________________________________________________________
22. The regulator assembly shipped with the grill head must be used.
23. Refer to the Owner’s Manual for use of the Side-Order Cooker®.
24. Refer to the Owner’s Manual for proper LP tank handling procedures.
25. Refer to the Owner’s Manual for the proper use and care of your gas grill.
26. For natural and for system LP grills, refer to Owner’s Manual for proper
procedures for connecting to the gas supply.
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Gas Grill Parts List
455 Inch² 3-Burner & 545 Inch² 3-Burner
Model Grill
455 INCH²
3-BURNER
545 INCH²
3-BURNER
Part Number
Qty.
2
Part Number
Qty.
2
Key
1
Part Description
Hood Knob
G1125350
B1008919
T1009088
20172301
20174203
20172201
21072501
20116811
20337403
20177203
G1125350
B1008919
T1009088
20172302
20174204
20172202
21072503
20116812
20337404
2
3
Lockwasher
2
2
1/4-20 x 1/2 Hex Head Screw
Sear Grid® Set (2 Pieces Per Set)
Hood with Nameplate
Briquettes
2
2
4
1
1
5
1
1
6
1
1
7
La-Va-Grate®
1
1
8
Burner Box Sub-Assembly
Burner, Rotis-A-Grate®
1
1
9
1
1
10a
Burner, Right Hand “P” Style (455 Inch² 3-Burner Only)
1
-
Includes 25 & 26
10b
11a
11b
Burner, Left Hand “P” Style (455 Inch² 3-Burner Only)
Includes 25 & 26
20177204
1
-
-
Burner, Right Hand “S” Style (545 Inch² 3-Burner Only)
Includes 25 & 26
20524704
20524703
1
1
Burner, Left Hand “S” Style (545 Inch² 3-Burner Only)
-
Includes 25 & 26
12
13
14
15
16
17
18
19
19
20
20
21
21
21
23
Hair Pin Clip
G1026609
20175601
20174801
20173203
20182601
20174901
20175102
20175402
20175401
G1031102
G1026743
20104302
G1827628
G1827584
20525201
2
2
1
3
1
1
1
3
3
2
2
1
1
1
2
G1026609
20175601
20174801
20173203
20182601
20174901
20175201
20175402
20175401
G1031353
G1031095
20104302
G1827628
G1827584
20525201
2
2
1
3
1
1
1
3
3
2
2
1
1
1
2
Clevis Pin
Control Box
Control Knob
Igniter Knob
Manifold Support, Upper w/Gasket
Manifold Assembly w/Gasket
Gas Valve-Natural Gas
Gas Valve-LP & System LP
Gas Orifice, Main Burner-Natural Gas
Gas Orifice, Main Burner-LP & System LP
LP Regulator w/Type I Connector and Hose
Natural Gas Regulator
System LP Regulator
Burner Locking Screw #10 x 1/2 Hex Head (SS)
(Not Shown)
24
Rotary Igniter
20182501
1
20182501
1
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Gas Grill Parts List
455 Inch² 3-Burner & 545 Inch² 3-Burner
Model Grill
455 INCH²
3-BURNER
545 INCH²
3-BURNER
Part Number
Qty.
2
Part Number
Qty.
2
Key
25
Part Description
Electrode & Collector Box Assembly
(Includes A-D Below)
G4313758
G4313758
A
B
Main Burner Electrode
#8 x 3/8 Hex Washer Head Screw (SS)
Collector Box
G1129990
20187001
G4163670
G4163698
G4313301
G1031406
20171601
20171701
G4313794
G1031102
G1026743
20118502
G4260574
G4260583
20176201
G0627006
G1129418
G4313696
G1130004
G4309147
G1026547
G1026538
20176401
B1015956
B1015965
G1026305
B1008062
20176501
B1008704
20103903
G1026789
1
3
G1129990
20187001
G4163670
G4163698
G4313301
G1031406
20171601
20171701
G4313794
G1031102
G1026743
20118602
G1260574
G4260583
20176202
G0627006
G1129418
G4313696
G1130004
G4309147
G1026547
G1026538
20176401
B1015956
B1015965
G1026305
B1008062
20176501
B1008704
20103903
G1026789
1
3
C
1
1
D
Collector Boxstrap
1
1
26
27
28
29
30
31
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
Glow Wire
2
2
5/16-18 Self Tapping Screw
Side Shelf
2
2
2
2
Side Shelf Frame
2
2
Cooking Shelf
1
1
Gas Orifice, Rotis Burner-Natural Gas
Gas Orifice, Rotis Burner-LP & System LP
Rotis-A-Grate®
1
1
1
1
1
1
Left Hand Spit Rod Support
Right Hand Spit Rod Support
Spit Rod
1
1
1
1
1
1
Spit Motor
1
1
Spit Rod Handle
1
1
Meat Hook Set (2 Per Set)
Rotis-A-Grate® Electrode
Smoke-It Tray®
1
1
1
1
1
1
#10 Acorn Nut
8
8
#10 Truss Head Screw
Shelf Support Backing Plate
1/4-20 x 1 1/4 Screw, Black
1/4-20 Hex Nut
8
8
4
4
8
8
8
8
#10 x 1/2 Hex Washer Head Screw (SS)
#10 x 5/8 Hex Washer Head Screw
Angle Supply Line Support
Electrode Bracket Screw
Shelf Assy. Screw (#8 x 1 1/2) (Not Shown)
2
2
6
6
1
1
1
1
4 (8)
1
4 (8)
1
"
"
1/8 x 3/8 NPT Bushing-Natural Gas and
System LP
"
"
52
53
54
1/8 x 1 1/2 Pipe Nipple-Natural Gas and
System LP
G1031380
G1031166
G4309129
1
1
1
G1031380
G1031166
G4309129
1
1
1
"
1/8 NPT Pipe Coupling-Natural Gas and
System LP
Rotis Pan (Not Shown)
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© 2004 Ducane Products Co., 1656 Fuldner Road, Barnwell, South Carolina 29812. DUCANE is a registered trademark of
Weber-Stephen Products Co. Used with permission. This product may be covered under various patents throughout the world.
20211810
01/24/05
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