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mDANGER Failure to follow the Dangers, Warnings and Cautions contained in this Owner’s Manual may result in serious bodily injury or death, or in a fire or an explosion causing damage to property. mWARNINGS m Do not store a spare or disconnected LP tank under or near this barbecue. m Improper assembly may be dangerous. Please carefully follow the assembly instructions in this manual. m After a period of storage, and/or nonuse, the Weber Gas Barbecue should be checked for gas leaks and burner obs
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WARRANTY Weber-Stephen Products Co. (Weber) hereby There are no other express warrants except as warrants to the ORIGINAL PURCHASER of this set forth herein and any applicable implied Weber Gas Barbecue that it will be free of warranties of merchantability and fitness are defects in material and workmanship from the limited in duration to the period of coverage of date of purchase as follows: this express written Limited Warranty. Some states do not allow limitation on how long an Aluminum Casti
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PATENTS AND TRADEMARKS © 1998 Weber. Weber, , Genesis, Flavorizer and Crossover are registered U.S. trademarks; Perma-Mount, Gas Catcher, FlameCheck, Steam-N-Chips, Spider Stopper, and Warm-Up are U.S. trademarks of Weber-Stephen Products Co., 200 East Daniels Road, Palatine, IL 60067-6266. U.S.A. Genesis Gas Barbecues are covered under the following patent nos.: U.S.A. #4,677,964; 4,727,853; #4,777,927; #4,829,978; #4,860,724; #4,941,817; #4,966,125; #5,070,776; #D293,067; #D316,355; Canada:
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f Contents Troubleshooting & Maintenance WARNINGS................................................................ 2 Annual Maintenance ........................................ 31 Warranty & Patents.................................................. 3-4 General Maintenance.................................. 32-34 General Instructions.................................................... 6 Troubleshooting .......................................... 35-36 Assembly .......................................
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General Instructions Your Weber Gas Barbecue is a portable outdoor cooking Storage appliance. With the Weber Gas Barbecue you can grill, n The gas must be turned OFF at the LP tank when the barbecue, roast and bake with results that are difficult to Weber Gas Barbecue is not in use. duplicate with indoor kitchen appliances. The closed lid and Flavorizer Bars produce that "outdoor" flavor in the food. n When the Weber Gas Barbecue is stored indoors, the gas supply must be disconnected and the LP
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® ® ® ® ® ® ® ® Step 1 Assembly Check package contents Tools needed Regular screwdriver Cooking box (assembly) Phillips screwdriver Hammer 7/16 inch or an adjustable wrench Lid (assembly) Pliers Block of wood LP tank Supplies needed Your LP tank is shipped empty for safety. After setting the LP fuel scale you will need to fill it. (See Step "Fill LP tank.") You will need a soap and water solution to check for gas LP tank filler adapter leaks. (See Step "Check for gas leaks.") Note - The hardw
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R R E E B B E E W W Right frame Control panel Front panel Caster frame Left frame Two casters Wheel frame Spacer Bracket Two frame connectors Two cooking grates Tank panel assembly Warming rack Five long Flavorizer Bars Warm-Up Basket Eight short Flavorizer Bars Thermometer Two wheels Left hand slide bar assembly Two aluminum drip pans Assembly consists of: Catch pan Left hand slide bar Support Axle Slide 8 R R E E B B E E W W
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Fuel scale assembly Two wheel hubcaps (actual size) Catch pan holder Two hinge pins (hardware size: 1/4 x 1 1/2 inch clevis pin) (actual size) Manifold bracket Five 1/4-20 x 2 inch bolts (actual size) Side burner assembly Six 1/4-20 x 1/2 inch bolts (actual size) Two 1/4-20 wing nuts (actual size) Burner grate Two 10-24 x 1 3/4 machine screws (actual size) Two side burner locks Note: The locks are taped to the inside Two 10-24 hex nuts of the side burner lid. (actual size) Side burner knob Eigh
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R E B E W Step 2 Step 3 Assemble wheels Assemble frame You will need: axle, two wheel hubcaps, two wheels, wheel You will need: left frame, right frame, two nylon washers, frame, hammer and a block of wood. two 1/4-20 x 1/2 inch bolts and a 7/16 inch wrench. Place one end of the axle on the block of wood (or other Note - Work on carpeted area (on grass, or on one of the protected surface). Tap on one hubcap. boxes) to protect the finish during frame assembly. Put one wheel on the axle, WEBER sid
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Step 4 Step 5 Continue frame assembly Complete frame assembly You will need: frame assembly, wheel frame assembly, You will need: partial frame assembly, two frame front panel, caster frame, four 1/4-20 x 1/2 inch bolts, connectors, four 1/4-20 x 2 inch bolts, four nylon four nylon washers and a 7/16 inch wrench. washers and a 7/16 inch wrench. Place the caster frame onto the tabs of the left frame with Hold one frame connector between the caster and wheel the dimple to the inside. Figure 3. Pl
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Slide the cooking box to the left within the frame. Put the Step 7 washer on the bolt. Take the spacer bracket and hold it up Install side burner locks to the frame making sure both tabs fit underneath the frame cross piece. Figure 8 (a). Insert the bolt through the center Note: The locks are taped to the inside of the side hole in the spacer bracket, frame and cooking box with the burner lid. head of the bolt outside the spacer bracket. Figure 8 (b). You will need: frame assembly, two side burn
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Your Weber Gas Barbecue burner assembly has been Step 9 factory assembled, pressure and flame tested. As a safety Install tank panel assembly precaution we recommend you check the burner alignment: You will need: tank panel assembly, 1/4-20 x 1 1/4 inch a) Do the valves fit into the ends of the burners? Figure 9(a). bolt, 1/4-20 hex nut, nylon washer and a 7/16 inch wrench. b) Are the ends of the burners under the washers at the Insert the tank panel tabs into the slots in the frame brace. left
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E F Step 10 Step 11 Add fuel scale Install igniter You will need: fuel scale, two 1/4-20 wing nuts and two Note - The igniter wires are already attached to the Gas nylon washers. Catcher Ignition Chamber and the igniter. This was done to factory test the ignition system. Slip the bolts on the back of the fuel scale assembly through the two small holes in the tank panel. Make sure indicator The igniter lock nut is on the igniter. rod of fuel scale is on the left side of the wheel frame. Insert t
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Step 13 Step 14 Install side burner Install manifold bracket You will need: side burner assembly, burner grate, and You will need: manifold bracket manifold bracket. Hook the bracket onto the manifold at the center burner valve. Figure 15. Place your hand underneath the bracket. mWARNING: Make sure gas supply is OFF. Lift the bracket, manifold and cooking box slightly as a unit Slide the side burner assembly into the open end of the and hook onto the frame brace. right frame. Route the side burn
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E F E E F F Step 15 Step 16 Set LP fuel scale Fill LP tank You will need: LP tank (empty). Note - The LP tank manufacturer is responsible for the materials, workmanship and performance of the tank. If Note - For accuracy, the fuel scale must be set with an the tank has a defect, malfunctions, or you have a empty tank. question regarding the tank, call the tank manufacturer's We utilize various LP tank manufacturers. Some of the customer service center. The phone number is on the tanks we receive
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E F Route the hose so it will not interfere with the scale Step 17 indicator rod. Connect LP tank The hose and regulator are connected in the following mWARNING; Make sure that the LP tank valve is manner: closed. Close by turning clockwise. Slide back the collar of the quick disconnect on the tank Hook the LP tank onto the fuel scale. Loosen the tank lock valve. Push the male fitting of the regulator into the quick wing nut. Swing the tank lock down. Tighten the wing nut. disconnect, and maint
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E E F F Step 18 mWARNING: Do not ignite burners while leak checking. Check for leaks by wetting the connections with the soap Check for gas leaks and water solution and watching for bubbles. If bubbles form or if a bubble grows there is a leak. m DANGER Do not use an open flame to check for gas Check: leaks. Be sure there are no sparks or open a) Hose to manifold connection. Figure 21 (a). flames in the area while you check for b) Regulator to tank connection. Figure 21 (b). leaks. This will re
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Step 19 Step 20 Install Flavorizer Bars and Cooking Grates Install the bottom tray You will need: five long Flavorizer Bars, eight short You will need: bottom tray, catch pan holder, catch pan and Flavorizer Bars and two cooking grates. one drip pan. Set the long Flavorizer Bars side to side in the lower position, then set the short Flavorizer Bars front to back in the upper position in the cooking box. Figure 22. Finger grip on front Front side of catch edge of bottom tray pan holder Figure 24
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Step 21 Step 22 Install the lid Install tool holders, control panel and burner control knobs You will need: lid, two hinge pins and two hair pin cotters. You will need: three tool holders, control panel, two Phillips Set the lid in place from the rear of the barbecue. Close screws/washers, a Phillips screwdriver, and three burner and align the hinge at the rear. Insert hinge pins from the control knobs. outside through the hinge. Insert hair pin cotters into the small holes in the hinge pins. Fi
