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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 © 1997 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. Printed in the U.S.A. 4
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f Contents Troubleshooting & Maintenance WARNINGS................................................................ 2 Annual Maintenance ........................................ 28 Warranty & Patents.................................................. 3-4 General Maintenance.................................. 29-31 General Instructions.................................................... 6 Troubleshooting ............................................... 32 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 Supplies needed LP tank 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 leaks. (See Step "Check for gas leaks.") Note - The hardware size of nuts, bolts
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R R E E B B E E W W Control panel Right frame Front panel Caster frame Left frame Two casters Wheel frame Two cooking grates Two frame connectors Warming rack Tank panel assembly Warm-Up Basket Five long Flavorizer Bars Thermometer Eight short Flavorizer Bars Left hand slide bar assembly Two wheels Assembly consists of: Left hand slide bar Two aluminum drip pans Support rod Catch pan Slide Axle 8 R R E E B B E E W W
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Fuel scale assembly Five 1/4-20 x 2 inch bolts (actual size) Six 1/4-20 x 1/2 inch bolts Catch pan holder (actual size) Two 1/4-20 wing nuts (actual size) Manifold bracket Two 10-24 x 1 3/4 machine screws (actual size) Spacer bracket Two 10-24 hex nuts (actual size) Check contents of hardware packs Eighteen 1/4 inch nylon washers (actual size) Three burner control knobs 1/4-20 keps nut Three tool holders 1/4-20 x 1 1/4 inch bolt (actual size) 1/4-20 hex nut Five tubing plugs (actual size) (two a
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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, You will need: left frame, right frame, two nylon washers, wheel 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, four connectors, four 1/4-20 x 2 inch bolts, four nylon 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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Your Weber Gas Barbecue burner assembly has been Step 7 factory assembled, pressure and flame tested. As a safety Add cooking box precaution we recommend you check the burner alignment: You will need: frame assembly, cooking box assembly, a) Do the valves fit into the ends of the burners? 1/4-20 x 2 inch bolt, 1/4 inch nylon washer, 1/4-20 keps Figure 8 (a). nut, pliers and a 7/16 inch wrench. b) Are the ends of the burners under the washers at the Turn frame assembly right side up. left rear a
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Step 8 Step 9 Install manifold bracket Install tank panel assembly You will need: manifold bracket You will need: tank panel assembly, 1 1/4 inch bolt, 1/4-20 hex nut, 1/4 inch nylon washer and a 7/16 inch Hook the bracket onto the manifold at the center burner wrench. valve. Figure 9. Place your hand underneath the bracket. Lift the bracket, manifold and cooking box slightly as a unit Insert the tank panel tabs into the slots in the frame brace. and hook onto the frame brace. Slide up until th
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E F Step 10 Step 11 Add fuel scale assembly Install igniter Note - The igniter wires are already attached to the Gas You will need: fuel scale, two 1/4-20 wing nuts and two Catcher Ignition Chamber and the igniter. This was done to nylon washers. 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.
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E F E E F F Step 12 Step 13 Set LP fuel scale Fill LP tank Note - The LP tank manufacturer is responsible for the You will need: LP tank (empty). 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 14 indicator rod. Check that the burner valves are off The hose and regulator are connected in the following You will need: one burner control knob. manner: Valves are shipped in the OFF position, but you should Slide back the collar of the quick disconnect on the tank check to be sure. Put the knob on each valve. Check by valve. Push the male fitting of the regulator into the quick pushing down and turning clockwise. If they do not
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E E F F Check: Step 16 a) Hose to manifold connection. Figure 18 (a). Check for gas leaks b) Regulator to tank connection. Figure 18 (b). m DANGER mWARNING: If there is a leak at connection (a), Do not use an open flame to check for gas retighten the fitting with a wrench and recheck for leaks. Be sure there are no sparks or open leaks with soap and water solution. flames in the area while you check for If a leak persists after retightening the fitting, turn OFF leaks. This will result in a fire
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Step 17 Step 18 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 19. Finger grip on front Front side of catch edge of bottom tray pan holder Figure 2
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Step 19 Step 20 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 Set the lid in place from the rear of the barbecue. Close and Phillips screws/washers, a Phillips screwdriver, and three align the hinge at the rear. Insert hinge pins from the burner control knobs. outside through the hinge. Insert hair pin cotters into the small holes in the hinge pins. F
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Insert one end of the hinge rod into the hole in the frame. Step 21 Figure 27 (a). Install swing table Insert the other end into the hole in the swing table end You will need: swing table end bracket, two 10-24 hex bracket. Figure 27 (b). Hold the end bracket at an angle so nuts, two 10-24 x 1 3/4 inch machine screws, slide bar the lower tab is inside the frame tube. Push the bracket into assembly, swing table, four nylon washers, screwdriver the frame. Check to see that the lower tab of the br
