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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 © 1999 Weber. Weber, , Flavorizer and Crossover are registered U.S. trademarks; Spirit, Gas Catcher, FlameCheck, and Spider Stopper are U.S. trademarks of Weber-Stephen Products Co., 200 East Daniels Road, Palatine, IL 60067-6266. U.S.A. Weber Gas Barbecues are covered under the following patent nos.: U.S.A. #4,677,964; 4,727,853; #4,829,978; #4,941,817; and #4,966,125; Canada: #1,279,540; #1,300,994; and #1,300,995. Printed in the U.S.A. 4
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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 Hammer Cooking box 7/16 inch open-end or an adjustable wrench (assembly) Pliers Block of wood Lid (assembly) Phillips screwdriver Supplies needed Your LP tank is shipped empty for safety. After setting the LP tank 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 and screws
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R R E E B B E E W W Left frame Tank panel assembly Right frame Front panel Wheel frame Catch pan holder Leg frame Catch pan Frame connector Drip pans (2) Work table Manifold bracket Thermometer Swing table assembly Wheels (2) Support rod Fuel scale assembly Accessory racks (2) Spacer bracket Warming rack Flavorizer Bars (5) 8 R R E E B B E E W W
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Check contents of hardware packs Plastic buttons (2) (actual size) Burner control knobs (3) 1/4-20 wing nuts (2) (actual size) Tool holders (2) 1/4 inch nylon washers (11) Tubing plugs (7) (two are spares) Hair pin cotters (2) Support rod holder Wheel hubcaps (2) Swing table end bracket 1/4-20 keps nut Hinge pins (2) Two Phillips screws/washers (hardware size: 1/4 x 1 1/2 inch clevis pin) (actual size) 1/4-20 x 2 inch bolt (actual size) 1/4-20 x 1 3/4 inch bolts (2) (actual size) 1/4-20 x 1/2 in
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R E B E W Step 2 Step 3 Assemble wheel frame Assemble top frame You will need: wheel frame, two wheels, two wheel hubcaps, You will need: left frame, right frame, two 1/4-20 x 1/2 inch hammer and a block of wood. bolts, two nylon washers and a 7/16 inch wrench. Set one end of wheel frame on the block of wood (or other Note - Work on carpeted area (on grass or one of the hard, protected surface). Put one wheel on axle, WEBER boxes) to protect the finish during frame assembly. side facing up, and
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Step 4 Step 6 Continue frame assembly Add front panel You will need: leg frame, wheel frame, four 1/4-20 x 1/2 inch You will need: front panel and two plastic buttons. bolts, four nylon washers and a 7/16 inch wrench. Turn frame assembly right side up. Place the leg frame onto the tabs of the left frame with the Align the panel with the holes in the frame and insert the dimple to the inside. Figure 3. Place the wheel frame onto plastic buttons through the front panel and frame. Figure 5. the tab
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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, work table spacer, 1/4-20 keps nut, 1/4-20 x 2 inch bolt, a) Do the valves fit into the ends of the burners? pliers and a 7/16 inch wrench. Figure 8 (a). Uncoil the hose. b) Are the ends of the burners under the washers at the left rear and left front of the c
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Step 8 Step 9 Install manifold bracket Install tank panel assembly and frame connector You will need: manifold bracket You will need: tank panel assembly, frame connector, two 1/4-20 x 1 3/4 inch bolts, two nylon washers 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 manifold, bracket and cooking box slightly and Insert the tank panel tabs into the slots in the frame brace. hook the tab of the brac
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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 assembly, two 1/4-20 wing nuts Catcher Ignition Chamber and the igniter. This was done to and two 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 whe
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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 all burner valves are off The hose and regulator are connected in the following Valves are shipped in the OFF position, but you should manner: check to be sure. Put the knob on each valve. Check by Slide back the collar of the quick disconnect on the tank pushing down and turning clockwise. If they do not turn valve. Push the male fitting of the regulator into the quick they are off, proceed to the next
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Check: Step 16 a) Hose to manifold connection. Figure 19 (a). Check for gas leaks b) Regulator to tank connection. Figure 19 (b). m DANGER mWARNING: If there is a leak at connection (a) Do not use an open flame to check for retighten the fitting with a wrench and recheck for gas leaks. Be sure there are no sparks or leaks with soap and water solution. open flames in the area while you check If a leak persists after retightening the fitting, turn OFF for leaks. This will result in a fire or the
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Step 17 Step 18 Install Flavorizer Bars and Cooking Grates Install the bottom tray You will need: five Flavorizer Bars and two cooking grates. You will need: bottom tray, catch pan holder, catch pan and one drip pan. Set the Flavorizer Bars side to side in the cooking box. Figure 20. Finger grip on front Front side of catch edge of bottom tray pan holder Figure 22 Hook the ends of the catch pan holder into the hole in the Figure 20 bottom tray. Figure 23. The front of the catch pan holder must
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Step 19 Step 20 Install Lid Add tool holders, control panel and burner control knobs You will need: lid, two hinge pins and two hair pin cotters. You will need: two tool holders, control panel, two Phillips Set the lid in place. Align the hinges at the rear of the screws/washers, a Phillips screwdriver, and three burner barbecue. Insert hinge pins from the outside. Insert hair pin control knobs. cotters into the small holes in the hinge pins. Figure 25. Hook the tool holders over the frame rail
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Insert one end of the hinge rod into the hole in the frame. Step 21 Figure 28 (a). Install swing table Insert the other end into the hole in the swing table end You will need: swing table assembly, support rod, support bracket. Figure 28 (b). Hold the end bracket at an angle so rod holder and swing table end bracket. the lower tab is inside the frame tube. Push the bracket into the frame. Check to see that the lower tab of the bracket is Allow the slide bar to hang down. Push the support rod hoo
