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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. 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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Contents Troubleshooting & Maintenance WARNINGS................................................................ 2 LP Tank Information .................................... 26-28 Warranty & Patents.................................................. 3-4 Annual Maintenance......................................... 29 General Instructions.................................................... 6 General Maintenance.................................. 30-32 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 Screwdriver Cooking box Phillips screwdriver (assembly) Hammer 7/16 inch open-end 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 leaks. (See Step "Check for gas leaks.") Note - The hardware size of nuts, bolt
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R R E E B B E E W W Left frame Five long Flavorizer Bars Eight short Flavorizer Bars Right frame Tank panel assembly Wheel frame Front panel Caster frame Catch pan holder Two frame connectors Catch pan Work table Two drip pans Swing table assembly Manifold bracket Support rod Thermometer Axle Two wheels Accessory rack Fuel scale assembly Warming rack Two casters Warm-Up Basket 8 R R E E B B E E W W
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Check contents of hardware packs Two plastic buttons (actual size) Three burner control knobs 1/4-20 keps nut Three tool holders Two 1/4-20 wing nuts (actual size) Five tubing plugs (two are spares) Fourteen 1/4 inch nylon washers Support rod holder Two hair pin cotters Swing table end bracket Two wheel hubcaps Two Phillips screws/washers Two hinge pins (hardware size: 1/4 x 1 1/2 inch clevis pin) (actual size) Five 1/4-20 x 2 inch bolts (actual size) 1/4-20 x 1 1/4 inch bolt (actual size) Six
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R E B E W Step 2 Step 3 Assemble wheels Assemble top frame You will need: axle, two wheel hubcaps, two wheels, You will need: left frame, right frame, two 1/4-20 x 1/2 inch wheel frame, hammer and a block of wood. bolts, two nylon washers 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 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: caster frame, wheel frame, four 1/4-20 x 1/2 You will need: partial frame assembly, two frame inch bolts, four nylon washers and a 7/16 inch wrench. connectors, four 1/4-20 x 2 inch bolts, four nylon washers and a 7/16 inch wrench. Place the caster frame onto the tabs of the left frame with the dimple to the inside. Figure 3. Place the wheel frame Hold one frame connector between the leg and wheel onto the tabs of the
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Step 6 Step 7 Insert casters Add front panel You will need: frame assembly and two casters. You will need: front panel and two plastic buttons. Push the casters firmly into the inserts in the ends of the Turn frame assembly right side up. caster legs. Figure 5. Align the panel with the holes in the frame and insert the plastic buttons through the front panel and frame. Figure 6. Plastic buttons View from rear of barbecue Figure 5 Figure 6 12
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Your Weber Gas Barbecue burner assembly has been Step 8 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 nut, Figure 9 (a). pliers and a 7/16 inch wrench. b) Are the ends of the burners under the washers at the Uncoil the hose. left rear and left front o
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Step 9 Step 10 Install manifold bracket Install tank panel assembly You will need: manifold bracket You will need: tank panel assembly, 1/4-20 x 1 1/4 inch bolt, 1/4-20 hex nut, nylon washer and a 7/16 inch wrench. Hook the bracket onto the manifold at the center burner valve. Place your hand underneath the bracket. Lift the Insert the tank panel tabs into the slots in the frame brace. manifold, bracket and cooking box slightly and hook the Figure 11. Frame brace Slots in frame brace tab of the
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E F Step 11 Step 12 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 13 Step 14 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. Note - For accuracy, the fuel scale must be set with an If 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 receiv
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E F Route the hose so it will not interfere with the scale Step 15 indicator rod. Check that all 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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Check: Step 17 a) Hose to manifold connection. Figure 20 (a). Check for gas leaks b) Regulator to tank connection. Figure 20 (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 or e
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Step 18 Step 19 Install the bottom tray Install Flavorizer Bars and Cooking Grates You will need: bottom tray, catch pan holder, catch pan and You will need: five long Flavorizer Bars, eight short one drip pan. Flavorizer Bars and two cooking grates. 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 21. Finger grip on front Front side of catch edge of bottom tray pan holder Figure 23
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Step 20 Step 21 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: three tool holders, control panel, two Set the lid in place. Align the hinges at the rear of the Phillips screws/washers, a Phillips screwdriver, and three barbecue. Insert hinge pins from the outside. Insert hair pin burner control knobs. cotters into the small holes in the hinge pins. Figure 26. Hook the tool holders over the frame ra
