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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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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 leaks. (See Step "Check for gas leaks.") LP tank filler adapter Note - The hardw
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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 Catch pan Slide Axle 8 R R E E B B E E W W
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Fuel scale assembly Two wheel hubcaps (actual size) Two hinge pins Catch pan holder (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) Six 1/4-20 x 1/2 inch bolts (actual size) Side burner assembly Two 1/4-20 wing nuts (actual size) Burner grate Two 10-24 x 1 3/4 machine screws (actual size) Side burner knob Two 10-24 hex nuts (actual size) Two side burner locks Note: The locks are Eighteen 1/4 inch nylon washers taped to the ins
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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, four connectors, four 1/4-20 x 2 inch bolts, four nylon washers nylon washers and a 7/16 inch wrench. 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. Pla
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Slide the cooking box to the left within the frame. Put the Step 7 washer on the bolt. Insert the bolt through the cooking Install side burner locks box and frame with the head of the bolt outside the box. Figure 8. Add keps nut. Tighten by holding the bolt with Note: The locks are taped to the inside of the side pliers while you tighten the nut with the 7/16 inch wrench. burner lid You will need: frame assembly, two side burner locks and a 7/16 inch wrench. Turn frame assembly right side up.
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E F Step 9 Step 10 Install tank panel assembly Add fuel scale You will need: tank panel assembly, 1/4-20 x 1 1/4 inch You will need: fuel scale, two 1/4-20 wing nuts and two bolt, 1/4-20 hex nut, nylon washer and a 7/16 inch wrench. nylon washers. Insert the tank panel tabs into the slots in the frame brace. Slip the bolts on the back of the fuel scale assembly through Slide up until the notch at the bottom of the tank panel fits the two small holes in the tank panel. Make sure indicator over th
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Step 11 Step 12 Install igniter Check that all burner valves are off Note - The igniter wires are already attached to the Gas You will need: one burner control knob. Catcher Ignition Chamber and the igniter. This was done to (Valves are shipped in the OFF position, but you should factory test the ignition system. check to be sure.) Put the knob on each valve. Check by The igniter lock nut is on the igniter. pushing down and turning clockwise. If they do not turn, they are off, proceed to the nex
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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 mWARNING: Make sure that the LP tank valve is following 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 main
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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 Check: Do not use an open flame to check for gas a) Hose to manifold connection. Figure 21 (a). leaks. Be sure there are no sparks or open b) Regulator to tank connection. Figure 21 (b). flames in the area while you check for leaks. This will re
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Step 19 Step 20 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 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.
