Weber 1000 Series Users Manual 98599 1097

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2015-01-05

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WARNING: Do not try to light this appliance
without reading "Lighting" instructions
section of this manual.
THIS GAS APPLIANCE IS DESIGNED FOR
OUTDOOR USE ONLY.
NOTICE TO INSTALLER: These instructions
must be left with the owner and the owner
should keep them for future use.
FOR YOUR SAFETY
If you smell gas:
1. Shut off gas to the appliance.
2. Extinguish any open flame.
3. Open lid.
4. If odor continues, immediately call your
gas supplier or your fire department.
FOR YOUR SAFETY
1. Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
2. An LP tank not connected for use shall
not be stored in the vicinity of this or
any other appliance.
WARNING: Follow all leak check procedures
carefully in this manual prior to barbecue
operation. Do this even if barbecue was
dealer assembled.
GENESIS®1000 Series
LP Gas Barbecue
Serial Number
Please use this number in registering your warranty and
any correspondence with the factory.
Owner’s Manual
National
Association
PROPANE
GAS
®
98599 10/97
DANGER
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.
WARNINGS
Do not store a spare or disconnected LP tank under or near this barbecue.
Improper assembly may be dangerous. Please carefully follow the assembly instructions in this manual.
After a period of storage, and/or nonuse, the Weber Gas Barbecue should be checked for gas leaks
and burner obstructions before using. See instructions in this manual for correct procedures.
Do not operate the Weber Gas Barbecue if there is a gas leak present.
Do not use a flame to check for gas leaks.
Combustible materials should never be within 24 inches of the top, bottom, back or sides of your
Weber Gas Barbecue.
Do not put a barbecue cover or anything flammable on or in the storage area under the barbecue.
Your Weber Gas Barbecue should never be used by children.
You should exercise reasonable care when operating your Weber Gas Barbecue. It will be hot during
cooking or cleaning, and should never be left unattended.
Should the burners go out during operation, turn all gas valves off. Open the lid and wait five minutes
before attempting to relight, using the lighting instructions.
Do not use charcoal or lava rock in your Weber Gas Barbecue.
Never lean over open grill or place hands or fingers on the front edge of the cooking box.
Should a grease fire occur, turn off all burners and leave lid closed until fire is out.
Do not enlarge valve orifices or burner ports when cleaning the valves or burners.
The Weber Gas Barbecue should be thoroughly cleaned on a regular basis.
LP gas is not natural gas. The conversion or attempted use of natural gas in an LP unit or LP gas in a
natural gas unit is dangerous and will void your warranty.
Do not attempt to disconnect any gas fitting while your barbecue is in operation.
Use heat-resistant barbecue mitts or gloves when operating barbecue.
LP GAS UNITS ONLY:
Use the regulator that is supplied with your Weber Gas Barbecue.
Do not attempt to disconnect the gas regulator or any gas fitting while your barbecue is in operation.
A dented or rusty LP tank may be hazardous and should be checked by your liquid propane supplier.
Do not use an LP tank with a damaged valve.
Although your LP tank may appear to be empty, gas may still be present, and the tank should be
transported and stored accordingly.
If you see, smell or hear the hiss of escaping gas from the LP tank:
1. Get away from LP tank.
2. Do not attempt to correct the problem yourself.
3. Call your fire department.
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Weber-Stephen Products Co. (Weber) hereby
warrants to the ORIGINAL PURCHASER of this
Weber Gas Barbecue that it will be free of
defects in material and workmanship from the
date of purchase as follows:
Aluminum Castings, 10 years,
Cooking Grates and Flavorizer Bars, 3 years,
All Remaining Parts, 5 years,
when assembled and operated in accordance
with the printed instructions accompanying it.
Weber may require reasonable proof of your
date of purchase. THEREFORE, YOU SHOULD
RETAIN YOUR SALES SLIP OR INVOICE.
This Limited Warranty shall be limited to the
repair or replacement of parts which prove
defective under normal use and service and
which on examination shall indicate, to Weber's
satisfaction, they are defective. Before returning
any parts, contact Weber-Stephen Products Co.
Customer Service Center. If Weber confirms the
defect and approves the claim, Weber will elect
to replace such parts without charge. If you are
required to return defective parts, transportation
charges must be prepaid. Weber will return parts
to the purchaser, freight or postage prepaid.
This Limited Warranty does not cover any failures
or operating difficulties due to accident, abuse,
misuse, alteration, misapplication, vandalism,
improper installation or improper maintenance or
service, or failure to perform normal and routine
maintenance, including but not limited to damage
caused by insects within the burner tubes, as set
out in this owner's manual.
Deterioration or damage due to severe weather
conditions such as hail, hurricanes, earthquakes
or tornadoes, discoloration due to exposure to
chemicals either directly or in the atmosphere, is
not covered by this Limited Warranty.
There are no other express warrants except as
set forth herein and any applicable implied
warranties of merchantability and fitness are
limited in duration to the period of coverage of
this express written Limited Warranty. Some
states do not allow limitation on how long an
implied warranty lasts, so this limitation may not
apply to you.
Weber is not liable for any special, indirect or
consequential damages. Some states do not
allow the exclusion or limitation of incidental or
consequential damages, so this limitation or
exclusion may not apply to you.
Weber does not authorize any person or
company to assume for it any other obligation or
liability in connection with the sale, installation,
use, removal, return, or replacement of its
equipment; and no such representations are
binding on Weber.
This Warranty applies only to products sold at
retail.
WEBER-STEPHEN PRODUCTS CO.
Customer Service Center
250 South Hicks Road
Palatine, IL 60067-6241
(800) 446-1071
LP Tank
The LP tank manufacturer is responsible for the
materials, workmanship and performance of the tank. If
the tank has a defect, malfunctions, or you have a
question regarding the tank, call the tank manufac-
turer's customer service center. The phone number is
on the warning decal which is permanently attached to
the tank. If the tank manufacturer has not resolved the
issue to your satisfaction, then call Weber-Stephen
Products Co., Customer Service Center.
WARRANTY
© 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: Rd
1987 Reg. #58,034; #1,279,540; #1,283,586; #1,300,994;
#1,300,995. Printed in the U.S.A.
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PATENTS AND TRADEMARKS
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Contents
WARNINGS................................................................ 2
Warranty & Patents.................................................. 3-4
General Instructions.................................................... 6
Assembly ............................................................... 7-22
Operating Instructions
Lighting........................................................ 23-24
Cooking ............................................................ 25
Storage and/or Nonuse .................................... 25
Cleaning .......................................................... 25
Troubleshooting & Maintenance
LP Tank Information .................................... 26-28
Annual Maintenance......................................... 29
General Maintenance.................................. 30-32
Troubleshooting................................................ 33
Parts Listing .............................................................. 35
FEATURES:
a) Convenient tables and racks.
b) Heavy gauge porcelain-on-steel lid seals in heat.
c) Rapid read thermometer for precision cooking
measures grill temperature, and can be removed and
inserted into the food.
d) Heavy gauge steel Flavorizer Bars distribute heat
within the grill. Flavorizer Bars heat just the right
amount of drippings for flavoring, letting excess fat
drip past to help prevent flare-ups.
e) Weber Warm-Up Basket for additional cooking or
warming space.
f) Separate burners for temperature control.
g) Crossover Ignition System with Gas Catcher Ignition
Chamber.
h) Fuel scale indicates LP gas supply.
i) Catch pan catches excess grease.
j) Locking casters for additional portability.
IMPORTANT NEW FEATURES:
Your Weber Gas Barbecue is equipped with a new and
improved LP tank connection, that has additional
safety features. They are:
1. The connection of the barbecue to the LP tank can be
made without the use of tools.
2. The new connection will not permit the flow of gas
until a positive gas connection is made.
3. If an accidental fire occurs at the LP tank connection,
the flow of gas is stopped by a temperature activated
shutoff.
4. If the LP supply hose becomes damaged, cut,
punctured, or accidentally fire damaged, the barbecue
connection is equipped with an excess flow control
that will limit the flow of gas if leakage or a fire occurs.
a
b
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d
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a
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j
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General Instructions
Your Weber Gas Barbecue is a portable outdoor cooking
appliance. With the Weber Gas Barbecue you can grill,
barbecue, roast and bake with results that are difficult to
duplicate with indoor kitchen appliances. The closed lid and
Flavorizer Bars produce that "outdoor" flavor in the food.
The Weber Gas Barbecue is portable so you can easily
change its location in your yard or on your patio. Portability
means you can take your Weber Gas Barbecue with you if
you move.
Liquid Propane (LP) gas supply is easy to use and gives
you more cooking control than charcoal fuel.
■These instructions will give you the minimum
requirements for assembling your Weber Gas
Barbecue. Please read the instructions carefully
before using your Weber Gas Barbecue. Improper
assembly can be dangerous.
■Not for use by children.
■If there are local codes that apply to portable gas grills,
you will have to conform to them. If there are no local
codes, you must conform to the latest edition of the
National Fuel Gas Code: ANSI Z 223.1.
■The pressure regulator supplied with the Weber
Gas Barbecue must be used. This regulator is set
for 10.5 inches of water column (pressure).
■This Weber Gas Barbecue is designed for use with
liquid propane (LP) gas only. Do not use with natural
(piped in city) gas. The valves, orifices, hose and
regulator are for LP gas only.
■Do not use with charcoal fuel.
■Check that the area under the control panel and the
bottom tray are free from debris that might obstruct
the flow of combustion or ventilation air.
■The area around the LP tank must be free and clear
from debris.
For Installation in Canada
These instructions, while generally acceptable, do not
necessarily comply with the Canadian Installation codes,
particularly with piping above and below ground. In
Canada the installation of this appliance must comply with
local codes and/or Standard CAN/CGA-B149.2 (Installation
Code for Propane Burning Appliances and Equipment).
Storage
■The gas must be turned OFF at the LP tank when the
Weber Gas Barbecue is not in use.
■When the Weber Gas Barbecue is stored indoors, the
gas supply must be disconnected and the LP tank
stored outdoors in a well-ventilated space.
■LP tanks must be stored outdoors in a well-ventilated
area out of the reach of children. Disconnected LP
tanks must not be stored in a building, garage or any
other enclosed area.
■When the LP tank is not disconnected from the Weber
Gas Barbecue, the appliance and LP tank must be
kept outdoors in a well-ventilated space.
Operating area
WARNING: Onlyuse this barbecue outdoors in a
well ventilated area. Do not use in a garage, building,
breezeway or any other enclosed area.
■Never use your Weber Gas Barbecue under an
unprotected combustible roof or overhang.
■Your Weber Gas Barbecue is not intended to be
installed in or on recreational vehicles and/or boats.
■Do not use combustible materials within 24 inches of
the top, bottom, back or sides of the grill.
■The entire cooking box gets hot when in use. Do not
leave unattended.
■Keep any electrical supply cord and the fuel supply
hose away from any heated surface.
■Keep the cooking area clear of flammable vapors
and liquids, such as gasoline, alcohol, etc., and
combustible materials.
■Never store an extra (spare) LP tank under or near
the Weber Gas Barbecue.
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Step 1
Check package contents
Cooking box
(assembly)
Lid
(assembly)
LP tank
LP tank filler adapter
Bottom tray
Two cooking grates
Control panel
Assembly
Tools needed
Screwdriver
Hammer
7/16 inch open-end or an adjustable wrench
Pliers
Block of wood
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, bolts and screws is given.
For example "1/4-20 x 2 inch bolt" means a bolt 1/4 inch in
diameter with 20 threads to the inch, 2 inches long. On a
small screw for example, "6-32 x 1/2 inch screw" means a
number 6 screw, with 32 threads to the inch, 1/2 inch long.
While we give much attention to our products,
unfortunately an occasional error may occur. If a part
is missing, do not go back to the store. Call the Weber
Customer Service Center toll free 1-800-446-1071 to
receive immediate assistance. Have your owner’s
manual and serial number of the barbecue available
for reference.
Phillips screwdriver
Left frame
Right frame
Wheel frame
Caster frame
Two frame connectors
Work table
Swing table assembly
Support rod
Axle
Accessory rack
Warming rack
Warm-Up Basket
Five long Flavorizer Bars
Eight short Flavorizer Bars
Tank panel assembly
Front panel
Catch pan holder
Catch pan
Two drip pans
Manifold bracket
Thermometer
Two wheels
Fuel scale assembly
Two casters
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Two plastic buttons
(actual size)
1/4-20 keps nut
Two 1/4-20 wing nuts
(actual size)
Fourteen 1/4 inch nylon washers
Two hair pin cotters
Two wheel hubcaps
Check contents of hardware packs
Three burner control knobs
Three tool holders
Five tubing plugs
(two are spares)
Support rod holder
Swing table end bracket
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 1/4-20 x 1/2 inch bolts
(actual size)
1/4-20 hex nut
(actual size)
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Two Phillips screws/washers
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Figure 1
Step 2
Assemble wheels
You will need: axle, two wheel hubcaps, two wheels,
wheel frame, hammer and a block of wood.
Place one end of the axle on the block of wood (or other
protected surface). Tap on one hubcap.
Put one wheel on the axle, WEBER side toward the
hubcap. Slide the axle through the frame. Add the other
wheel, WEBER side out. Tap on the hubcap. Figure 1.
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Figure 2
Step 3
Assemble top frame
You will need: left frame, right frame, two 1/4-20 x 1/2 inch
bolts, two nylon washers and a 7/16 inch wrench.
Note - Work on carpeted area (on grass or one of the
boxes) to protect the finish during frame assembly.
Lay the leg pieces as shown so the leg tabs point up.
Figure 2.
Slip the two frame pieces together with the tabs inside.
Figure 2 (a). Slip washers on bolts, insert bolts as shown
and tighten. Figure 2 (b). (If you try to insert a bolt and
there are no holes, you have the left frame turned the
wrong way. Turn the left frame around.)
Leg tabs
Frame tabs
(a)
(b)
Right frame
Left frame
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Figure 3
Step 4
Continue frame assembly
You will need: caster frame, wheel frame, four 1/4-20 x 1/2
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
onto the tabs of the right frame with the dimple to the
inside. The fuel scale decal should face away as shown.
Figure 3.
The leg tabs must be on the inside of the frames.
Add the washers to the bolts, insert in the holes as shown
and tighten with the wrench. Figure 3.
Dimples to
the inside
Fuel scale
decal
Step 5
Complete frame assembly
You will need: partial frame assembly, two frame
connectors, four 1/4-20 x 2 inch bolts, four nylon
washers and a 7/16 inch wrench.
Hold one frame connector between the leg and wheel
frame. Add the nylon washer to the bolt. Put the bolt
through the frame and screw into frame connector.
Tighten.
Repeat procedure with the other frame connector. Figure 4.
Figure 4
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Figure 6
Step 7
Add front panel
You will need: front panel and two plastic buttons.
Turn frame assembly right side up.
Align the panel with the holes in the frame and insert the
plastic buttons through the front panel and frame. Figure 6.
View from rear
of barbecue
Plastic buttons
Step 6
Insert casters
You will need: frame assembly and two casters.
Push the casters firmly into the inserts in the ends of the
caster legs. Figure 5.
Figure 5
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Your Weber Gas Barbecue burner assembly has been
factory assembled, pressure and flame tested. As a safety
precaution we recommend you check the burner alignment:
a) Do the valves fit into the ends of the burners?
Figure 9 (a).
b) Are the ends of the burners under the washers at the
left rear and left front of the cooking box? The screws
are only guides. Do not tighten. Figure 9 (b).
c) Are the wing nuts under the burner assembly hand
tight? Do not tighten with pliers. Figure 9 (c).
If you answered YES to a, b and c, the burners are
correctly aligned. If you answered NO, the burners are
misaligned. Contact Weber-Stephen Customer Service.
Do not use barbecue.
Guide screw
(a)
(b)
(c)
Wing nuts
View from
behind
cooking
box
Figure 9
Figure 7
Step 8
Add cooking box
You will need: frame assembly, cooking box (assembly),
1/4-20 x 2 inch bolt, 1/4 inch nylon washer, 1/4-20 keps nut,
pliers and a 7/16 inch wrench.
Uncoil the hose.
Set the cooking box in the frame so the burner tubes are
under the frame brace. Figure 7.
Burner tubes
Frame brace
Slide the cooking box to the left within the frame. Put washer
on bolt. Insert the bolt through the cooking box and frame
with the head of the bolt outside the box. Figure 8. Add the
keps nut. Tighten by holding the bolt with pliers while you
tighten the nut with a wrench.
Figure 8
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Frame brace Manifold bracket
Figure 10
Step 9
Install manifold bracket
You will need: manifold bracket
Hook the bracket onto the manifold at the center burner
valve. Place your hand underneath the bracket. Lift the
manifold, bracket and cooking box slightly and hook the
tab of the bracket onto the frame brace. Figure 10.
Step 10
Install tank panel assembly
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.
Insert the tank panel tabs into the slots in the frame brace.
Figure 11.
Figure 11
Figure 12
Cross brace
Tank panel tabs
Slots in frame brace Frame brace
Slide tank panel up until notch at bottom of panel fits over
the cross brace. Insert one bolt with washer through the
hole in the bottom of the tank panel and through the wheel
frame. Add hex nut and tighten with the 7/16 inch wrench.
Figure 12.
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Step 11
Add fuel scale assembly
You will need: fuel scale assembly, two 1/4-20 wing nuts
and two nylon washers.
Slip the bolts on the back of the fuel scale assembly through
the two small holes in the tank panel. Make sure indicator
rod of fuel scale is on the left side of the wheel frame.
Add washers then wing nuts and tighten. Figure 13.
Figure 13
View from front left View from front right
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Step 12
Install igniter
Note - The igniter wires are already attached to the Gas
Catcher Ignition Chamber and the igniter. This was done to
factory test the ignition system.
The igniter lock nut is on the igniter.
Insert the top of the igniter up through the large part of
the keyhole in the frame brace. Figure 14 (b). Loosen the
igniter lock nut and slide the igniter into the small part of
the keyhole. Figure 14 (c). Tighten the igniter lock nut.
Figure 14.
Note - If the igniter works loose, carefully tighten the igniter
lock nut with an adjustable wrench or pliers.
Figure 14
Igniter lock nut
Keyhole in
frame brace
Small part of keyhole
in frame brace
Frame brace
Frame brace
(a)
(b)
(c)
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Step 13
Set LP fuel scale
You will need: LP tank (empty).
Note - For accuracy, the fuel scale must be set with an
empty tank.
We utilize various LP tank manufacturers. Some of the
tanks we receive have differing top collar assemblies.
(The top collar is the metal protective ring around the
valve.) One series of tanks mounts with the valve facing
front. The other tanks mount with the valve facing away
from the fuel scale. These types of tanks are illustrated
in Figure 15.
Loosen the tank lock wing nut. Tighten so the lock is
held up out of the way. Figure 15 (a). Lift and hook the
tank onto the fuel scale. With an empty LP tank, adjust
the fuel scale setting to E with scale setting (top) wing
nut. Figure 15 (b).
CAUTION: Do not remove adjustment wing nut from
tank scale.
After adjusting tank scale, push tank down a couple of
times to check that the tank scale is set on “E”.
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F
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Figure 15
Tank lock
wing nut
(a) (b)
Scale setting
wing nut
Step 14
Fill LP tank
Note - The LP tank manufacturer is responsible for the
materials, workmanship and performance of the tank.
If the tank has a defect, malfunctions, or you have a
question regarding the tank, call the tank manufacturer's
customer service center. The phone number is on the
warning decal which is permanently attached to the tank.
If the tank manufacturer has not resolved the issue to
your satisfaction, then call Weber-Stephen Products Co.,
Customer Service Center.
To fill, take the LP tank and filler adapter to an RV center or
look up gas-propane in the phone book for other sources
of LP gas.
WARNING: We recommend that your LP tank be
filled at an authorized LP gas dealer by a qualified
attendant, who fills the tank by weight.
IMPROPER FILLING IS DANGEROUS.
Tell your LP dealer that this is a new LP tank. The air must
be removed from a new LP tank before the initial filling.
Your LP tank dealer is equipped to do this.
WARNING: If you exchange your LP tank, make
sure you get a similar tank in return. Your LP tank is
equipped with a quick-disconnect valve and an OPD
(Overfilling Prevention Device). Other LP tanks are not
compatible with your barbecue connection.
The LP tank must be installed, transported and stored in
an upright position. LP tank should not be dropped or
handled roughly.
Never store or transport the LP tank where temperatures
can reach 125° Fahrenheit (too hot to hold by hand – for
example: do not leave the LP tank in a car on a hot day).
For full instructions on safe handling of LP tanks, see
Section "Operating Instructions".
17
Figure 16
Step 15
Check that all burner valves are off
You will need: one burner control knob.
Valves are shipped in the OFF position, but you should
check to be sure. Put the knob on each valve. Check by
pushing down and turning clockwise. If they do not turn,
they are off, proceed to the next step. Figure 16.
Route the hose so it will not interfere with the scale
indicator rod.
The hose and regulator are connected in the following
manner:
Slide back the collar of the quick disconnect on the tank
valve. Push the male fitting of the regulator into the quick
disconnect, and maintain pressure. Slide the collar closed.
Figure 18 (a). Figure 18 (b) shows the quick disconnect
engaged and various components of the tank and
regulator. Regulator vent hole should be at 3, 6, or 9
o'clock. It should not be pointed up. Figure 18 (c).
Figure 18
Turn so regulator vent
does not collect water
Hose
Tank lock
wing nut
Quick disconnect
engaged
Valve handwheel
close clockwise
Tank valve
Collar
Male
fitting
Pressure
relief valve
Tank
Regulator
Regulator
vent
(a)
(b)
(c)
Step 16
Connect LP tank
WARNING: Make sure that the LP tank valve is
closed. Close by turning clockwise.
Hook the LP tank onto the fuel scale. Loosen the tank lock
wing nut. Swing the tank lock down. Tighten the wing nut.
Figure 17.
Figure 17
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Step 17
Check for gas leaks
WARNING: You should check for gas leaks every
time you disconnect and reconnect a gas fitting.
Note - All factory made connections have been thoroughly
checked for gas leaks. The burners have been flame
tested. As a safety precaution you should recheck all
fittings for leaks before using your Weber Gas Barbecue.
Shipping and handling may have loosened or damaged a
gas fitting.
WARNING: Perform these leak checks even if your
barbecue was dealer or store assembled.
You will need: a soap and water solution and a rag or
brush to apply it.
To perform leak checks: open tank valve by turning the
tank valve handwheel counterclockwise. Figure 19.
Figure 19
DANGER
Do not use an open flame to check for gas
leaks. Be sure there are no sparks or open
flames in the area while you check for
leaks. This will result in a fire or explosion
which can cause serious bodily injury or
death and damage to property.
Check:
a) Hose to manifold connection. Figure 20 (a).
b) Regulator to tank connection. Figure 20 (b).
WARNING: : If there is a leak at connection (a) ,
retighten the fitting with a wrench and recheck for
leaks with soap and water solution.
If a leak persists after retightening the fitting, turn OFF
the gas. DO NOT OPERATE THE BARBECUE. Contact
Weber-Stephen Customer Service.
c) Valves to manifold connections. Figure 20 (c).
d) The hose to regulator connection. Figure 20 (d).
WARNING: If there is a leak at connections
(b), (c) or (d), turn OFF the gas. DO NOT OPERATE
THE BARBECUE. Contact Weber-Stephen Customer
Service.
When leak checks are complete, turn gas supply OFF at
the source and rinse connections with water.
Check for leaks by wetting the connections with the soap
and water solution and watching for bubbles. If bubbles
form or if a bubble grows there is a leak.
Note - Since some leak test solutions, including soap and
water, may be slightly corrosive, all connections should be
rinsed with water after checking for leaks.
WARNING: Do not ignite burners when leak checking.
(a)
Figure 20
(c)
(d)
(b)
19
Figure 24
Figure 23
Figure 25
Bottom tray
Finger grip on front
edge of bottom tray
Finger grip
Front side of catch
pan holder
Step 18
Install Flavorizer Bars and Cooking Grates
You will need: five long Flavorizer Bars, eight short
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.
Figure 21
The open "U" of the cooking grates goes down. Set
the cooking grates onto the ledges in the cooking box.
Figure 22.
Figure 22
Step 19
Install the bottom tray
You will need: bottom tray, catch pan holder, catch pan and
one drip pan.
Hook the ends of the catch pan holder into the hole in the
bottom tray. Figure 24. The front of the catch pan holder
must be on the same side as the finger grip of the
bottom tray.
Slide the bottom tray onto the mounting rails under the
cooking box with finger grip toward you. Figure 25.
CAUTION: Do not line bottom tray with aluminum foil.
It can cause grease fires by trapping the grease and not
allowing grease to flow into the catch pan.
Put the foil drip pan into the catch pan.
Slide the catch pan into the catch pan holder with its finger
grip towards you.
20
Step 20
Install Lid
You will need: lid, two hinge pins and two hair pin cotters.
Set the lid in place. Align the hinges at the rear of the
barbecue. Insert hinge pins from the outside. Insert hair pin
cotters into the small holes in the hinge pins. Figure 26.
Hair pin cotter
Hinge pin
Figure 26
Step 21
Add tool holders, control panel and burner
control knobs
You will need: three tool holders, control panel, two
Phillips screws/washers, a Phillips screwdriver, and three
burner control knobs.
Hook the tool holders over the frame rail. Figure 27.
Set the control panel in place over both frame braces.
Hold the Crossover Ignition button up while setting the
control panel in place. Line up the holes in the control
panel with the holes in the inserts in the frame brace.
Insert screws and tighten with a Phillips screwdriver until
snug. Do not overtighten. Figure 27 (a).
Push on the three burner control knobs. Figure 27 (b).
Figure 27
Tool holders
Insert in
frame brace
Control panel
Phillips screws/
washers
(a)
(b)
Crossover
Ignition
Button
21
Slot in frame
(view from below)
Insert one end of the hinge rod into the hole in the frame.
Figure 29 (a).
Insert the other end into the hole in the swing table end
bracket. Figure 29 (b). Hold the end bracket at an angle so
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
hooked in the slot in the frame. Figure 29 (c).
To fully seat the bracket, you may have to tap it lightly with a
hammer.
WARNING: If swing table end bracket is in any way
cracked or damaged, do not use swing table. Call our
Customer Service Center to order a new part.
Install support rod holder on leg. Figure 29 (d). Hook the
support rod into the support rod holder.
WARNING: The load limit for the swing table is
30 pounds.
Figure 29
(c)
(d)
View from rear
of barbecue
Hinge rod
(b)
(a)
Step 22
Install swing table
You will need: swing table assembly, support rod, support
rod holder and swing table end bracket.
Allow the slide bar to hang down. Push the support rod
into the lower support bracket. Figure 28 (a). Swing the
rod up so you can slide the rod all the way inside the
locking tab. Figure 28 (b). The rod should swing freely
inside the locking tab. Figure 28 (c).
Figure 28
(a)
(b) (c)
Support rod
22
Step 23
Complete accessory installation
You will need: Warm-Up Basket, warming rack, work
table, accessory rack, three tubing plugs, thermometer
and a hammer.
Insert one end of the Weber Warm-Up Basket into the hole
in the right end of the lid and the other end into the slot in
the left end of the lid. Figure 30 (a).
Set the warming rack into the slots at the rear of the
cooking box. Figure 30 (b).
Set the work table onto the left side rails. Figure 30 (c).
Set the accessory rack in place between the two frame
connectors. Figure 30 (d).
Insert the thermometer into its holder. Figure 30 (e).
Insert the tubing plugs into the ends of the frame. To fully
seat the plugs, you may have to tap them lightly with a
hammer. Figure 30 (f).
Figure 30
(a)
(b)
(c)
(d)
(e)
(f)
CAUTION: To keep the barbecue stationary, the tabs
on the locking casters should be in the down position.
23
Lighting
Summary lighting instructions are on the control panel.
6
8
5
2
7
4
3
1
Figure 1
Crossover Ignition System
WARNING: The burner control knobs must be in the
OFF position before turning on the LP tank valve. If
they are not in the OFF position, when you turn on the
LP tank valve, the excess flow control will activate,
limiting the flow of gas from the LP tank. If this should
occur, turn OFF the LP tank valve and burner control
knobs and start over.
OPERATING INSTRUCTIONS
DANGER
Failure to open lid while igniting the
barbecue, or not waiting 5 minutes to
allow the gas to clear if the barbecue does
not light, may result in an explosive flame-
up which can cause serious bodily injury
or death.
DANGER
When the excess flow control is activated,
a small amount of gas is still flowing to
the burners. After turning OFF the tank
and burner control knobs, wait at least 5
minutes for the gas to clear before
attempting to light the barbecue. Failure
to do so may result in an explosive flame-
up which can cause serious bodily injury
or death.
Crossover Ignition System
Note - The Crossover Ignition System ignites the Front
burner with a spark from the igniter electrode inside the Gas
Catcher Ignition Chamber. You generate the energy for the
spark by pushing the Crossover Ignition Button until it clicks.
WARNING: Check hose before each use of barbecue
for nicks, cracking, abrasions or cuts. If the hose is
found to be damaged in any way, do not use the
barbecue. Replace using only Weber authorized
replacement manifold assembly. Order from Weber-
Stephen Products Co., Customer Service Center or
authorized dealer.
4) Turn the tank on by turning the tank valve
counterclockwise.
WARNING: Do not lean over open barbecue. Keep
your face and body at least one foot away from the
matchlight hole when lighting the barbecue.
5) Push Front burner control knob down and turn to
START/ HI.
6) Push the Crossover Ignition Button several times, so it
clicks each time.
7) Check that the burner is lit through the matchlight hole
on the front of the cooking box.
WARNING: If the burner does not light, turn the
Front burner control knob to OFF and wait 5 minutes
to let the gas clear before you try again or try to light
with a match.
8) After the FRONT burner is lit you can turn on the other
burners.
Note - Always light the FRONT burner first. The other
burners ignite from the FRONT burner.
To Extinguish
Turn gas supply OFF at the source, then push down
and turn each burner control knob clockwise to OFF.
1) Open the lid. Figure 1.
2) Check that the fuel scale reads more than “E”.
Note - E = empty; F = full.
3) Make sure all burner control knobs are OFF. (Push
each burner control knob down and turn clockwise.)
24
Manual Lighting 4) Turn the tank on by turning the tank valve
counterclockwise.
5) Strike a match and put the flame into the matchlight
hole in the front of the cooking box.
WARNING: Do not lean over open barbecue. Keep
your face and body at least one foot away from the
matchlight hole when lighting the barbecue.
6) Push Front burner control knob down and turn to
START/ HI.
7) Check that the burner is lit by looking through the
matchlight hole on the front of the cooking box.
WARNING: If the burner does not light, turn the Front
burner control knob to OFF and wait 5 minutes to let
the gas clear before you try again or try to light with a
match.
8) After the FRONT burner is lit you can turn on the other
burners.
Note - Always light the FRONT burner first. The other
burners ignite from the FRONT burner.
To Extinguish
Turn gas supply OFF at the source, then push down
and turn each burner control knob clockwise to OFF.
DANGER
Failure to open lid while igniting the
barbecue, or not waiting 5 minutes to
allow the gas to clear if the barbecue does
not light, may result in an explosive flame-
up which can cause serious bodily injury
or death.
8
6
2
4
3
1
7
5
Figure 2
Manual Lighting
DANGER
When the excess flow control is activated,
a small amount of gas is still flowing to
the burners. After turning OFF the tank
and burner control knobs, wait at least 5
minutes for the gas to clear before
attempting to light the barbecue. Failure
to do so may result in an explosive flame-
up which can cause serious bodily injury
or death.
1) Open the lid. Figure 2.
2) Check that fuel scale reads more than “E”.
Note - E = empty; F = full.
3) Make sure all burner control knobs are OFF. (Push
each burner control knob down and turn clockwise.)
WARNING: The burner control knobs must be in the
OFF position before turning on the LP tank valve. If
they are not in the OFF position, when you turn on the
LP tank valve, the excess flow control will activate,
limiting the flow of gas from the LP tank. If this should
occur, turn OFF the LP tank valve and burner control
knobs and start over.
25
Cooking
WARNING: Do not move the Weber Gas Barbecue
when operating or hot.
You can adjust the FRONT, CENTER and BACK burners as
desired. The control settings High (H), Medium (M), Low
(L), or Off (O) are described in your Weber cookbook. The
cookbook uses these notations to describe the settings of
the FRONT, CENTER, and BACK burners. For example, to
sear steaks you would use (HHH) (all burners at high).
Then to complete cooking you would use (MOM) (FRONT
at medium, CENTER off, and BACK at medium). See your
Weber cookbook for detailed cooking instructions.
Note: The temperatures inside your cooking box, for the
first few uses, while surfaces are still very reflective, may
be hotter than those shown in your cookbook. Cooking
conditions may require the adjustment of the burner
controls to attain the correct cooking temperatures.
CAUTION: Replace thermometer in lid when not in
use. Do not leave thermometer in food while cooking.
If burners go out during cooking, open lid, turn off all
burners and wait 5 minutes before relighting.
Preheating
Your Weber Gas Barbecue is an energy efficient
appliance. It operates at a low B.T.U. rate for economy. To
preheat, after lighting, close lid and turn all burners to high
(HHH). Preheating to between 500° and 550° F (260° and
290° C) will take 10 to 15 minutes depending on
conditions such as air temperature and wind.
Drippings and grease
The Flavorizer Bars are designed to "smoke" the right
amount of drippings for flavorful cooking. Excess drippings
and grease accumulate in the catch pan under the bottom
tray. Disposable foil liners are available that fit the catch pan.
WARNING: Check the bottom tray for grease build-
up before each use. Remove excess grease to avoid a
grease fire in the bottom tray.
Periodic Cleaning
WARNING: Turn your Weber Gas Barbecue OFF and
wait for it to cool before cleaning.
CAUTION: Do not clean your Flavorizer Bars or
cooking grates in a self-cleaning oven. Replacement
cooking grates and Flavorizer Bars are available
through your retailer or the Weber-Stephen Customer
Service Center.
Outside surfaces - Use a warm soapy water solution.
CAUTION: Do not use oven cleaner, abrasive
cleansers (kitchen cleansers) cleaners that contain
citrus products or abrasive cleaning pads on barbecue
or cart surfaces.
Bottom tray - Remove excess grease and then wash with
warm soapy water.
Flavorizer Bars and Cooking Grates- Clean with a
suitable brass bristle brush. As needed, remove from grill
and wash with warm soapy water.
Catch pan - Disposable foil trays are available, or you can
line the catch pan with aluminum foil. To clean the catch
pan, wash with warm soapy water.
Thermometer - Wipe with warm soapy water, clean with
plastic scrub ball. Do not put in dishwasher or submerge in
water.
Inside cooking box - Brush any debris off of burners tubes.
DO NOT ENLARGE BURNER PORTS (OPENINGS). Wash
inside of cooking box with warm soapy water.
Inside Lid - While lid is warm, wipe inside with paper towel
to prevent flaking due to grease build-up.
Storage and/or Nonuse
■The gas must be turned off at the LP tank when the
Weber Gas Barbecue is not in use.
■When the Weber Gas Barbecue is stored indoors, the
gas supply must be DISCONNECTED and the LP
tank stored outdoors in a well-ventilated space.
■LP tanks must be stored outdoors in a well- ventilated
area out of reach of children. Disconnected LP tanks
must not be stored in a building, garage or any other
enclosed area.
Storage and/or Nonuse continued
■When the LP tank is not disconnected from the Weber
Gas Barbecue, the appliance and LP tank must be
kept outdoors in a well-ventilated space.
■The Weber Gas Barbecue should be checked for
gas leaks and any obstructions in the burner tubes
before using. (See Sections "General and Annual
Maintenance.")
■Check that the areas under the control panel and the
bottom tray are free from debris that might obstruct
the flow of combustion or ventilation air.
■The Spider Stopper Guards should also be checked for
any obstructions. (See Section "Annual Maintenance.")
26
Scale setting wing nut
Tank lock
wing nut
Tank valve
Collar
(a)
(b)
Figure 3
Refilling the LP tank
We recommend that you refill before the scale indicator
reaches "E".
Note - If you run out of fuel, check the indicator setting
and/or adjust the fuel scale indicator setting with the scale
setting wing nut, while the tank is empty so you do not run
out again.
Removal of the LP tank
1) Close tank valve (turn clockwise). Figure 3 (a).
2) Slide the collar back on the quick disconnect to
disengage the fitting. Figure 3 (b).
3) Loosen tank lock wing nut and turn tank lock up out of
the way.
4) Lift tank off.
To refill take LP tank and tank filler adapter to a "Gas
Propane" dealer.
WARNING: We recommend that your LP tank be
filled at an authorized LP gas dealer, by a qualified
attendant, who fills the tank by weight. IMPROPER
FILLING IS DANGEROUS.
WARNING: If you exchange your LP tank, make
sure you get a similar tank in return. Your LP tank is
equipped with a quick-disconnect valve and an OPD
(Overfilling Prevention Device). Other LP tanks are
not compatible with your barbecue connection.
Connecting the filled LP tank
WARNING: Make sure that the LP tank valve is
closed. Close by turning clockwise.
Figure 4
DANGER
Do not use an open flame to check for gas
leaks. Be sure there are no sparks or open
flames in the area while you check for
leaks. This will result in a fire or explosion
which can cause serious bodily injury or
death and damage to property.
You will need: LP tank, a soap and water solution and a
rag or brush to apply it.
Note - Since some leak test solutions, including soap and
water, may be slightly corrosive, all connections should be
rinsed with water after checking for leaks
a) Lift and hook the tank onto the fuel scale.
b) Loosen the tank lock wing nut. Swing the tank lock
down. Tighten the wing nut. Figure 4.
27
c) Connect the hose to the tank. Route the hose so it
does not interfere with the scale indicator rod. Slide
back the collar of the quick disconnect on the tank
valve. Figure 5 (a). Push the male fitting of the
regulator into the quick disconnect, and maintain
pressure. Slide the collar closed. Figure 5 (b). If it does
not engage or lock, repeat procedure. Gas will not flow
unless the quick disconnect is properly engaged.
f) Check for leaks by wetting the fitting with the soap
and water solution and watching for bubbles. If
bubbles form or if a bubble grows there is a leak.
If leak does not stop, turn off the gas and contact
Weber-Stephen Customer Service. Do not use the
barbecue.
g) When leak checks are complete, turn gas supply OFF
and rinse connections with water.
LP Tank
The LP tank manufacturer is responsible for the materials,
workmanship and performance of the tank. If the tank has
a defect, malfunctions, or you have a question regarding
the tank, call the tank manufacturer's customer service
center. The phone number is on the warning decal which
is permanently attached to the tank. If the tank manufacturer
has not resolved the issue to your satisfaction, then call
Weber-Stephen Products Co., Customer Service Center.
Figure 6
Male fitting
Regulator Collar
Quick disconnect
engaged
Figure 5
(a)
(b)
d) Mix soap and water.
e) Open the tank valve. Figure 6.
2828
Safe handling tips for LP Gas
■Liquid Propane (LP) gas is a petroleum product as are
gasoline and natural gas. LP gas is a gas at regular
temperatures and pressures. Under moderate
pressure, inside a cylinder, LP gas is a liquid. As the
pressure is released the liquid readily vaporizes and
becomes gas.
■LP gas has an odor similar to natural gas. You should
know this odor.
■LP gas is heavier than air. Leaking LP gas may collect
in low areas that prevent dispersion.
■To fill, take the LP tank to an RV center, or look up
gas-propane in the phone book for other sources of
LP gas.
WARNING: We recommend that your LP tank be
filled at an authorized LP gas dealer, by a qualified
attendant, who fills the tank by weight. IMPROPER
FILLING IS DANGEROUS.
WARNING: If you exchange your LP tank, make
sure you get a similar tank in return. Your LP tank is
equipped with a quick-disconnect valve and an OPD
(Overfilling Prevention Device). Other LP tanks are not
compatible with your barbecue connection.
■Air must be removed from a new LP tank before the
initial filling. Your LP dealer is equipped to do this.
■The LP tank must be installed, transported and stored
in an upright position. LP tanks should not be dropped
or handled roughly.
■Never store or transport the LP tank where temperatures
can reach 125° F (too hot to hold by hand - for example:
do not leave the LP tank in a car on a hot day).
Note - A refill will last about 20 hours of cooking time at
normal use. The fuel scale will indicate the propane
supply so you can refill before running out. You do not
have to run out before you refill.
■Treat "empty" LP tanks with the same care as when
full. Even when the LP tank is empty of liquid there
still may be gas pressure in the cylinder. Always
close the tank valve before disconnecting.
■Do not use a damaged LP tank. Dented or rusty LP
tanks or LP tanks with a damaged valve may be
hazardous and should be replaced with a new one
immediately.
■The joint where the hose connects to the LP tank must
be leak tested each time the LP tank is reconnected.
For example, test each time the LP tank is refilled.
■Be sure the regulator is mounted with the small vent
hole pointed downward so it will not collect water. This
vent should be free of dirt, grease, bugs etc.
Liquid Propane (LP) Tank(s)
■The LP tank and connections supplied with your
Weber Gas Barbecue have been designed and tested
to meet government, American Gas Association and
Underwriters Laboratories requirements.
■Replacement LP tanks supplied by Weber satisfy the
requirements. Check to be sure the tank has a D.O.T.
certification, and has been tested within five years.
Your LP gas supplier can do this for you. Figure 7.
If you have questions about spare LP tanks, please
call Weber-Stephen Customer Service.
DOT 4BA240
1/97
Date Tested
20 lb LP tank
D.O.T. Certification (example)
■All LP tank supply systems must include a collar to
protect the tank valve.
■The LP tank must be a 20 lb size (18 1/4 inches high,
12 1/4 inches in diameter).
■The LP tank must be constructed and marked in
accordance with the specifications for LP gas cylinders
of the U.S. Department of Transportation (D.O.T.).
Figure 7
29
c) Valves to manifold connections. Figure 8 (c).
d) The hose to regulator connection. Figure 8 (d).
WARNING: If there is a leak at connection
(b), (c) or (d), turn OFF the gas. DO NOT OPERATE
THE BARBECUE. Contact Weber-Stephen Customer
Service.
When leak checks are complete, turn gas supply OFF at
the source and rinse connections with water.
Inspection and Cleaning of the Weber Spider
Stopper Guards
To inspect the Spider Stopper Guards, remove the control
panel and look to see if they have dust or dirt on their
outside surfaces. If they are dirty, brush off the outside
surface of the Spider Stopper Guards with a soft bristle
brush (an old toothbrush for example). Check that there
are no gaps in the Spider Stopper Guards’ seams or in the
fit around the burners or valves. (See Section "General
Maintenance".)
Figure 8
(b)
(c)
(d)
(a)
Annual Maintenance
After a period of nonuse we recommend that you perform
the following maintenance procedures for your safety.
WARNING: Check hose before each use of barbecue
for nicks, cracking, abrasions or cuts. If the hose is
found to be damaged in any way, do not use the
barbecue. Replace using only Weber authorized
replacement manifold assembly. Order from Weber-
Stephen Products Co., Customer Service Center or
authorized dealer.
■Inspect the burners for correct flame pattern. Clean if
necessary, following the procedures outlined in the
"General Maintenance" section of this manual.
■Check all gas fittings for leaks.
DANGER
Do not use an open flame to check for gas
leaks. Be sure there are no sparks or open
flames in the area while you check for
leaks. This will result in a fire or explosion
which can cause serious bodily injury or
death, and damage to property.
WARNING: You should check for gas leaks every
time you disconnect and reconnect a gas fitting.
You will need: a soap and water solution and a rag or
brush to apply it.
To perform leak checks: Make sure all burners are in the
OFF position. Turn on gas supply.
WARNING: Do not ignite burners while leak checking.
Check for leaks by wetting the connections with the soap
and water solution and watching for bubbles. If bubbles
form or if a bubble grows there is a leak.
Note - Since some leak test solutions, including soap and
water, may be slightly corrosive, all connections should be
rinsed with water after checking for leaks.
Check:
a) Hose to manifold connection. Figure 8 (a).
b) Regulator to tank connection. Figure 8 (b).
WARNING: If there is a leak at connection (a)
retighten the fitting with a wrench and recheck for
leaks with soap and water solution.
If a leak persists after retightening the fitting, turn OFF
the gas. DO NOT OPERATE THE BARBECUE. Contact
Weber-Stephen Customer Service.
30
General Maintenance
Weber Spider Stopper Guards
Your Weber Gas Barbecue, as well as any outdoor gas
appliance, is a target for spiders and other insects. They
can nest in the venturi section of the burner tubes. This
blocks the normal gas flow, and can cause the gas to flow
back out of the air shutter. Figure 9. This could result in a
fire in and around the air shutters, under the control panel,
causing serious damage to your barbecue.
Main Burner Flame Pattern
The Weber Gas Barbecue burners have been factory set
for the correct air and gas mixture. The correct flame
pattern is shown in Figure 11.
Burner inside
cooking box
Figure 11 Dark blue
Light blue
Tips occasionally yellowish
Figure 9
Venturi
Air shutter Venturi fin
Weber Spider
Stopper Guard
Figure 10
DANGER
Failure to correct these symptoms may
result in a fire which can cause serious
bodily injury or death and cause damage
to property.
Figure 12
Figure 13
The Weber Spider Stopper Guard is factory installed. It fits
tightly around the air shutter section of the burner tube and
the valve, thereby preventing spiders and other insects
access to the burner tubes through the air shutter openings.
Figure 10.
We recommend that you inspect the Weber Spider
Stopper Guards at least once a year. (See Section
“Annual Maintenance”.) Also inspect and clean the
Spider Stopper Guards if any of the following
symptoms should ever occur.
1. The smell of gas in conjunction with the burner flames
appearing yellow and lazy.
2. Barbecue does not reach temperature.
3. Barbecue heats unevenly.
4. One or more of the burners do not ignite.
If the flames do not appear to be uniform the length of the
burner tube, follow the burner cleaning procedures.
Main Burner Cleaning Procedure
Turn off the gas supply. Remove the manifold. (See
Section “Replacing the main burners”.)
Look inside each burner with a flashlight. Figure 12.
Clean the inside of the burners with a wire (a straightened
out coat hanger will work). Figure 13. Check and clean the
air shutter opening at the ends of the burners. Check and
clean the valve orifices at the base of the valves. Use a
brass bristle brush to clean outside of burners. This is to
make sure all the burner ports are fully open.
CAUTION: Do not enlarge the burner ports when
cleaning.
Replacing Main Burners
a) Your Weber Gas Barbecue must be OFF and cool.
b) Turn gas OFF at source.
c) Remove control panel: take off the burner control
knobs. Remove the screws holding the control panel
in place. Lift off the control panel.
31
View from behind
cooking box
Wing nuts
Figure 15
Guide screw
Figure 16
Crossover tube
Figure 17
Figure 14
d) Unlatch the Spider Stopper Guards and remove.
Figure 14.
e) Remove the manifold bracket and unscrew the two
wing nuts that hold the manifold to the cooking box.
Pull the manifold and valve assembly out of the
burners and carefully set it down. Figure 15.
f) Slide the burner assembly out from under the guide
screw and washer in the corners of the cooking box.
Figure 16.
g) Lift and twist the burner assembly slightly, to separate
the crossover tube from the burners. Figure 17.
Remove the burners from the cooking box.
Figure 18
Valve
Burner
(a)
(b)
h) To reinstall the burners, reverse steps c) through g).
CAUTION: The burner openings must be positioned
properly over the valve orifices. Figure 18a.
Check proper assembly before fastening manifold in
place. Figure 18b.
32
i) Reinstall the Spider Stopper Guards. Slightly rotate
the Spider Stopper Guards so that the seams are in
line with the Venturi fins. There should be no gaps in
the seams or in the fit around the burners and valves.
Figure 19.
Venturi fin
Figure 19
Check fit
around valve
Check fit around burner
Figure 20
White wire
Black wire
CAUTION: If the Spider Stopper Guards do not fit
tightly, contact Weber-Stephen Customer Service.
WARNING: After reinstalling the gas lines, they
should be leak checked with a soap and water
solution before using the barbecue. See Step“Check
for gas leaks”.
■Check that the Crossover Ignition button pushes the
igniter (button) down, and returns to the up position.
■Check to see if the igniter is loose in the frame.
Tighten if necessary; See Step “Install igniter” for
correct procedure.
If the Crossover Ignition System still fails to light, contact
Weber-Stephen Customer Service.
Crossover Ignition System Operations
If the Crossover Ignition System fails to ignite the Front
burner, light the Front burner with a match. If the Front
burner lights with a match, then check the Crossover
Ignition System.
■Check that both the white and black ignition wires are
attached properly. Figure 20.
Problem
Burners burn with a yellow or orange
flame, in conjunction with the smell of gas.
Burners do not light. -or-
Burners have a small flickering flame in the
HIGH position. -or-
Barbecue temperature only reaches 250˚ to
300˚ degrees in the HIGH position.
Burner does not light, or flame is low in
HIGH position.
Experiencing flare-ups:
CAUTION: Do not line the bottom tray
with aluminum foil.
Burner flame pattern is erratic. Flame is low
when burner is on HIGH. Flames do not run
the whole length of the burner tube.
Inside of lid appears to be “peeling.”
(Resembles paint peeling.)
Fuel scale shows that there is gas in the LP
tank, but tank is empty.
Check
Inspect Weber Spider Stopper
Guards for possible obstructions.
(Blockage of holes.)
The excess flow safety device,
which is part of the barbecue to tank
connection, may have activated.
Is LP fuel low or empty?
Is fuel hose bent or kinked?
Does the Front burner light with a
match?
Are you preheating barbecue in the
prescribed manner?
Are the cooking grates and
Flavorizer Bars heavily coated with
burned-on grease?
Is the bottom tray "dirty" and not
allowing grease to flow into catch
pan?
Are burners clean?
The lid is porcelain-on-steel, not
paint. It cannot “peel.” What you are
seeing is baked on grease that has
turned to carbon and is flaking off.
THIS IS NOT A DEFECT.
Check adjustment of fuel scale.
Cure
Clean Weber Spider Stopper
Guards. (See Section "Annual
Maintenance".)
To reset the excess flow safety
device turn all burner control
knobs and the tank valve OFF.
Disconnect the regulator from the
tank. Turn burner control knobs
to HIGH. Wait at least 1 minute.
Turn burner control knobs OFF.
Reconnect the regulator to the
tank. Turn tank valve on slowly.
Refer to “Lighting Instructions”.
Refill LP tank.
Straighten fuel hose.
If you can light the Front burner
with a match, then check the
Crossover Ignition System.
All burners on high for 10 to 15
minutes for preheating.
Clean thoroughly. (See Section
"Periodic Cleaning".)
Clean bottom tray.
Clean burners. (See Section
"General Maintenance".)
Clean thoroughly. (See Section
"Periodic Cleaning".)
Fuel scale must be adjusted with
an empty tank.
TROUBLESHOOTING
If problems cannot be corrected by using these methods, please contact Weber-Stephen Customer Service.
33
34
W
E
B
E
R
W
E
B
E
R
®®
®®
®®
®®
1
2
3
6
7
8
10
9
13-14
21
22
15
27 29 30
31 33
63
55
65
60
53
51
50
49
48
47
45
44
43
42
41
40
39
61-62
54
52
28
23 37
38
46
11
12
16
17
20
18
5
4
2625
24 32
19
10,14
64
35
1 Lid (assembly)
2 Lid handle
3 Warm-Up Basket
4 Warming rack
5 Short Flavorizer bars (8)
6 Long Flavorizer bars (5)
7 Cooking grates (2)
8 Work table
9 Tubing plugs (5)
10 1/4-20 x 2 inch bolts (5)
11 Swing table end bracket
12 Left frame
13 1/4-20 x 1/2 inch bolts (6)
14 1/4 inch nylon washers (14)
15 Caster frame
16 Swing table assembly
17 Support rod holder
18 Support rod
19 Casters (2)
20 Bottom tray
21 Catch pan holder
22 Catch pan
23 Drip pans (2)
24 Accessory rack
25 Frame connectors (2)
26 Wheel hubcaps (2)
27 Wheels (2)
28 Tool holders (3)
29 Wheel frame
30 Front panel
31 Plastic buttons (2)
32 Axle
33 Tank glides (2)
34 Glide axle
35 Glide hubcaps (2)
36 Tank panel
37 1/4-20 x 1 1/4 inch bolt
38 1/4-20 hex nut
39 Hair pin cotters (2)
40 Hinge pins (2)
41 Thermometer
42 1/4-20 keps nut
43 Cooking box
44 Burner control knobs (3)
45 Control panel
46 Igniter button
47 Phillips screws/washers (2)
48 Crossover tube
49 Front and back burners (2)
50 Center burner
51 1/4-20 stainless steel wing nuts (2)
52 Spider Stopper Guards (3)
53 Manifold assembly
54 Manifold bracket
55 Igniter
56 Igniter lock nut
57 Gas catcher ignition chamber
58 Igniter wire (black)
59 Igniter wire (white)
60 Right frame
61 Fuel scale
62 1/4-20 wing nuts (2)
63 LP tank
64 Filler adapter
65 Control panel insert (2)
WARNING: Use only Weber factory
authorized parts. The use of any part that is
not factory authorized can be dangerous.
This will also void your warranty.
Parts List
All items are single quantities unless otherwise specified.
Parts can be ordered directly from Weber-Stephen
Products Company by phone or mail.
Note - Do not return parts to Weber-Stephen Products Co.
without first contacting the Customer Service Center by
phone or mail. Returning the part may not be necessary.
While we give much attention to our products,
unfortunately an occasional error may occur. If a part is
missing, do not go back to the store. Call the Weber
Customer Service Center toll free 1-800-446-1071 to
receive immediate assistance. Have your owner’s manual
and serial number of the barbecue available for reference.
Weber-Stephen Products Company
Customer Service Center
250 South Hicks Road
Palatine, IL 60067-6241
(800) 446-1071
A FINAL WORD
OF THANKS
hank you for choosing a Weber Barbecue.
Our family here at Weber has worked hard
to produce the highest quality products
for your satisfaction.
While we give much attention to our products, an
occasional error may occur. Our knowledgeable Customer
Service staff is prepared to help you with any problems
with parts or assembly.
Call our toll free number 1-800-446-1071.
For quicker service, please have your owner’s manual
available for reference. We also welcome any comments or
suggestions you might have regarding our products.
We wish your family the
best in outdoor cooking enjoyment.
Weber-Stephen Products Company
Customer Service Center
200 East Daniels Road
Palatine, Illinois 60067-6266
T

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