Weber 55767 Owners Manual Genesis Silver C LP Guide 10/28/2003 PDF File

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GENESIS®
WARNING: Follow all leak-check
procedures carefully in this manual prior to
barbecue operation. Do this even if the
barbecue was dealer-assembled.
NOTICE TO INSTALLER: These instructions
must be left with the owner and the owner
should keep them for future use.
THIS GAS APPLIANCE IS DESIGNED FOR
OUTDOOR USE ONLY.
WARNING
1. Do not store spare liquid propane
cylinder within 10 feet (3m) of this
appliance.
2. Do not store or use gasoline or other
flammable liquids or vapors within 25
feet (8m) of this appliance.
DANGER
If you smell gas:
1. Shut off gas to the appliance.
2. Extinguish any open flames.
3. Open lid
4. If odor continues, keep away from the
appliance and immediately call your gas
supplier or your fire department.
Leaking gas may cause a fire or explosion
which can cause serious bodily injury or
death, or damage to property.
YOU MUST READ THIS OWNER’S GUIDE
BEFORE OPERATING YOUR GAS GRILL
55767 US 10/28/03
Premium Cast Iron LP
US English
LP Gas Grill Owner’s Guide
WARNING: Do not try to light this
appliance without reading the “Lighting”
Instructions section of this manual
A328_LP.b
Ba303.b
B308_LP.b
C202_LP.d
D202_LP.c
E201.c
#55767
A-2
Dangers & Warnings
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 liquid propane cylinder 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 use. 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. Accessible parts of the barbecue may
be very hot. Keep young children away while it is in use.
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, or moved while in operation.
Should the burners go out while in 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.
Liquid propane gas is not natural gas. The conversion or attempted use of natural gas in a liquid
propane unit or liquid propane 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.
Keep any electrical supply cord and the fuel supply hose away from any heated surfaces.
Combustion byproducts produced when using this product contain chemicals known to the state of
California to cause cancer, birth defects, or other reproductive harm.
Do not use this barbecue unless all parts are in place. The unit must be properly assembled
according to the instructions outlined in the “Assembly Instruction” section of the Owner’s Guide.
LIQUID PROPANE 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 liquid propane cylinder may be hazardous and should be checked by your liquid
propane supplier. Do not use a liquid propane cylinder with a damaged valve.
Although your liquid propane cylinder may appear to be empty, gas may still be present, and the
cylinder should be transported and stored accordingly.
If you see, smell or hear the hiss of escaping gas from the liquid propane cylinder:
1. Move away from liquid propane cylinder.
2. Do not attempt to correct the problem yourself.
3. Call your fire department.
A-3
Contents
Danger & Warnings ..................................................................................A-2
Warranty ..................................................................................................A-4
General Instructions .................................................................................A-5
Cooking ...................................................................................................A-6
Cleaning ..................................................................................................A-6
Exploded View .........................................................................................A-7
Parts List ...................................................................................................A-9
Unpacking ...............................................................................................A-10
Assembly Instructions...............................................................................B-a
Gas Instructions .......................................................................................C-1
Leak Checking .........................................................................................C-3
Refilling the LP Cylinder...........................................................................C-4
Safe handling tips for LP Gas ....................................................................C-5
Operating.................................................................................................D-1
Lighting ....................................................................................................D-1
Manual Lighting .......................................................................................D-2
Lighting the side burner............................................................................D-3
Troubleshooting .......................................................................................D-4
Side Burner Troubleshooting.....................................................................D-5
Maintenance ............................................................................................E-1
Replacing Main Burners ...........................................................................E-2
Crossover® Ignition System Operations .....................................................E-2
A-4
Weber-Stephen Products Co. (Weber) hereby warrants to
the ORIGINAL PURCHASER of this Weber® gas grill that
it will be free of defects in material and workmanship from
the date of purchase as follows:
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 that 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 the Customer service
representative in your region using the contact
information sheet provided with your manual. 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 regions 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 regions 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
1890 Roselle Road, Suite 308
Schaumburg, IL 60195
USA
www.weber.com
LP Cylinder
The LP cylinder manufacturer is responsible for the
materials, workmanship and performance of the cylinder.
If the cylinder has a defect, malfunctions, or you have a
question regarding the cylinder, call the cylinder
manufacturer’s customer service center. The phone
number is on the warning label, which is permanently
attached to the cylinder. If the cylinder manufacturer has
not resolved the issue to your satisfaction, then call
Weber-Stephen Products Co., Customer Service Center.
Warranty
Aluminum Castings, lifetime, 1 year paint
Stainless Steel Hood Section, 25 years
Porcelain Hood Section, 25 years
Burners, 10 years
Igniter, 3 years
Porcelain Enameled
Cooking Grates, 3 years no rust
through
Porcelain Enameled Cast Iron
Cooking Grates, 5 years no rust
through
Stainless Steel Cooking Grates, 7 years no rust
through
Porcelain Enameled
Flavorizer® Bars, 1 year no rust
through
Stainless Steel
Flavorizer® Bars, 5 year no rust
through
Thermoplastic/Thermoset Parts, 10 years Excluding
fading
All Remaining Parts, 5 years
A-5
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, 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 require-
ments 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/NFPA54.
• 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 areas around the LP cylinder 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 (Installa-
tion Code for Propane Burning Appliances and Equip-
ment).
Operating
WARNING: Only use this barbecue outdoors in a
well-ventilated area. Do not use in a garage, build-
ing, breezeway or any other enclosed area.
WARNING: Your Weber® gas barbecue shall not be
used under an unprotected combustible roof or
overhang.
WARNING: Your Weber® gas barbecue is not in-
tended to be installed in or on recreational vehicles
and/or boats.
WARNING: Do not use the barbecue within 24
inches of combustible materials, top, bottom, back
or sides of the grill.
WARNING: The entire cooking box gets hot when in
use. Do not leave unattended.
WARNING: Keep any electrical supply cord and the
fuel supply hose away from any heated surface.
WARNING: Keep the cooking area clear of flam-
mable vapors and liquids such as gasoline, alcohol,
etc., and combustible materials.
WARNING: Never store an extra (spare) LP cylinder
under or near the Weber® gas barbecue.
Storage and/or Nonuse
• The gas must be turned off at the liquid propane cylinder
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
cylinder stored outdoors in a well-ventilated space.
• LP cylinder must be stored outdoors in a well -ventilated
area out of reach of children. Disconnected LP cylinder
must not be stored in a building, garage or any other
enclosed area.
• When the LP cylinder 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 Maintenance and Annual
Maintenance.”)
• Check that the areas under the control panel and the
slide out bottom tray are free from debris that might
obstruct the flow of combustion or ventilation air.
• The Spider /Insect Screens should also be checked for
any obstructions. (See Section: “Annual Maintenance.”)
A-6
General Instructions
Cooking
WARNING: Do not move the Weber® gas barbecue
when operating or while barbecue is hot.
You can adjust the FRONT 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 and BACK burners. For example, to sear
steaks, you would set all burners at H (high). Then to
complete cooking, you would set FRONT and BACK at M
(medium). Refer to your Weber® cookbook for detailed
cooking instructions.
Note: The temperature 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. Such as wind and weather, may require the
adjustment of the burner controls to obtain 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 five minutes before relighting.
Preheating - Your Weber® gas barbecue is an energy-
efficient appliance. It operates at an economical low BTU
rate. To preheat: after lighting, close lid and turn all
burners to high (HH). 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 correct amount of drippings for
flavorful cooking. Excess drippings and grease will
accumulate in the catch pan under the slide out bottom
tray. Disposable foil drip pans 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 slide out bottom tray.
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.
For availability of replacement cooking grates and
Flavorizer® bars contact the
Customer Service Representative in your region using
the contact information sheet
provided with your manual.
Outside surfaces - Use a warm soapy water solution to
clean, then rinse with water.
CAUTION: Do not use oven cleaner, abrasive
cleansers (kitchen cleansers) cleaners that contain
citrus products, or abrasive cleaning pads on
barbecue or cart surfaces.
Slide out Bottom tray - Remove excess grease, then
wash with warm soapy water, then rinse
Flavorizer® bars and Cooking grates - Clean with a
suitable brass bristle brush. As needed, remove from grill
and wash with warm soapy water, then rinse with 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, then rinse.
Thermometer - Wipe with warm soapy water; clean with
plastic scrub ball. Do not put in dishwasher or submerge
in water.
Inside cooking module - Brush any debris off of burner
tubes. DO NOT ENLARGE BURNER PORTS
(OPENINGS). Wash inside of cooking box with warm
soapy water and a water rinse.
Inside Lid - While lid is warm, wipe inside with paper
towel to prevent grease build-up. Flaking built-up grease
resembles paint flakes.
Stainless steel surfaces - Wash with a soft cloth and a
soap and water solution. Be careful to scrub with the grain
direction of the stainless steel.
Thermoset surfaces - Wash with a soft cloth and a soap
and water solution.
Do not use cleaners that contain acid, mineral spirits
or xylene. Rinse well after cleaning.
Thermoset work surfaces are not to be used as
cutting boards.
A-7
Exploded View
12
Genesis
®
Silver-C PremHD LP
10220
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A-8
Exploded View List
1. Hinge Pin
2. Left Endcap
3. Shroud
4. Handle
5. Warm-Up™ Basket
6. Warming Rack
7. Cooking Grates
8. Flavorizer® Bars
9. Cooking Box
10. 1/4-20 keps nut
11. Slide Out Bottom Tray
12. Work Surface
13. Catch Pan Holder
14. Left Rear Trim Assembly Arm
15. 1/4 - 14 x 5/8 inch bolt
16. Left Trim Piece
17. Left Front Trim Assembly Arm
18. 1/4 - 20 x 2 1/4 inch bolt
19. Fuel Gauge Hardware
20. Left Swing-Up Table Assembly
21. 1/4 - 20 x 1 inch bolt
22. Nylon Washer
23. Caster Frame
24. Caster
25. Bottom Rack
26. Wheel
27. Hubcap
28. Hair Pin Cotter
29. Right Endcap
30. Thermometer Bezel Assembly
31. Thermometer Assembly
32. Handle Hardware
33. Control Panel Knobs
34. Control Panel
35. Control Panel Hardware
36. Crossover® Ignition Button
37. Crossover® tube
38. Front / Rear Burner
39. Center Burner
40. Manifold Hardware
41. Manifold, Hose and regulator (assembled)
42. Catch Pan
43. Disposable Drip Pan
44. Igniter
45. Top Frame Assembly
46. Side Burner
47. Fuel Gauge
48. Right Rear Trim Assembly Arm
49. Right Trim Piece
50. Right Front Trim Assembly Arm
51. Right Swing-Up Table Assembly
52. Front Panel
53. LP Tank
54. Cylinder Glides
55. Wheel Frame
56. 1/4 - 20 x 1 3/4 inch bolt
A-9
Parts List
Cooking Box Assembly - 1
Caster Frame - 1
Wheel Frame - 1
Bottom Rack - 1
Left Trim Assembly - 1
Left Side Swing Up Table - 1
Side Table - 1
Flavorizer® Bars - 5
Warm-Up™ Basket - 1
Warming Rack - 1
LP Tank - 1
Bottom Tray - 1
Catch-Pan Holder - 1
Catch-Pan - 1
Disposable Drip Pans - 2
1 inch Bolts (1/4 x 20 x 1 inch Bolt) - 8
Nylon Washer - 8
Wrench - 1
Right Trim Assembly - 1
Side Burner - 1
Cooking Grate - 2
7/16 inch Wrench - 1
Right Side Swing Up Table - 1
A-10
Unpacking
1
2
3
4
B-a
1
• Push down firmly until Bottom Rack Locking Clip, "locks" under the rail.
• Arrow sticker to the front.
b
a
c
123
Ba303.b
B-b
2
a
• Push down firmly on both sides to
ensure bottom rack is locked under
the rails. WARNING: Do not go to
next step if bottom rack is not locked in place
b
321
B-c
3
• Install bolts at indicated locations. Use supplied tool to tighten.
Recheck each bolt for tightness with a 7/16” open end wrench.
B-1
4
B308_LP.b
B-2
5
B-3
6
a
b
7
B-4
ab
8
c
B-5
10
9
b
a
12
11
B-6
12
C-1
Gas Instructions
Important LP Cylinder Information
Failure to follow these DANGER statements exactly may
result in a fire causing death or serious injury.
DANGER
NEVER store a spare LP Cylinder under or near this
barbecue.
NEVER fill the tank beyond 80% full.
Your Weber® gas grill is equipped with a cylinder
supply system designed for vapor withdrawal.
WARNING: Only use this grill outdoors in a well-
ventilated area. Do not use in a garage, building,
breezeway or any other enclosed area.
The LP cylinder supplied with your barbecue is
equipped with an OPD (Overfilling Prevention Device)
and a QCC1 or Type 1 (CGA810) cylinder connection.
The cylinder connection is compatible with the
barbecue connection.
This is a secondary device to prevent the overfilling of your
LP cylinder. The proper filling methods for the filling of your
cylinder are by weight or volume, as described in NFPA 58.
Please make sure your filling station fills your LP cylinder
by weight or volume. Ask your filling station to read purging
and filling instructions on the LP cylinder before attempting
to fill.
WARNING: Do not exchange the LP tank provided
with your barbecue, unless the exchange LP tank is
equipped with an OPD. Otherwise you will lose the
OPD (Overfilling Prevention Device) feature. If there
is not an LP tank available for exchange equipped
with an OPD, we recommend that you have your LP
tank filled at an authorized LP gas dealer by a
qualified attendant.
Connecting the Liquid Propane
Cylinder
WARNING: Make sure that the LP cylinder valve is
closed. Close by turning valve clockwise.
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.
Sparks or flames will result in a fire or
explosion which can cause serious bodily
injury or death, and damage to property.
Raises up while filling
then stops when full.
Check that all burner valves are off
Valves are shipped in the OFF position, but you should
check to be sure that they are turned OFF. Check by
pushing down and turning clockwise. If they do not turn,
they are off. Proceed to the next step. If they do turn
continue turning them clockwise until they stop, then they
are off. Proceed to the next step.
Fill liquid propane cylinder
Note - The liquid propane cylinder manufacturer is
responsible for the materials, workmanship and
performance of the cylinder. If the cylinder has a defect,
malfunctions, or you have a question regarding the
cylinder, call the cylinder manufacturer’s customer service
center. The phone number is on the warning decal, which
is permanently attached to the cylinder. If the cylinder
manufacturer has not resolved the issue to your
satisfaction, then contact the Customer Service
Representative in your region using the contact information
sheet provided with your manual.
To fill, take the liquid propane cylinder and filler adapter to
an RV center or look up gas-propane in the phone book for
other sources of liquid propane gas.
WARNING: We recommend that your liquid propane
cylinder be filled at an authorized liquid propane
gas dealer by a qualified attendant, who fills the
tank by weight.
IMPROPER FILLING IS DANGEROUS.
Tell your liquid propane dealer that this is a new liquid
propane cylinder. The air must be removed from a new
liquid propane cylinder before the initial filling. Your liquid
propane cylinder dealer is equipped to do this.
The liquid propane cylinder must be installed, transported
and stored in an upright position, and should not be
dropped or handled roughly.
Never store or transport the liquid propane cylinder where
temperatures can reach 125° Fahrenheit (too hot to hold
by hand – for example: do not leave the liquid propane
cylinder in a car on a hot day).
For full instructions on safe handling of liquid propane
cylinders, see Section “Operating”.
C202_LP.d
C-2
Gas Instructions
Pass regulator through left hole in support panel.
We utilize various LP tank manufacturers. Some of the
tanks have differing top collar assembles. (The top collar
is the metal protective ring around the valve.) One series
of tanks mount with the valve facing front. The other tanks
mount with the valve facing away from the fuel scale.
These types of tanks are illustrated below.
You will need: LP cylinder, a soap and water solution and a
rag or brush to apply it.
1) Turn the LP cylinder so the opening of the valve is
either to the front, side or rear of the Weber® gas
barbecue. Lift and hook the cylinder onto the fuel
gauge.
2) Loosen the cylinder lock wing nut. Swing the cylinder
lock down. Tighten the wing nut.
To Connect the hose to the cylinder:
3) Remove the plastic dust cover from the valve.
4) Screw the regulator coupling onto the tank valve,
clockwise, or to the right. Hand-tighten only.
Note: This is a new type of connection. It tightens
clockwise and will not allow gas to flow unless the
connection is tight. The connection requires tightening by
hand only.
WARNING: Do not use a wrench to tighten the
connection. Using a wrench could damage the
regulator coupling and could cause a leak.
5) Mix soap and water.
6) Turn on the cylinder valve.
7) 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 there is a leak, turn off the gas and tighten the fitting. Turn
the gas back on and recheck with the soap and water
solution.
If leak does not stop, Contact the Customer Service
Representative in your region using the contact information
sheet provided with your manual. Do not use the barbecue.
8) When leak checking is complete, turn gas supply OFF
at the source and rinse connections with water.
C-3
Gas Instructions
Check for gas 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.
Sparks or open flames 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.
Note - All factory-made connections have been thoroughly
checked for gas leaks. The burners have been flame-tested.
As a safety precaution however, you should recheck all
fittings for leaks before using your Weber Gas Barbecue.
Shipping and handling may loosen or damage 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.
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.
Make sure side burner is OFF.
To perform leak checks: open cylinder valve by turning the
cylinder valve hand-wheel counterclockwise.
WARNING: Do not ignite burners when 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.
Remove control panel and burner control knobs
You will need: Phillips screwdriver.
1) Remove control knobs.
2) Unhook side burner from Cookbox Frame.
3) Remove screws with a Phillips screwdriver
4) Pull up igniter button until it sticks in the up position and
remove control panel from grill.
(3)
(4)
(1)
(2)
5) Replace control panel when Leak Check is completed.
C-4
Gas Instructions
Liquid Propane Cylinder
The liquid propane cylinder 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 contact the Customer Service
Representative in your region using the contact information
sheet provided with your manual.
Refilling the Liquid Propane Cylinder
We recommend that you refill the LP cylinder before it is
completely empty.
Removal of the LP cylinder
1) Close cylinder valve (turn clockwise).
2) Unscrew regulator coupling by turning
counterclockwise, by hand only.
3) Loosen cylinder lock wing nut and turn cylinder lock up
out of the way.
4) Lift cylinder off.
To refill, take LP cylinder to a “Gas Propane” dealer.
WARNING: We recommend that your LP cylinder be
filled at an authorized LP gas dealer, by a qualified
attendant, who fills the cylinder by weight.
IMPROPER FILLING IS DANGEROUS.
CAUTION: When transporting the LP cylinder make
sure the plastic dust cover is in place over the
valve. This will keep dust and dirt from the threaded
portion of the valve.
Checking the fuel level in your tank
Check the fuel level by viewing the color indicator level
line on the side of the tank scale.
1) Empty
2) Medium
3) Full
(3)
(1)
(1) (2) (3)
(1)
(2)
(3)
(4)
(5)
(6)
Check:
1) Hose to manifold connection.
WARNING: If there is a leak at connection (1),
retighten the fitting with a wrench and recheck for
leaks with soap and water solution.
If a leak persists after re-tightening the fitting, turn OFF
the gas. DO NOT OPERATE THE GRILL. Contact the
Customer Service Representative in your region using
the contact information sheet provided with your
manual.
2) Regulator to cylinder connection.
3) Manifold to side burner hose connection.
4) Side burner hose to side burner connection.
5) Valves to manifold connections.
6) Hose to regulator connection.
WARNING: If there is a leak at connections (2,3,4,5 or
6), turn OFF the gas. DO NOT OPERATE THE GRILL.
Contact the Customer Service Representative in your
region using the contact information sheet provided
with your manual.
When leak checks are complete, turn gas supply OFF at
the source and rinse connections with water.
C-5
Gas Instructions
Safe handling tips for Liquid Propane
Gas Cylinders
■ 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
be aware of this odor.
■ LP gas is heavier than air. Leaking LP gas may collect
in low areas and prevent dispersion.
■ To fill, take the LP cylinder 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 cylinder 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 cylinder, make
sure you get a similar tank in return. Your LP
cylinder is equipped with a quick closing coupling
or type 1 valve and an OPD (Overfilling Prevention
Device). Other LP cylinders may not be compatible
with your barbecue connection.
■ Air must be removed from a new LP cylinder before the
initial filling. Your LP dealer is equipped to do this.
■ The LP cylinder must be installed, transported and
stored in an upright position. LP cylinders should not be
dropped or handled roughly.
■ Never store or transport the LP cylinder where
temperatures can reach 125° F (too hot to hold by hand
- for example: do not leave the LP cylinder 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 cylinders 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
cylinder valve before disconnecting.
CAUTION: When transporting the LP cylinder make
sure the plastic dust cover is in place over the
valve. This will keep dust and dirt from the threaded
portion of the valve.
■ Do not use a damaged LP cylinder. Dented or rusty LP
cylinders or LP cylinders with a damaged valve may be
hazardous and should be replaced with a new one
immediately.
Liquid Propane (LP) Cylinder(s)
■The joint where the hose connects to the LP cylinder
must be leak tested each time the LP cylinder is
reconnected. For example, test each time the LP
cylinder is refilled.
■ Be sure the regulator is mounted with the small vent
hole pointed downward so that it will not collect water.
This vent should be free of dirt, grease, bugs etc.
■The LP cylinder and connections supplied with your
Weber® gas barbecue have been designed and tested
to meet government, American Gas Association, and
Underwriters Laboratories requirements.
Liquid Propane Cylinder requirements
■ Replacement LP cylinders supplied by Weber satisfy
the above requirements. Check to be sure other
cylinders have a D.O.T. certification(1), and date
tested(2) is within five years. Your LP gas supplier can
do this for you.
If you have questions about spare LP cylinders
contact the Customer Service Representative in your
region using the contact information sheet provided
with your manual.
■All LP tank supply systems must include a collar to
protect the cylinder valve.
■The LP cylinder must be a 20-lb. size (18 1/4 inches
high, 12 1/4 inches in diameter).
■The LP cylinder must be constructed and marked in
accordance with the specifications for LP gas cylinders
of the U.S. Department of Transportation (D.O.T.).
For Canada Only
Liquid Propane Cylinder requirements
WARNING: Replacement LP tanks must match the
regulator connection supplied with this barbecue.
Note: Your retailer can help you match a replacement tank
to your barbecue
■All LP tank supply systems must include a collar to
protect the cylinder valve.
■The LP cylinder must be a 20-lb. size (18 1/4 inches
high, 12 1/4 inches in diameter).
■The LP cylinder must be constructed and marked in
accordance with the specifications for LP gas cylinders,
T.C.
DOT 4BA240
00/01
(1)
(2)
D-1
Operating Instructions
Lighting
Summary lighting instructions are on the control panel.
DANGER
Failure to open the lid while igniting the
barbecue’s burners, 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.
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 barbe-
cue 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
®
autho-
rized replacement hose. Contact the Customer
Service Representative in your region using the
contact information sheet provided with your
manual.
*The grill illustrated may have slight differences than the
model purchased.
1) Open the lid.
2) Make sure all burner control knobs are turned OFF.
(Push control knob down and turn clockwise to ensure
that it is in the OFF position.)
WARNING: The burner control knobs must be in the
OFF position before turning on the liquid propane
cylinder tank valve. If they are not in the OFF
position, when you turn on the LP cylinder valve,
the “excess gas flow control” feature will activate,
limiting the flow of gas from the LP cylinder. If this
should occur, turn OFF the LP cylinder valve and
burner control knobs. Then start over.
DANGER:
When the “excess gas flow control” feature is
activated, a small amount of gas I still flowing to the
burners. After turning OFF the cylinder 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.
3) Turn the cylinder on by turning the cylinder valve
counterclockwise.
WARNING: Do not lean over the open barbecue.
Keep your face and body at least one foot away
from the matchlight hole when lighting the
barbecue.
4) Push Front burner control knob down and turn to
START/HI.
5) Push the Crossover
®
ignition button several times, so it
clicks each time.
6) Check that the burner is lit by looking through the
matchlight hole on the front of the cooking box. You
should see a flame.
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.
7) After the FRONT burner is lit you can turn on the other
burner or burners.
Note - Always light the FRONT burner first. The
other burner or burners ignite from the FRONT
burner.
To Extinguish
Push down and turn each burner control knob clock-
wise to the OFF position. Turn gas supply OFF at the
source.
1
6
2
3
45
7
D202_LP.c
D-2
Operating Instructions
Manual Lighting
DANGER
Failure to open the lid while igniting the
barbecue’s burners, 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.
1) Open the lid.
2) Make sure all burner control knobs are turned OFF.
(Push each knob down and turn clockwise to ensure
they are in the off position.)
WARNING: The burner control knobs must be in the
OFF position before turning on the liquid propane
cylinder valve. If they are not in the OFF position,
when you turn on the LP cylinder valve, the “excess
gas flow control” feature will activate, limiting the
flow of gas from the LP cylinder. If this should
occur, turn OFF the LP tank valve and burner
control knobs. Then start over.
DANGER
When the “excess gas flow control” feature is
activated, a small amount of gas is still
flowing to the burners. After turning OFF the
cylinder 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.
3) Turn the cylinder on by turning the cylinder valve
counterclockwise.
4) 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.
5) Push Front burner control knob down and turn to
START/HI.
6) Check that the burner is lit by looking through the
matchlight hole on the front of the cooking box. You
should see a flame
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.
7) After the FRONT burner is lit you can turn on the other
burner.
Note - Always light the FRONT burner first. The other
burner or burners ignite from the FRONT burner.
To Extinguish
Push down and turn each burner control knob clock-
wise to the OFF position. Turn gas supply OFF at the
source.
*The grill illustrated may have slight differences than the
model purchased.
1
4,6
2
3
5
7
D-3
Operating Instructions
The side burner has a separate ignition system from the
main cooking box.
DANGER
Failure to open the lid while igniting the side
burner, or not waiting 5 minutes to allow the
gas to clear if the side burner does not light,
may result in an explosive flame-up which can
cause serious bodily injury or death.
Lighting only the side burner.
1) Open the side burner lid.
2) Check that the side burner valve is turned OFF. (Push
each knob down and turn clockwise to ensure they are
in the off position.), and all main burner control valves
are OFF (push down and turn clockwise).
3) Turn the LP tank valve on (turn counter-clockwise).
4) Push down and turn the side burner control valve to HI.
5) Push the side burner igniter button several times so it
clicks each time.
CAUTION: Side burner flame may be difficult to see
on a bright sunny day.
5
2, 4
1
3
2
1
WARNING: If the side burner does not light:
1) Turn OFF the side burner control valve.
2) Wait 5 minutes to let the gas clear before you
try again or try to light with a match.
Lighting the side burner if the main burners are lit.
1) Open the side burner lid.
2) Push down and turn the side burner control to HI.
3) Press the side burner igniter button several times so it
clicks each time.
CAUTION: Side burner flame may be difficult to see
on a bright sunny day.
WARNING: If the side burner does not light:
1) Turn OFF the side burner control valve.
2) Wait 5 minutes to let the gas clear before you
try again or try to light with a match.
D-4
Troubleshooting
Problem Check Cure
Burners burn with a yellow or
orange flame, in conjunction with
the smell of gas.
Inspect Weber® Insect / Spider
screens for possible instructions.
(Blockage of holes.)
Clean Weber® Insect / Spider
screens. (See Section “Annual
Maintenance”)
Burners do not light. -or- Burners
have a small flickering flame in
the HIGH position. -or-
Barbecue temperature only
reaches 250˚ to 300˚ in the HIGH
position.
The excess flow safety device,
which is part of the barbecue to
cylinder connection, may have
activated.
To reset the excess flow safety
device turn all burner control knobs
and the cylinder valve OFF.
Disconnect the regulator from the
cylinder. Turn burner control knobs to
HIGH. Wait at least 1 minute. Turn
burner control knobs OFF. Reconnect
the regulator to the cylinder. Turn
cylinder valve on slowly. Refer to
“Lighting Instructions”.
Burner does not light, or flame is
low in HIGH position.
Is LP fuel low or empty?
Is fuel hose bent or kinked?
Does the Front burner light with a
match?
Refill LP cylinder.
Straighten fuel hose.
If you can light the Front burner with
a match, then check the Crossover®
Ignition System.
Experiencing flare-ups:
CAUTION: Do not line the
bottom tray with aluminum foil.
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?
All burners on high for 10 to 15
minutes for preheating.
Clean thoroughly. (See Section
“Cleaning”)
Clean bottom tray
Burner flame pattern is erratic.
Flame is low when burner is on
HIGH. Flames do not run the
whole length of the burner tube.
Are burners clean? Clean burners. (See Section
“Annual Maintenance”.)
Inside of lid appears to be
“peeling.” (Resembles paint
peeling.)
The lid is porcelain-on-steel, not
paint. It cannot “peel”. What you are
seeking is baked on grease that has
turned to carbon and is flaking off.
THIS IS NOT A DEFECT.
Clean thoroughly. (See Section
“Cleaning”.)
If problems cannot be corrected by using these methods, please contact the Customer
Service Representative in your region using the contact information sheet provided with
your manual.
D-5
Problem Check Cure
Side Burner does not light.
Flame is low in HIGH position.
Flame is very yellow in
conjunction with the smell of gas,
OR
Burner makes popping noise in
conjunction with the smell of gas.
Push button ignition does not
work.
Is gas supply off? Turn supply on.
Is the fuel hose bent or kinked? Straighten hose.
Inspect the Weber® Insect / Spider
screen for possible obstructions.
(lockage of holes.)
Clean Weber® Insect / Spider
screen (See section “Annual
Maintenance”)
Does burner light with a match? If match lights burner, checkigniter
(see below).
Side Burner maintenance
WARNING: All gas controls and supply valves
should be in the OFF position.
Check igniter: Remove side burner cover. To remove
side burner cover, remove control knob and screws
that hold cover to bottom(1).
Make sure wire is connected between igniter and
electrode. Check that igniter lock nut is tight.
Note: If the igniter works loose, carefully tighten the
igniter lock nut with an adjustable wrench or pliers.
Adjust igniter electrode to burner. Gap should be 1/8 to
3/16 inch from tip of electrode to burner. Spark should
be a white/blue color, not yellow.
1) Igniter
2) Igniter Wire
3) Venturi/Burner
4) 1/8 to 3/16 inch gap between electrode and burner
Side Burner Troubleshooting
(4)
(1) (2)
(3)
E-1
Maintenance
(1)
(1)
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.
1) Burner tube
2) Tips occasionally flicker yellow
3) Light blue
4) Dark blue
If the flames do not appear to be uniform throughout the
burner tube, follow the burner cleaning procedures.
Main Burner Cleaning Procedure
Turn off the gas supply. Remove the manifold.
Look inside each burner with a flashlight.
Clean the inside of the burners with a wire (a straightened-
out coat hanger will work). 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 Steel 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.
(2)
(3)
(4)
(1)
Weber® Spider /Insect screens
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(1) of the burner tubes. This
blocks the normal gas flow, and can cause the gas to flow
back out of the air shutter. This could result in a fire in and
around the air shutters, under the control panel, causing
serious damage to your barbecue.
The burner tube air shutter is fitted with a stainless steel
screen(1) to prevent spiders and other insects access to
the burner tubes through the air shutter openings.
We recommend that you inspect the Spider/Insect
screens at least once a year. (See Section “Annual
Maintenance”.) Also inspect and clean the the Spider/
Insect screens 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.
DANGER
Failure to correct the above mentioned symptoms may
result in a fire, which can cause serious bodily injury
or death, and cause damage to property.
Annual Maintenance
Inspection and cleaning of the Spider/Insect screens
To inspect the spider/insect screens, remove the control
panel. If there is dust or dirt on the screens, remove the
burners for cleaning the screens. Refer to Maintenance,
Replacing Main Burners. Brush the spider/inspect
screens, lightly, with a soft bristle brush (i.e. an old
toothbrush).
CAUTION: Do not clean the spider/insect screens
with hard or sharp tools. Do not dislodge the
spider/insect screens or enlarge the screen
openings.
Lightly tap the burner to get debris and dirt out of the
burner tube. Once the spider/insect screens and burners
are clean replace the burners.
If the spider/insect screen becomes damaged or cannot be
cleaned, call Weber-Stephen Products Customer Service
for replacement parts.
E201.c
E-2
Maintenance
Replacing Main Burners
1) Your Weber® gas barbecue must be OFF and cool.
2) Turn gas OFF at source.
3) To remove control panel: take off the burner control
knobs. Remove the screws holding the control panel in
place. Lift off the control panel.
4) Unhook the manifold bracket(1) and unscrew the two
wing nuts(2) that hold the manifold to the cooking box.
Pull the manifold and valve assembly out of the
burners and carefully set it down.
5) Slide the burner assembly out from under the guide
screw and washer(1) in the corners of the cooking box.
6) Lift and twist the burner assembly slightly, to separate
the crossover tube(1) from the burners. Remove the
burners from the cooking box.
(2)
(1)
(1)
7) To reinstall the burners, reverse 3) through 7).
CAUTION: The burner openings(1) must be
positioned properly over the valve orifices(2).
Check proper assembly before fastening manifold in place.
(1)
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.”)
(2)
(1)
(1) (2)
Crossover® Ignition System Operations
If the Crossover® ignition system fails to ignite the Left
burner, light the Left burner with a match. If the Left
burner lights with a match, then check the Crossover®
ignition system.
■ Check that both the white(1) and black(2) ignition wires
are attached properly.
■ Check that the Crossover® ignition button pushes
the igniter (button) down, and returns to the up
position.
If the Crossover® ignition system still fails to light,
Contact the Customer Service Representative in your
region using the contact information sheet provided
with your manual.

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