Weber 900 Natural Gas Barbecue Owners Manual NG Guide 98654 10/1997 PDF File

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Serial Number

Please use this number in registering your warranty and
any correspondence with the factory.

900 Natural
Gas Barbecue

Owner’s Manual

WEB

WEB
E
R

WARNING: Follow all leak check procedures
carefully in this manual prior to barbecue
operation. Do this even if barbecue was
dealer assembled.
NOTICE TO INSTALLER: These instructions
must be left with the owner and the owner
should keep them for future use.
FOR YOUR SAFETY
Do not store or use gasoline or other
flammable vapors and liquids in the vicinity
of this or any other appliance.

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.
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.
98654

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.

WARRANTY
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:

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.

Aluminum Castings, 10 years,
Flavorizer Bars, 3 years,

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.

Cast Iron Cooking Grates, 5 years,
All Remaining Parts, 5 years,
when assembled and operated in accordance
with the printed instructions accompanying it.

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.

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 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

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.

PATENTS AND TRADEMARKS
© 1997 Weber. Weber, , Flavorizer and Crossover are registered
U.S. trademarks; Spirit, Gas Catcher, FlameCheck, and Spider
Stopper are U.S. trademarks of Weber-Stephen Products Co., 200
East Daniels Road, Palatine, IL 60067-6266. U.S.A. Weber Gas
Barbecues are covered under the following patent nos.: U.S.A.
#4,677,964; 4,727,853; #4,829,978; #4,941,817; and #4,966,125;
Canada: #1,279,540; #1,300,994; and #1,300,995.
Printed in the U.S.A.

Contents
WARNINGS ................................................................ 2
Warranty & Patents.................................................. 3-4
General Instructions.................................................... 6
Assembly ............................................................... 7-20
Operating Instructions
Lighting........................................................ 21-22
Cooking ............................................................ 23
Storage and/or Nonuse .................................... 23
Cleaning .......................................................... 23
Cast Iron Cooking Grates................................. 24
Troubleshooting & Maintenance
Annual Maintenance......................................... 25
General Maintenance.................................. 26-28
Troubleshooting................................................ 29
Parts Listing .............................................................. 31
b
c

e
f

FEATURES:
a) Convenient tables and racks.

e) Separate burners for temperature control.

b) Heavy gauge porcelain-on-steel lid seals in heat.

c) Rapid read thermometer for precision cooking.

Crossover Ignition System with Gas Catcher Ignition
Chamber.

g) Catch pan catches excess grease.

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.

General Instructions
Storage

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.

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.

■

This Weber Gas Barbecue is designed for natural
(piped in city) gas only. Do not use Liquid Propane
(LP) bottled gas.The valves, orifices and hose are for
natural 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.

■

When the Weber Gas Barbecue is stored indoors, the
gas supply must be disconnected.

WARNING: Only use this barbecue outdoors in a
well ventilated area. Do not use in a garage, building,
breezeway or any other enclosed area.

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.

■

The gas must be turned OFF at the natural gas supply
when the Weber Gas Barbecue is not in use.

Operating area

The natural gas supply is easy to use and gives you more
cooking control than charcoal fuel.
■

■

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.

Gas supply testing
■

Disconnect your Weber Gas Barbecue when the gas
supply is being tested at high pressures. This
appliance and its individual shutoff valve must be
disconnected from the gas supply piping system
during any pressure testing of that system at test
pressures in excess of 1/2 psig (3.5 kPa).

■

Turn off your Weber Gas Barbecue when the gas
supply is being tested at low pressures. This appliance
must be isolated from the gas supply piping system by
closing its individual manual shutoff valve during any
pressure testing of the gas supply piping system at the
pressure equal to or less than 1/2 psig (3.5 kPa).

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).

Step 1

Assembly

Check package contents

Tools needed
Hammer

Cooking box
(assembly)
7/16 and 3/4 inch open-end or an adjustable wrench

Pliers

Lid
(assembly)

Block of wood

®
®

Phillips screwdriver

Supplies needed

Hose

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.

Bottom tray

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.

Cooking grates (2)

Flavorizer Bars (5)

Control panel

Catch pan holder

Wheel frame

Catch pan

Leg frame

Drip pans (2)

Frame connector

Thermometer

Work table

Wheels (2)

Swing table assembly

Support rod

Accessory racks (2)

Warming rack

WE B E R

Right frame

Front panel

WE BE

Left frame

Check contents of hardware packs
Plastic buttons (2)
(actual size)

Burner control knobs (3)

1/4 inch nylon washers (9)

Tool holders (3)

Hair pin cotters (2)

Tubing plugs (7)
(two are spares)

Wheel hubcaps (3)
Support rod holder

1/4-20 keps nut
Swing table end bracket
Phillips screws/washers (2)

Manifold bracket

Hinge pins (2)
(hardware size: 1/4 x 1 1/2 inch clevis pin)
(actual size)

1/4-20 x 2 inch bolt
(actual size)

1/4-20 x 1 3/4 inch bolts (2)
(actual size)

1/4-20 x 1/2 inch bolts (6)
(actual size)

Step 2

Step 3

Assemble wheel frame

Assemble top frame

You will need: wheel frame, two wheels, two wheel
hubcaps, hammer and a block of wood.

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.

Set one end of wheel frame on the block of wood (or other
hard, protected surface). Put one wheel on axle, WEBER
side facing up, and tap on one hubcap. Figure 1.

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.)

WE BE

WE B E R

Repeat with other wheel and hubcap.
R

Frame tabs

Figure 1

(a)

Leg tabs
Right frame

Left frame

(b)

Figure 2

Step 4

Step 6

Continue frame assembly

Add front panel

You will need: leg frame, wheel frame, four 1/4-20 x
1/2 inch bolts, four nylon washers and a 7/16 inch wrench.

You will need: front panel and two plastic buttons.

Place the leg 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.
Figure 3.

Align the panel with the holes in the frame and insert the
plastic buttons through the front panel and frame. Figure 5.

Turn frame assembly right side up.

Plastic buttons

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
View from rear
of barbecue

Figure 3
Figure 5

Step 5
Install tubing plugs
You will need: two tubing plugs and a hammer.
Insert tubing plugs into the ends of the leg frame. Figure 4.
To fully seat the plugs, you may have to tap them lightly
with a hammer.

Figure 4

Step 7

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:

Add cooking box
You will need: frame assembly, cooking box assembly,
1/4-20 keps nut, 1/4-20 x 2 inch bolt, pliers and a 7/16 inch
wrench.

a) Do the valves fit into the ends of the burners?
Figure 8 (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 8 (b).

Set the cooking box in the frame so the burner tubes are
under the frame brace. Figure 6.

c) Are the wing nuts under the burner assembly hand
tight? Do not tighten with pliers. Figure 8 (c).

Burner tubes

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.

Frame brace

Guide screw

(b)

Figure 6

Slide the cooking box to the left within the frame. Put
washer on bolt. Insert the bolt through the frame and
cooking box with the head of the bolt outside the frame.
Figure 7. Add the keps nut. Tighten by holding the bolt
with pliers while you tighten the nut with a wrench.

(a)

(c)

Figure 8

Figure 7

View from
behind
cooking
box

Wing nuts

Step 8

Step 10

Install manifold bracket

Install gas supply

You will need: manifold bracket

General Specifications for Piping

Hook the bracket onto the manifold at the center burner
valve. Figure 9. 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.

Note - Contact your local municipality for building
codes regulating outdoor gas barbecue installations.
In absence of Local Codes, you must conform to the
latest edition of ANSI Z223.1. WE RECOMMEND THAT
THIS INSTALLATION BE DONE BY A PROFESSIONAL.

Frame brace

Manifold bracket

Some of the following are general requirements taken
from ANSI Z223.1, for gas supply installations. Refer to
ANSI Z223.1 latest edition for complete specifications.
■

This barbecue is designed to operate at 7 inches of
water column pressure (.2526 psi).

■

A manual shut-off valve must be installed outdoors,
immediately ahead of the quick disconnect.

■

An additional manual shut-off valve indoors should be
installed in the branch fuel line in an accessible
location near the supply line.

■

The quick disconnect connects to a 3/8 inch NPT
thread from the gas source. The quick disconnect
fitting is a hand-operated device that automatically
shuts OFF the flow of gas from the source when the
barbecue is disconnected.

■

The quick disconnect fitting can be installed
horizontally, or pointing downward. Installing the fitting
with the open end pointing upward can result in
collecting water and debris.

■

The dust covers (supplied plastic plugs) help keep the
open ends of the quick disconnect fitting clean while
disconnected.

Figure 9

Step 9
Install frame connector
You will need: frame connector, two 1/4-20 x 1 3/4 inch
bolts, two nylon washers and a 7/16 inch wrench.
Slip a washer on a bolt and insert through the hole in the
cross brace and into the end of the frame connector. Insert
the other bolt and washer into the other end through the
cross brace and into the frame connector. Hold the frame
connector square and tighten the bolts. Figure 10.

WARNING: Do not route the 12’ hose under a deck.
The hose must be visible.

Figure 10

Test connections

Typical natural gas supply installation. Figure 11.

All connections and joints must be thoroughly tested for
leaks in accordance with local codes and all listed
procedures in the latest edition of ANSI Z223.1.

Gas supply
Inside wall

 DANGER

Outside wall

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 gas
leaks. This will result in a fire or explosion
which can cause serious bodily injury or
death, and damage to property.

Shut off
To barbecue
Locking
shut off

Quick disconnect
Male fitting

The quick disconnect is
installed above ground

Figure 11

Install gas supply (continued)
■

Pipe compound should be used which is resistant to
the action of natural gas when connections are made.

■

The outdoor connector must be firmly attached to
rigid, permanent construction.

Gas line piping
■

If the length of line required does not exceed 50 feet,
use a 5/8" O.D. tube. One size larger should be used
for lengths greater than 50 feet.

■

Gas piping may be copper tubing, type K or L;
polyethylene plastic tube, with a minimum wall
thickness of .062 inch; or standard weight (schedule
40) steel or wrought iron pipe.

■

Copper tubing must be tin-lined if the gas contains
more than 0.3 grams of hydrogen sulfide per 100
cubic feet of gas.

■

Plastic tubing is suitable only for outdoor, underground
use.

■

Gas piping in contact with earth, or any other material
which may corrode the piping, must be protected
against corrosion in an approved manner.

■

Underground piping must have a minimum of 18" cover.

Step 11

Step 12

Install igniter

Check that all burner valves are off

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.

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 13.

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. Loosen the igniter lock nut and
slide the igniter into the small part of the keyhole. Tighten
the igniter lock nut. Figure 12.

Note - If the igniter works loose, carefully tighten the igniter
lock nut with an adjustable wrench or pliers.

(a)

Figure 13

Step 13
Connect flexible hose to manifold
Frame brace

You will need: the 12 foot natural gas supply hose and a
3/4 inch wrench.

(b)

Thread fitting end of hose onto manifold. Figure 14 (a).
Tighten with wrench.
(a)

Figure 12

Keyhole in
frame brace

Igniter lock nut

(c)

Figure 14
Frame brace
Small part of keyhole
in frame brace

Step 14

Check:

Check for gas leaks

a) Hose to manifold connection. Figure 16 (a).
WARNING: If there is a leak at the hose to manifold
connection, Figure 16 (a), retighten the hose fitting
with a wrench and recheck for leaks with soap and
water solution.

 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.

If a leak persists after retightening the fitting, turn OFF
the gas. DO NOT OPERATE THE BARBECUE. Contact
Weber-Stephen Customer Service.
b) Valves to manifold connections. Figure 16 (b).
c) The hose to quick disconnect connection.Figure 16 (c).

WARNING: You should check for gas leaks every
time you disconnect and reconnect a gas fitting.

WARNING: If there is a leak at connections b or c,
turn OFF the gas. DO NOT OPERATE THE BARBECUE.
Contact Weber-Stephen Customer Service.

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.

When leak checks are complete, turn gas supply OFF at
the source and rinse connections with water.

WARNING: Perform these leak checks even if your
barbecue was dealer or store assembled.

(a)

You will need: a soap and water solution and a rag or
brush to apply it.
To perform leak checks: Slide back the collar of the quick
disconnect. Push male fitting of the hose into the quick
disconnect, and maintain pressure. Figure 15 (a). Slide
the collar closed. Figure 15 (b). If it does not engage or
lock, repeat procedure. Gas will not flow unless the quick
disconnect is properly engaged.

(b)

Locking shut off
To barbecue

(a)
Outside
house wall
(c)

Male fitting
(b)

Figure 16

Collar

Quick disconnect
engaged

Figure 15
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.

Step 15

Step 16

Install Flavorizer Bars and Cooking Grates

Install the bottom tray

You will need: five Flavorizer Bars and two cooking grates.

You will need: bottom tray, catch pan holder, catch pan and
one drip pan.

Set the Flavorizer Bars side to side in the cooking box.
Figure 17.

Finger grip on front
edge of bottom tray

Front side of catch
pan holder

Figure 19
Hook the ends of the catch pan holder into the hole in the
bottom tray. Figure 20. The front of the catch pan holder
must be on the same side as the finger grip of the
bottom tray.

Figure 17

Set the cooking grates onto the ledges in the cooking box.
Figure 18.

Finger grip

Figure 20
Slide the bottom tray onto the mounting rails under the
cooking box with finger grip toward you. Figure 21.
Figure 18

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.

Bottom tray

Figure 21
Put the foil drip pan into the catch pan.
Slide the catch pan into the catch pan holder with its finger
grip towards you.

Step 17

Step 18

Install Lid
You will need: lid, two hinge pins and two hair pin cotters.

Add tool holders, control panel and burner
control knobs

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 22.

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 23.
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 23 (a).

Hair pin cotter

Hinge pin

Push on the burner control knobs. Figure 23 (b).
Insert in
frame brace
(a)
Crossover
Ignition Button

Figure 22

Control panel
Phillips screws/
washers
(b)

Tool holders

Figure 23

Step 22

Insert one end of the hinge rod into the hole in the frame.
Figure 25 (a).

Install swing table

Insert the other end into the hole in the swing table end
bracket. Figure 25 (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 25 (c).

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 24 (a). Swing the
rod up so you can slide the rod all the way inside the
locking tab. Figure 24 (b). The rod should swing freely
inside the locking tab. Figure 24 (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 25 (d). Hook the
support rod into the support rod holder.
WARNING: The load limit for the swing table is
30 pounds.
Hinge rod

(b)

(c)

(a)
(b)

Support rod
(a)

Figure 24
View from rear
of barbecue

Slot in frame
(view from below)
(c)

(d)

Figure 25

Step 20
Complete accessory installation
You will need: work table, two accessory racks, warming
rack, three tubing plugs and thermometer.
Set one accessory rack across the bottom braces in front
of the frame connector. Figure 26 (a).
Set the second accessory rack across the bottom braces
behind the frame connector. Figure 26 (b).
Open the lid and set the warming rack into the slots at the
rear of the cooking box. Figure 26 (c).
Set the work table onto the left side rails. Figure 26 (d).
Insert the thermometer into its holder. Figure 26 (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 26 (f).
(e)
(d)
(c)

(b)

(f)

(a)

Figure 26

OPERATING INSTRUCTIONS
Lighting

1) Open the lid. Figure 1.

Summary lighting instructions are on the control panel.

2) Make sure all burner control knobs are turned OFF.
(Push each knob down and turn clockwise.)
3) Turn the gas supply valve on.

 DANGER

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.

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 flameup which can cause serious bodily injury
or death.

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.

Crossover Ignition System

6) Check that the burner is lit by looking through the
matchlight hole on the front of the cooking box.

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: 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
burners.

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 hose. Order from WeberStephen Products Co., Customer Service Center or
authorized dealer.

Note - Always light the FRONT burner first. The other
burners ignite from the FRONT burner.

To Extinguish

Crossover Ignition System

Turn gas supply OFF at the source, then push down
and turn each burner control knob clockwise to OFF.

7
5

6
4

Figure 1

Manual Lighting

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.

 DANGER

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.
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.

1) Open the lid. Figure 2.

7) After the FRONT burner is lit you can turn on the other
burners.

2) Make sure all burner control knobs are turned OFF.
(Push each knob down and turn clockwise.)

Note - Always light the FRONT burner first. The other
burners ignite from the FRONT burner.

3) Turn the gas supply valve on.
4) Strike a match and put the flame into the matchlight
hole in the front of the cooking box.

To Extinguish
1

Manual Lighting

Turn gas supply OFF at the source, then push down
and turn each burner control knob clockwise to OFF.

4,6
5

Figure 2

Cooking

Storage and/or Nonuse

WARNING: Do not move the Weber Gas Barbecue
when operating or hot.

■

When storing the Weber Gas Barbecue, make sure
that the inside shut off valve and/or locking outdoor
shut off valve is secured in the OFF position. When
the Weber Gas Barbecue is stored indoors, the gas
supply MUST BE DISCONNECTED.

■

After a period of storage and/or nonuse the Weber
Gas Grill 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.")

■

Keep the appliance area clear and free from
combustible materials, gasoline and other flammable
vapors and liquids.

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.
If burners go out during cooking, open lid, turn off all
burners and wait 5 minutes before relighting.

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.

Periodic Cleaning

Preheating

WARNING: Turn your Weber Gas Barbecue OFF and
wait for it to cool before cleaning.

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.

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 Products
Service Center.

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.

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.

WARNING: Check the bottom tray for grease buildup before each use. Remove excess grease to avoid a
grease fire in the bottom tray.

Bottom tray - Remove excess grease and then wash with
warm soapy water.
Flavorizer Bars - Brush with a suitable barbecue brush
(brass bristle), or 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.

Cast Iron Cooking Grates

Maintenance - Clean grates by turning on the barbecue
burner control knobs to HHH and wipe off debris with stiff
bristled wire brush. This should be done every time you
use the barbecue.

WARNING: Follow all safety instructions provided
with your barbecue. Do not drop cast iron grates, they
will break. Prior to storing, grease very lightly with
solid vegetable shortening or vegetable cooking spray,
then wipe dry with a paper towel. Store in a dry place.

Reseasoning - After each use the grates may be
reseasoned by coating with a solid vegetable shortening,
closing the lid and leaving the cast iron grates in grill until
it is cool.

First Time Use - Wash thoroughly with a mild dishwashing
liquid to remove the wax coating used for protection in
shipping. Rinse with hot water and dry completely with a soft
cloth or paper towel. NEVER ALLOW TO DRAIN DRY, OR
WASH IN A DISHWASHER. You must season the grates
before first use to prevent rust and keep foods from sticking.

A vegetable cooking spray may be used as a convenient
method for quick reseasoning.
Tips - The cast iron grates will turn black with use. The
pores of the iron will be sealed, providing a durable
coating that helps to prevent foods from sticking. The
grates will further season with use. Regular applications of
solid vegetable shortening or vegetable cooking spray will
improve its resistance to rust.

Seasoning Cast Iron Grates - A solid vegetable
shortening is recommended for the initial seasoning.
Spread a thin coating of solid vegetable shortening over
entire surface of the cast iron grates with a paper towel.
Be certain the entire surface, including all corners, has
been coated thoroughly. (Do not use salted fat such as
margarine or butter.)

Rust, a metallic taste or discolored foods are signs of
improper or inadequate seasoning or may result from
cooking acidic foods. If this occurs, wash thoroughly and
reseason.

Preheat grill for 10 minutes. Turn burners to MOM with lid
closed. Allow grill to heat for 1 to 1 1/2 hours. Turn all
burners to OFF. Leave cooking grates in barbecue until
they are cool. Your cast iron cooking grates are now ready
to use.

Since cast iron holds heat well, you will not need to use
extremely high cooking temperatures. Best results are
obtained with medium to medium-high heat. Do not
overheat.
As with all cast iron, the more the use, the easier the
maintenance.

Important Note: To prevent rusting the cast iron
grates should be reseasoned frequently. If rust
occurs, clean with a steel wool scouring pad, rinse
with hot water and dry. Coat with a solid vegetable
shortening or a vegetable cooking spray and heat in
grill or oven as indicated above.

WARNING: Do not apply vegetable cooking spray to
a grate in a hot grill.

Annual Maintenance

Check:
a) Hose to manifold connection. Figure 3 (a).

After a period of nonuse we recommend that you perform
the following maintenance procedures for your safety.

WARNING: If there is a leak at the hose to manifold
connection, Figure 3 (a), retighten the hose fitting with
a wrench and recheck for leaks with soap and water
solution.

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 hose. Order from Weber-Stephen Products
Co., Customer Service Center or authorized dealer.
■

■

If a leak persists after retightening the fitting, turn OFF
the gas. DO NOT OPERATE THE BARBECUE. Contact
Weber-Stephen Customer Service.

Inspect the burners for correct flame pattern. Clean if
necessary, following the procedures outlined in the
"General Maintenance" section of this manual.

b) Valves to manifold connections. Figure 3 (b).

Check all gas fittings for leaks.

WARNING: If there is a leak at connections (b) or (c),
turn OFF the gas. DO NOT OPERATE THE BARBECUE.
Contact Weber-Stephen Customer Service.

c) The hose to quick disconnect connection.
Figure 3 (c).

When leak checks are complete, turn gas supply OFF at
the source and rinse connections with water.

(a)

WARNING: You should check for gas leaks every
time you disconnect and reconnect a gas fitting.
WARNING: Perform these leak checks even if your
barbecue was dealer or store assembled.

(b)

You will need: a soap and water solution and a rag or
brush to apply it.
To perform leak checks: Plug end of gas supply hose into
the quick disconnect, then 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.

(c)

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.

Figure 3

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".)
25

General Maintenance

Main Burner Flame Pattern

Weber Spider Stopper Guards

The Weber Gas Barbecue burners have been factory set
for the correct air and gas mixture. The correct flame
pattern is shown in Figure 6.

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 4. This could result in a
fire in and around the air shutters, under the control panel,
causing serious damage to your barbecue.

Tips occasionally yellowish
Burner inside
cooking box

Light blue

Venturi
Dark blue

Flames

Figure 6
If the flames do not appear to be uniform the length of the
burner tube, follow the burner cleaning procedures.

Venturi fin

Air shutter

Figure 4

Main Burner Cleaning Procedure

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 5.

Turn off the gas supply. Remove the manifold.
(See Section “Replacing the main burners”.)
Look inside each burner with a flashlight.Figure 7.

Weber Spider
Stopper Guard

Figure 7
Clean the inside of the burners with a wire (a straightened
out coat hanger will work). Figure 8. 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.

Figure 5
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.

Figure 8

2. Barbecue does not reach temperature.

CAUTION: Do not enlarge the burner ports when
cleaning.

3. Barbecue heats unevenly.
4. One or more of the burners do not ignite.

 DANGER

Replacing Main Burners

Failure to correct these symptoms may
result in a fire which can cause serious
bodily injury or death and cause damage
to property.

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.

h) To reinstall the burners, reverse steps c) through g).

d) Unlatch the Spider Stopper Guards and remove.
Figure 9.

CAUTION: The burner openings must be positioned
properly over the valve orifices. Figure 13 (a).
Check proper assembly before fastening manifold in
place. Figure 13 (b).
Valve
orifice

(a)

Figure 9
Burner opening

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 10.
View from behind
cooking box

(b)

Wing nuts

Figure 10
f)

Figure 13

Slide the burner assembly out from under the guide
screw and washer in the corners of the cooking box.
Figure 11.

Guide screw

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 14.

Check fit
around valve

Figure 11
Venturi fin

g) Lift and twist the burner assembly slightly, to separate
the crossover tube from the burners. Figure 12.
Remove the burners from the cooking box.

Check fit around burner

Crossover tube

Figure 14
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”).

Figure 12

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 15.

White wire

Black wire

Figure 15
■

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.

TROUBLESHOOTING
Problem

Check

Cure

Burners burn with a yellow or orange
flame, in conjunction with the smell of gas.

Inspect Weber Spider Stopper
Guards for possible obstructions.
(Blockage of holes.)

Clean Weber Spider Stopper
Guards. (See Section "Annual
Maintenance".)

Burner does not light, or flame is low
in HIGH position.

Is fuel hose bent or kinked?

Straighten fuel hose.

Does the Front burner light with a
match?

If you can light the Front
burner with a match, then
check the Crossover Ignition
System.

Are you preheating barbecue in the
prescribed manner?

All burners on high for 10 to
15 minutes for preheating.

Are the cooking grates and
Flavorizer Bars heavily coated with
burned-on grease?

Clean thoroughly. (See
Section "Periodic Cleaning".)

CAUTION: Do not line the bottom tray with
aluminum foil.

Is the bottom tray "dirty" and not
allowing grease to flow into catch
pan?

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
"General Maintenance".)

Experiencing flare-ups:

Inside of lid appears to be “peeling.”
(Resembles paint peeling.)

The lid is porcelain-on-steel, not
Clean thoroughly. (See
paint. It cannot "peel". What you are Section "Periodic Cleaning".)
seeing is baked on grease that has
turned to carbon and is flaking off.
THIS IS NOT A DEFECT.

If problem cannot be corrected by using these methods, please contact Weber-Stephen Customer Service.

1
30
31

32
2
3

4
5
33
34
35
36
37
38
39
40
41
42

7
8

43
44

11-12
13
53
46-48
49
50
51

15
16
52
17

E BE R

20
21 22 23 24

21 25 26

27
28

12
29

Parts List
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.

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.

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31

Weber-Stephen Products Company
Customer Service Center
250 South Hicks Road
Palatine, IL 60067-6241
(800) 446-1071

Lid (assembly)
Lid handle
Warming rack
Flavorizer bars (5)
Cooking grates (2)
Work table
Tubing plugs (7)
1/4-20 x 2 inch bolt
Swing table end bracket
Left frame
1/4-20 x 1/2 inch bolts (6)
1/4 inch nylon washers (9)
Leg frame
Swing table
Support rod holder
Support rod
Bottom tray
Catch pan holder
Catch pan
Drip pans (2)
Accessory racks (2)
Frame connector
Wheel hubcaps (3)
Wheels (2)
Tool holders (3)
Wheel frame
Front panel
Plastic buttons (2)
1/4-20 x 1 3/4 inch bolts (2)
Hair pin cotters (2)
Hinge pins (2)

32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53

Thermometer
1/4-20 keps nut
Cooking box
Burner control knobs (3)
Control panel
Igniter button
Phillips screws/washers (2)
Crossover tube
Front and back burners (2)
Center burner
1/4-20 stainless steel wing nuts (2)
Spider Stopper Guards (3)
Manifold assembly
Manifold bracket
Igniter
Igniter lock nut
Gas catcher ignition chamber
Right frame
Igniter wire (black)
Igniter wire (white)
Hose (includes quick disconnect)
Control panel inserts (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.

A FINAL WORD
OF THANKS
hank you for choosing a Weber Barbecue.
TOur
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

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