Owner’s Manual

Serial Number

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

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DANGER

If you smell gas:

1. Shut off gas to the appliance.

2. Extinguish any open flame.

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.

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WARNING

1. Do not store spare LP 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.

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.

THIS GAS APPLIANCE IS DESIGNED FOR

OUTDOOR USE ONLY.

WARNING: Do not try to light this appliance without reading "Lighting" instructions section of this manual.

92726 11/98

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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.

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WARNINGS

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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.

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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.

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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.

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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.

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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.

2

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:

Aluminum Castings, 10 years,

Recycled Work Surfaces, 10 years

Cooking Grates, 3 years,

Flavorizer Bars, 5 years,

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

Weber may require reasonable proof of your date of purchase. THEREFORE, YOU SHOULD

RETAIN YOUR SALES SLIP OR INVOICE.

This Limited Warranty shall be limited to the repair or replacement of parts which prove defective under normal use and service and which on examination shall indicate, to Weber's satisfaction, they are defective. Before returning any parts, contact Weber-Stephen Products Co. Customer

Service Center. If Weber confirms the defect and approves the claim, Weber will elect to replace such parts without charge. If you are required to return defective parts, transportation charges must be prepaid. Weber will return parts to the purchaser, freight or postage prepaid.

This Limited Warranty does not cover any failures or operating difficulties due to accident, abuse, misuse, alteration, misapplication, vandalism, improper installation or improper maintenance or service, or failure to perform normal and routine maintenance, including but not limited to damage caused by insects within the burner tubes, as set out in this owner's manual.

Deterioration or damage due to severe weather conditions such as hail, hurricanes, earthquakes or tornadoes, discoloration due to exposure to chemicals either directly or in the atmosphere, is not covered by this Limited Warranty.

There are no other express warrants except as set forth herein and any applicable implied warranties of merchantability and fitness are limited in duration to the period of coverage of this express written Limited Warranty. Some states do not allow limitation on how long an implied warranty lasts, so this limitation may not apply to you.

Weber is not liable for any special, indirect or consequential damages. Some states do not allow the exclusion or limitation of incidental or consequential damages, so this limitation or exclusion may not apply to you.

Weber does not authorize any person or company to assume for it any other obligation or liability in connection with the sale, installation, use, removal, return, or replacement of its equipment; and no such representations are binding on Weber.

This Warranty applies only to products sold at retail.

WEBER-STEPHEN PRODUCTS CO.

Customer Service Center

250 South Hicks Road

Palatine, IL 60067-6241

(800) 446-1071

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PATENTS AND TRADEMARKS

© 1998 Weber. Weber, , Genesis, Flavorizer and Crossover are registered U.S. trademar ks; Per ma-Mount, Gas Catcher,

FlameCheck, Steam-N-Chips, Spider Stopper, and Warm-Up are

U.S. trademarks of Weber-Stephen Products Co., 200 East Daniels

Road, Palatine, IL 60067-6266. U.S.A. Genesis Gas Barbecues are covered under the following patent nos.: U.S.A. #4,677,964;

4,727,853; #4,777,927; #4,829,978; #4,860,724; #4,941,817;

#4,966,125; #5,070,776; #D293,067; #D316,355; Canada: Rd

1987 Reg. #58,034; #1,279,540; #1,283,586; #1,300,994;

#1,300,995. Printed in the U.S.A.

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Contents

WARNINGS ................................................................ 2

Warranty & Patents .................................................. 3-4

General Instructions.................................................... 6

Assembly ............................................................... 7-21

Operating Instructions

Lighting........................................................ 22-23

Cooking ............................................................ 24

Storage and/or Nonuse .................................... 24

Cleaning .......................................................... 24

Troubleshooting & Maintenance

Annual Maintenance......................................... 25

General Maintenance.................................. 26-28

Troubleshooting ................................................ 29

Parts Listing .............................................................. 31 b c e a d f g h i a

FEATURES: a) Convenient tables and racks.

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

c) Rapid read thermometer for precision cooking measures grill temperature, and can be removed and inserted into the food.

d) Heavy gauge steel Flavorizer Bars distribute heat within the grill. Flavorizer Bars heat just the right amount of drippings for flavoring, letting excess fat drip past to help prevent flare-ups.

e) Weber Warm-Up Basket for additional cooking or warming space.

f) Separate burners for temperature control.

g) Crossover Ignition System with Gas Catcher Ignition

Chamber.

h) Catch pan catches excess grease.

i) Locking casters for additional portability.

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General Instructions

Your Weber Gas Barbecue is a portable outdoor cooking appliance. With the Weber Gas Barbecue you can grill, barbecue, roast and bake with results that are difficult to duplicate with indoor kitchen appliances. The closed lid and

Flavorizer Bars produce that "outdoor" flavor in the food.

The Weber Gas Barbecue is portable so you can easily change its location in your yard or on your patio. Portability means you can take your Weber Gas Barbecue with you if you move.

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

■ These instructions will give you the minimum requirements for assembling your Weber Gas

Barbecue. Please read the instructions carefully before using your Weber Gas Barbecue. Improper assembly can be dangerous.

■ Not for use by children.

■ If there are local codes that apply to portable gas grills, you will have to conform to them. If there are no local codes, you must conform to the latest edition of the National Fuel Gas Code: ANSI Z 223.1.

■ 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.

Storage

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

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

Operating area

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

■ Never use your Weber Gas Barbecue under an unprotected combustible roof or overhang.

■ Your Weber Gas Barbecue is not intended to be installed in or on recreational vehicles and/or boats.

■ Do not use combustible materials within 24 inches of the top, bottom, back or sides of the grill.

■ The entire cooking box gets hot when in use. Do not leave unattended.

■ Keep any electrical supply cord and the fuel supply hose away from any heated surface.

■ Keep the cooking area clear of flammable vapors and liquids, such as gasoline, alcohol, etc., and combustible materials.

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-B149.1 (Installation

Code for Natural Gas Burning Appliances and Equipment).

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).

6

Assembly

Tools needed

Regular screwdriver

Step 1

Check package contents

Cooking box

(assembly)

Phillips screwdriver

Hammer

7/16 and 3/4 inch open-end or an adjustable wrench

Lid

(assembly)

Pliers

Block of wood

Hose

Supplies needed

You will need a soap and water solution to check for gas leaks. (See Step "Check for gas leaks.")

Note - The hardware size of nuts, bolts and screws is given. For example "1/4-20 x 2 inch bolt" means a bolt

1/4 inch in diameter with 20 threads to the inch, 2 inches long. On a small screw for example, "6-32 x 1/2 inch screw" means a number 6 screw, with 32 threads to the inch, 1/2 inch long.

While we give much attention to our products, unfortunately an occasional error may occur. If a part is missing, do not go back to the store. Call the Weber

Customer Service Center toll free 1-800-446-1071 to receive immediate assistance. Have your owner’s manual and serial number of the barbecue available for reference.

Bottom tray

Two cooking grates

Control panel

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Left frame

Right frame

Wheel frame

Caster frame

Two frame connectors

Work table

Swing table assembly

Left hand slide bar

Axle

Two accessory trays

Warming rack

Warm-Up Basket

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Five long Flavorizer Bars

Eight short Flavorizer Bars

Front panel

Catch pan holder

Catch pan

Two drip pans

Manifold bracket

Thermometer

Two wheels

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Two casters

Spacer bracket

Check contents of hardware packs

Three burner control knobs

Three tool holders

Five tubing plugs

(two are spares)

Swing table end bracket

Two hinge pins

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

(actual size)

Five 1/4-20 x 2 inch bolts

(actual size)

Six 1/4-20 x 1/2 inch bolts

(actual size)

Two plastic buttons

(actual size)

1/4-20 keps nut

Fifteen 1/4 inch nylon washers

Two hair pin cotters

Two wheel hubcaps

Two 10-24 hex nuts

Two 10-24 x 1 3/4 inch machine screws

Two Phillips screws/washers

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Step 2

Assemble wheels

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

Place one end of the axle on the block of wood (or other protected surface). Tap on one hubcap.

Put one wheel on the axle, WEBER side toward the hubcap. Slide the axle through the frame. Add the other wheel, WEBER side out. Tap on the hubcap. Figure 1.

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Step 3

Assemble frame

You will need: left frame, right frame, two 1/4-20 x 1/2 inch bolts, two nylon washers and a 7/16 inch wrench.

Note - Work on carpeted area (on grass or one of the boxes) to protect the finish during frame assembly.

Lay the leg pieces as shown so the leg tabs point up.

Figure 2.

Slip the two frame pieces together with the tabs inside.

Figure 2 (a). Slip washers on bolts, insert bolts as shown and tighten. Figure 2 (b). (If you try to insert a bolt and there are no holes, you have the left frame turned the wrong way. Turn the left frame around.)

Frame tabs

(a)

Figure 1

Leg tabs

Left frame

Right frame

(b)

Figure 2

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Step 4

Continue frame assembly

You will need: caster frame, wheel frame, four 1/4-20 x

1/2 inch bolts, four nylon washers and a 7/16 inch wrench.

Place the caster frame onto the tabs of the left frame with the dimple to the inside. Figure 3. Place the wheel frame onto the tabs of the right frame with the dimple to the inside. Figure 3.

The leg tabs must be on the inside of the frames.

Add the washers to the bolts, insert in the holes as shown and tighten with the wrench. Figure 3.

Dimples to the inside

Step 5

Complete frame assembly

You will need: partial frame assembly, two frame connectors, four 1/4-20 x 2 inch bolts, four nylon washers and a

7/16 inch wrench.

Hold one frame connector between the caster and wheel frame. Add the nylon washer to the bolt. Put the bolt through the frame and screw into frame connector.

Tighten.

Repeat procedure with the other frame connector. Figure 4.

Figure 4

Figure 3

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Step 6

Insert casters

You will need: frame assembly and two casters.

Push the casters firmly into the inserts in the ends of the caster legs. Figure 5.

Step 7

Add front panel

You will need: front panel and two plastic buttons.

Turn frame assembly right side up.

Align the panel with the holes in the frame and insert the plastic buttons through the front panel and frame. Figure 6.

Plastic buttons

View from rear of barbecue

Figure 5

Figure 6

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Step 8

Add cooking box

You will need: frame assembly, cooking box assembly,

1/4-20 x 2 inch bolt, nylon washer, 1/4-20 keps nut, pliers and a 7/16 inch wrench.

Set the cooking box in the frame so the burner tubes are under the frame brace. Figure 7.

Burner tubes

Frame brace

Your Weber Gas Barbecue burner assembly has been factory assembled, pressure and flame tested. As a safety precaution we recommend you check the burner alignment: a) Do the valves fit into the ends of the burners?

Figure 9 (a). b) Are the ends of the burners under the washers at the left rear and left front of the cooking box? The screws are only guides. Do not tighten. Figure 9 (b).

c) Are the wing nuts under the burner assembly hand tight? Do not tighten with pliers. Figure 9 (c).

If you answered YES to a, b and c, the burners are correctly aligned. If you answered NO, the burners are misaligned. Contact Weber-Stephen Customer Service.

Do not use barbecue.

Guide screw

Figure 7

Slide the cooking box to the left within the frame. Put the washer on the bolt. Take the spacer bracket and hold it up to the frame making sure both tabs fit underneath the frame cross piece. Figure 8 (a). Insert the bolt through the center hole in the spacer bracket, frame and cooking box with the head of the bolt outside the spacer bracket.

Figure 8 (b). Add keps nut. Figure 8. Tighten by holding the bolt with pliers while you tighten the nut with a wrench.

Frame cross piece

(a)

Spacer bracket

(b) Keps nut

(b)

Figure 9

(a)

View from behind cooking box

(c)

Wing nuts

Tab

Bolt

Nylon washer

Figure 8

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Step 9

Install manifold bracket

You will need: manifold bracket

Hook the bracket onto the manifold at the center burner valve. Place your hand underneath the bracket. Lift the manifold, bracket and cooking box slightly and hook the tab of the bracket onto the frame brace. Figure 10.

Frame brace

Manifold bracket

Step 10

Install igniter

Note - The igniter wires are already attached to the Gas

Catcher Ignition Chamber and the igniter. This was done to factory test the ignition system.

The igniter lock nut is on the igniter.

Insert the top of the igniter up through the large part of the keyhole in the frame brace. Figure 11 (b). Loosen the igniter lock nut and slide the igniter into the small part of the keyhole. Figure 11 (c). Tighten the igniter lock nut.

Figure 11.

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

(a)

Figure 10

Frame brace

(b)

Figure 11

Keyhole in frame brace

Igniter lock nut

(c)

Frame brace

Small part of keyhole in frame brace

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Step 11

Install gas supply

General Specifications for Piping

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.

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.

■ 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.

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

Typical natural gas supply installation. Figure 12.

Gas supply

Inside wall

Outside wall

To barbecue

Quick Disconnect

Male fitting

Shut off

Locking shut off

Figure 12 The quick disconnect is installed above ground

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.

Test connections

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.

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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 gas leaks. This will result in a fire or explosion which can cause serious bodily injur y or death, and damag e to property.

Step 12

Check that all burner valves are off

You will need: one burner control knob.

Valves are shipped in the OFF position, but you should check to be sure. Put the knob on each valve. Check by pushing down and turning clockwise. If they do not turn they are off, proceed to the next step.Figure 13.

Step 13

Connect flexible hose to manifold

You will need: the 12 foot natural gas supply hose and a

3/4 inch wrench.

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

Tighten with wrench.

(a)

Figure 13

Figure 14

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Step 14

Check for gas leaks

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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.

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

Note - All factory made connections have been thoroughly checked for gas leaks. The burners have been flame tested. As a safety precaution you should recheck all fittings for leaks before using your Weber Gas Barbecue.

Shipping and handling may have loosened or damaged a gas fitting.

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

You will need: a soap and water solution and a rag or brush to apply it.

To perform leak checks: 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.

Locking shut off

Outside house wall

To barbecue

(a)

Check: a) Hose to manifold connection. Figure 16 (a).

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

If a leak persists after retightening the fitting, turn OFF

the gas. DO NOT OPERATE THE BARBECUE. Contact

Weber-Stephen Customer Service.

b) Valves to manifold connections. Figure 16 (b).

c) Hose to quick disconnect connection. Figure 16 (c).

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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.

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

(a)

(b)

(c)

Figure 16

Male fitting

Collar

(b)

Quick disconnect engaged

Figure 15

Turn on gas supply.

Check for leaks by wetting the connections with the soap and water solution and watching for bubbles. If bubbles form or if a bubble grows there is a leak.

Note - Since some leak test solutions, including soap and water, may be slightly corrosive, all connections should be rinsed with water after checking for leaks.

 WARNING: Do not ignite burners when leak checking.

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Step 15

Install Flavorizer Bars and Cooking Grates

You will need: five long Flavorizer Bars, eight short

Flavorizer Bars and two cooking grates.

Set the long Flavorizer Bars side to side in the lower position, then set the short Flavorizer Bars front to back in the upper position in the cooking box. Figure 17.

Step 16

Install the bottom tray

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

Finger grip on front edge of bottom tray

Figure 19

Front side of catch pan holder

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

The open "U" of the cooking grates goes down. 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.

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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.

Figure 18

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.

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Step 17

Install Lid

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

Set the lid in place. Align the hinges at the rear of the barbecue. Insert hinge pins from the outside. Insert hair pin cotters into the small holes in the hinge pins. Figure 22.

Hair pin cotter

Hinge pin

Step 18

Add tool holders, control panel and burner control knobs

You will need: three tool holders, control panel, two Phillips screws/washers, a Phillips screwdriver, and three burner control knobs.

Hook the tool holders over the frame rail. Figure 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).

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

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Step 19

Install swing table

You will need: swing table end bracket, two 10-24 hex nuts, two 10-24 x 1 3/4 inch machine screws, slide bar assembly, swing table, four nylon washers, screwdriver and pliers.

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).

Insert one end of the hinge rod into the hole in the frame.

Figure 25 (a).

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).

To fully seat the bracket, you may have to tap it lightly with a hammer.

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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.

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WARNING: The load limit for the swing table is

30 pounds.

Hinge rod

(a)

(b)

(b) (c)

Support rod

(a)

Figure 24

View from rear of barbecue

(c)

Slot in frame

(view from below)

Figure 25

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Position slide bar assembly on the outside of the caster frame. Put a nylon washer on each 1 3/4 inch screw, insert screws through frame and slide bar assembly and add nylon washers and hex nuts. Tighten nuts using a screwdriver and pliers. Figure 26.

Notch to the front

Slide bar

View from front of barbecue

Step 20

Complete accessory installation

You will need: Warm-Up Basket, warming rack, work table, accessory rack, three tubing plugs, thermometer and a hammer.

Insert one end of the Weber Warm-Up Basket into the hole in the right end of the lid and the other end into the slot in the left end of the lid. Figure 28 (a).

Set the warming rack into the slots at the rear of the cooking box. Figure 28 (b).

Set the work table onto the left side rails. Figure 28 (c).

Set the accessory rack in place between the two frame connectors. Figure 28 (d).

Insert the thermometer into its holder. Figure 28 (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 28 (f).

Figure 26

(a)

To lower table: Pull support rod up to disengage slide lock, and lower table. To raise table, lift table up and engage slide in locked position. Figure 27.

(b)

(e)

(c)

(f)

Slide

Support rod

View from rear of barbecue

(d)

Figure 28

 CAUTION: To keep the barbecue stationary, the tabs on the locking casters should be in the down position.

Unlocked position

Figure 27

Locked position

21

OPERATING INSTRUCTIONS

Lighting

Summary lighting instructions are on the control panel.

 DANGER

Failure to open lid while igniting the barbecue, or not waiting 5 minutes to allow the gas to clear if the barbecue does not light, may result in an explosive flame-up which can cause serious bodily injury or death.

Crossover Ignition System

Note - The Crossover Ignition System ignites the Front burner with a spark from the igniter electrode inside the Gas

Catcher Ignition Chamber. You generate the energy for the spark by pushing the Crossover Ignition Button until it clicks.

 WARNING: Check hose before each use of barbecue for nicks, cracking, abrasions or cuts. If the hose is found to be damaged in any way, do not use the barbecue. Replace using only Weber authorized replacement hose. Order from Weber-Stephen Products

Co., Customer Service Center or authorized dealer.

Crossover Ignition System

1

1) Open the lid. Figure 1.

2) Make sure all burner control knobs are turned OFF.

(Push each burner control knob down and turn clockwise.)

3) Turn gas supply valve on.



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.

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.

 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.

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

To Extinguish

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

2

5

7

3

6

Figure 1

4

22

Manual Lighting



DANGER

Failure to open lid while igniting the barbecue, or not waiting 5 minutes to allow the gas to clear if the barbecue does not light, may result in an explosive flame-up which can cause serious bodily injury or death.

1) Open the lid. Figure 2.

2) Make sure all burner control knobs are turned OFF.

(Push each burner control knob down and turn clockwise.)

3) Turn gas supply valve on.

4) Strike a match and put the flame into the matchlight hole in the front of the cooking box.

Manual Lighting

1

 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.

 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.

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

To Extinguish

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

2

4

6

5

Figure 2

7

3

23

Cooking

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

You can adjust the FRONT, CENTER and BACK burners as desired. The control settings High (H), Medium (M), Low

(L), or Off (O) are described in your Weber cookbook. The cookbook uses these notations to describe the settings of the FRONT, CENTER, and BACK burners. For example, to sear steaks you would use (HHH) (all burners at high).

Then to complete cooking you would use (MOM) (FRONT at medium, CENTER off, and BACK at medium). See your

Weber cookbook for detailed cooking instructions.

Note: The temperatures inside your cooking box, for the first few uses, while surfaces are still very reflective, may be hotter than those shown in your cookbook. Cooking conditions may require the adjustment of the burner controls to attain the correct cooking temperatures.

 CAUTION: Replace thermometer in lid when not in use. Do not leave thermometer in food while cooking.

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

Preheating

Your Weber Genesis Gas Barbecue is an energy efficient appliance. It operates at a low B.T.U. rate for economy. To preheat, after lighting, close lid and turn all burners to high

(HHH). Preheating to between 500° and 550° F (260° and

290° C) will take 10 to 15 minutes depending on conditions such as air temperature and wind.

Drippings and grease

The Flavorizer Bars are designed to "smoke" the right amount of drippings for flavorful cooking. Excess drippings and grease accumulate in the catch pan under the bottom tray. Disposable foil liners are available that fit the catch pan.



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

Storage and/or Nonuse

■ 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.")

Periodic Cleaning



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



CAUTION: Do not clean your Flavorizer Bars or cooking grates in a self-cleaning oven. Replacement cooking grates and Flavorizer Bars are available through your retailer or the Weber-Stephen Customer

Service Center.

Outside surfaces - Use a warm soapy water solution.

 CAUTION: Do not use oven cleaner, abrasive cleansers (kitchen cleansers) cleaners that contain citrus products or abrasive cleaning pads on barbecue or cart surfaces.

Bottom tray - Remove excess grease and then wash with warm soapy water.

Flavorizer Bars and Cooking Grates- Clean with a suitable brass bristle brush. As needed, remove from grill and wash with warm soapy water.

Catch pan - Disposable foil trays are available, or you can line the catch pan with aluminum foil. To clean the catch pan, wash with warm soapy water.

Thermometer - Wipe with warm soapy water, clean with plastic scrub ball. Do not put in dishwasher or submerge in water.

Inside cooking box - Brush any debris off of burners tubes.

DO NOT ENLARGE BURNER PORTS (OPENINGS). Wash inside of cooking box with warm soapy water.

Inside Lid - While lid is warm, wipe inside with paper towel to prevent flaking due to grease build-up.

24

Annual Maintenance

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



WARNING: Check hose before each use of barbecue for nicks, cracking, abrasions or cuts. If the hose is found to be damaged in any way, do not use the barbecue. Replace using only Weber authorized replacement hose. Order from Weber-Stephen Products

Co., Customer Service Center or authorized dealer.

■ Inspect the burners for correct flame pattern. Clean if necessary, following the procedures outlined in the

"General Maintenance" section of this manual.

■ Check all gas fittings for leaks.



DANGER

Do not use an open flame to check for gas leaks. Be sure there are no sparks or open flames in the area while you check for leaks. This will result in a fire or explosion which can cause serious bodily injury or death, and damage to property.

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

You will need: a soap and water solution and a rag or brush to apply it.

To perform leak checks: Make sure all burners are in the

OFF position. Turn on gas supply.



WARNING: Do not ignite burners while leak checking.

Check for leaks by wetting the connections with the soap and water solution and watching for bubbles. If bubbles form or if a bubble grows there is a leak.

Note - Since some leak test solutions, including soap and water, may be slightly corrosive, all connections should be rinsed with water after checking for leaks.

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

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

If a leak persists after retightening the fitting, turn OFF

the gas. DO NOT OPERATE THE BARBECUE. Contact

Weber-Stephen Customer Service.

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

c) Hose to quick disconnect connection. Figure 3 (c).



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.

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

(a)

(b)

(c)

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

Weber Spider Stopper Guards

Your Weber Gas Barbecue, as well as any outdoor gas appliance, is a target for spiders and other insects. They can nest in the venturi section of the burner tubes. This blocks the normal gas flow, and can cause the gas to flow back out of the air shutter. Figure 4. This could result in a fire in and around the air shutters, under the control panel, causing serious damage to your barbecue.

Venturi

Main Burner Flame Pattern

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

Tips occasionally yellowish

Burner inside cooking box

Light blue

Venturi fin

Air shutter

Figure 4

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.

Flames

Dark blue

Figure 6

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

Main Burner Cleaning Procedure

Turn off the gas supply. Remove the manifold. (See

Section “Replacing the main burners”.)

Look inside each burner with a flashlight. Figure 7.

Weber Spider

Stopper Guard

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.

2.

Barbecue does not reach temperature.

3.

Barbecue heats unevenly.

4.

One or more of the burners do not ignite.



DANGER

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

Figure 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 8

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

Replacing Main Burners a) Your Weber Gas Barbecue must be OFF and cool.

b) Turn gas OFF at source.

c) Remove control panel: take off the burner control knobs. Remove the screws holding the control panel in place. Lift off the control panel.

26

d) Unlatch the Spider Stopper Guards and remove.

Figure 9.

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



CAUTION: The burner openings must be positioned properly over the valve orifices. Figure 13a.

Check proper assembly before fastening manifold in place.

Figure 13b.

(a)

Valve

Figure 9 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

Burner

(b)

Wing nuts

Figure 10 f) Slide the burner assembly out from under the guide screw and washer in the corners of the cooking box.

Figure 11.

Guide screw

Figure 13 i) Reinstall the Spider Stopper Guards. Slightly rotate the Spider Stopper Guards so that the seams are in line with the Venturi fins. There should be no gaps in the seams or in the fit around the burners and valves.

Figure 14.

Check fit around valve

Figure 11 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.

Crossover tube

Venturi fin

Check fit around burner

Figure 14

Figure 12

27

 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”.)

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, See

Section "Manual Lighting", and contact Weber-Stephen

Customer Service.

28

TROUBLESHOOTING

Problem

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

Check

Inspect Weber Spider Stopper

Guards for possible obstructions.

(Blockage of holes.)

Cure

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?

Does the Front burner light with a match?

Straighten fuel hose.

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

System.

Experiencing flare-ups: 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".)

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

Clean bottom tray.



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

Burner flame pattern is erratic. Flame is low when burner is on HIGH. Flames do not run the whole length of the burner tube.

Are burners clean?

Inside of lid appears to be “peeling.”

(Resembles paint peeling.)

Clean burners. (See Section

"General Maintenance".)

The lid is porcelain-on-steel, not paint. It cannot “peel.” What you are seeing is baked on grease that has turned to carbon and is flaking off.

THIS IS NOT A DEFECT.

Clean thoroughly. (See

Section "Periodic Cleaning".)

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

11

12

13

14

15

16

17-18

19

20

23

24

25

26

13, 18

21

22

27

28

29

3

4

5

6

7

8

9

10

1

2

W

E B E R

W

30

30

31

32

45

38

46

47

48

49

50-51

52

53

54

39

40

41

42

43

44

33

34

35

36

37

38

55

Parts List

All items are single quantities unless otherwise specified.

Parts can be ordered directly from Weber-Stephen

Products Company by phone or mail.

Note - Do not return parts to Weber-Stephen Products

Co. without first contacting the Customer Service

Center by phone or mail. Returning the part may not be necessary.

While we give much attention to our products, unfortunately an occasional error may occur. If a part is missing, do not go back to the store. Call the Weber

Customer Service Center toll free 1-800-446-1071 to receive immediate assistance. Have your owner’s manual and serial number of the barbecue available for reference.

Weber-Stephen Products Company

Customer Service Center

250 South Hicks Road

Palatine, IL 60067-6241

(800) 446-1071

1 Hair pin cotters (2)

2 Hinge pins (2)

3 Right endcap

4 Shroud assembly

5 Lid handle

6 Warm-Up Basket

7 Warming rack

8 Short Flavorizer bars (8)

9 Long Flavorizer bars (5)

10 Cooking grates (2)

11 Work table

12 Tubing plugs (5)

13 1/4-20 x 2 inch bolts (5)

14 Spacer bracket

15 Swing table end bracket

16 Left frame

17 1/4-20 x 1/2 inch bolts (6)

18 1/4 inch nylon washers (11)

19 Caster frame

20 Swing table

21 Slide bar assembly

22 Slide bar hardware

23 Casters (2)

24 Frame connectors (2)

25 Accessory trays (2)

26 Bottom tray

27 Catch pan holder

28 Catch pan

29 Drip pans (2)

30 Left endcap

31 Thermometer

32 Thermometer holder

33 1/4-20 keps nut

34 Cooking box (Assembly)

35 Burner control knobs (3)

36 Control panel

37 Igniter button

38 Control panel hardware

39 Crossover tube

40 Front and back burners (2)

41 Center burner

42 1/4-20 stainless steel wing nuts (2)

43 Spider Stopper Guards (3)

44 Manifold assembly

45 Manifold bracket

46 Igniter (Assembly)

47 Right frame

48 Tool holders (3)

49 Wheel frame

50 Front panel

51 Plastic buttons (2)

52 Wheel hubcaps (2)

53 Wheels (2)

54 Axle

55 Hose



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.

31

A F

INAL

W

ORD

OF

T

HANKS

T

hank you for choosing a Weber Barbecue.

Our family here at Weber has worked hard to produce the highest quality products for your satisfaction.

While we give much attention to our products, an occasional error may occur. Our knowledgeable Customer

Service staff is prepared to help you with any problems with parts or assembly.

Call our toll free number 1-800-446-1071.

For quicker service, please have your owner’s manual available for reference. We also welcome any comments or suggestions you might have regarding our products.

We wish your family the best in outdoor cooking enjoyment.

Weber-Stephen Products Company

Customer Service Center

200 East Daniels Road

Palatine, Illinois 60067-6266