GENESIS 1000 Series - Appliance Factory Parts

GENESIS 1000 Series - Appliance Factory Parts
GENESIS 1000 Series
®
®
®
Propane Fixed Piping System
Owner's Manual
GAS
BARBECUE
Serial Number
Please use this number in registering your warranty and
any correspondence with the factory.
®
®
gama
®
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.
© 1992, Weber-Stephen Products Co.
62713
3/94
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
■
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.
■
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.
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:
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,
Cooking Grates and Flavorizer Bars, 3 years,
All Remaining Parts, 5 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.
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.
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 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 WeberStephen 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
(708) 705-8660
(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.
3
PATENTS AND TRADEMARKS
© 1992 Weber. Weber, , Genesis, Flavorizer and Crossover are
registered U.S. trademarks; Spirit, Perma-Mount, Gas Catcher,
FlameCheck, Steam-N-Chips, Spider Stopper, and Warm-Up are
U.S. trademarks of Weber-Stephen Products Co., 200 East Daniels
Road, Palatine, IL 60067-6266.
Spirit 500, 700, and Genesis 1000-5500 Gas Barbecues are
covered under one or more of the following patent nos.: U.S. patent
#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;
Australia: #95,034; #598,709; Austria: #E68678; Belgium: #0-233-187;
Canada: Rd 1987 Reg. #58,034; #1,279,540; #1,283,586;
#1,300,994; #1,300,995; France: Brevet #0-233-187; Germany:
DBP #3682191; Italy: #0-233-187; Luxembourg: Brevet #0-233-187;
Netherlands: Ned. Octrooi #0-233-187; New Zealand: #224,786;
Sweden: #0-233-187; Switzerland #0-233-187; United Kingdom:
#0-233-187.
Printed in the U.S.A.
4
Contents
Warnings.................................................................... 2
Warranty & Patents.................................................. 3-4
General Instructions.................................................... 6
Assembly ............................................................... 7-22
Operating Instructions
Lighting........................................................ 23-24
Cooking ............................................................ 25
Storage and/or Nonuse .................................... 25
Cleaning .......................................................... 25
Troubleshooting & Maintenance
Annual Maintenance......................................... 29
General Maintenance.................................. 30-32
Troubleshooting................................................ 33
Parts Listing .............................................................. 35
b
c
e
a
d
f
g
h
i
a
FEATURES:
a) Convenient tables and racks.
e) Weber Warm-Up Basket for additional cooking or
warming space.
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.
f)
Separate burners for temperature control.
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.
h) Catch pan catches excess grease.
g) Crossover Ignition System with Gas Catcher Ignition
Chamber.
i)
5
Locking casters for additional portability.
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.
■
The valves and orifices of this barbecue are set to
operate at 10.5 inches of water column pressure.
■
This Weber Gas Barbecue is designed for use with
liquid propane (LP) gas only. Do not use with natural
(piped in city) gas. The valves and orifices are for
LP gas only.
■
Do not use with charcoal fuel.
■
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 fuel supply
when the Weber Gas Barbecue is not in use.
Operating area
Liquid Propane (LP) gas supply is easy to use and gives
you more cooking control than charcoal fuel.
■
■
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).
6
■
Never use your Weber Gas Barbecue under an
unprotected combustible roof or overhang.
■
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.
Step 1
Assembly
Check package contents
Tools needed
Screwdriver
Cooking box
(assembly)
Hammer
7/16 and 3/4 inch open-end or an adjustable wrench
Lid
(assembly)
Pliers
®
®
Block of wood
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 available for reference.
Two cooking grates
Control panel
7
Left frame
Five long Flavorizer Bars
Eight short Flavorizer Bars
Right frame
Front panel
Wheel frame
Catch pan holder
Caster frame
Catch pan
Two frame connectors
Two drip pans
Work table
Manifold bracket
Swing table assembly
Thermometer
Two casters
Accessory rack
Warming rack
Warm-Up Basket
8
R
Axle
WE BE
Two wheels
WE B E R
Support rod
Check contents of hardware packs
Two plastic buttons
(actual size)
Three burner control knobs
1/4-20 acorn nut
(actual size)
Three tool holders
Two 1/4-20 wing nuts
(actual size)
Five tubing plugs
(two are spares)
Fourteen 1/4 inch nylon washers
Support rod holder
Two hair pin cotters
Swing table end bracket
Two wheel hubcaps
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)
9
Step 3
Assemble wheels
Assemble top frame
You will need: axle, two wheel hubcaps, two wheels,
wheel frame, 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.
Place one end of the axle on the block of wood (or other
protected surface). Tap on one hubcap.
Note - Work on carpeted area (on grass or one of the
boxes) to protect the finish during frame assembly.
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.
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
Step 2
R
Frame tabs
(a)
Figure 1
Leg tabs
Right frame
Left frame
(b)
Figure 2
10
Step 4
Step 5
Continue frame assembly
Complete 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.
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.
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.
Hold one frame connector between the leg and wheel
frame. Add the nylon washer to the bolt. Put the bolt
through the frame and screw into frame connector.
Tighten.
The leg tabs must be on the inside of the frames.
Repeat procedure with the other frame connector.
Figure 4.
Add the washers to the bolts, insert in the holes as
shown and tighten with the wrench. Figure 3.
Dimples to
the inside
Fuel scale
decal
Figure 4
Figure 3
11
Step 6
Step 7
Insert casters
Add front panel
You will need: frame assembly and two casters.
You will need: front panel and two plastic buttons.
Push the casters firmly into the inserts in the ends of the
caster legs. Figure 5.
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
12
Step 8
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 x 2 inch bolt, 1/4 inch nylon washer, 1/4-20 acorn
nut, pliers and a 7/16 inch wrench.
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 thumb screws under the burner assembly
hand tight? Do not tighten with pliers. Figure 9 (c).
Set the cooking box in the frame so the burner tubes are
under the frame brace. Figure 7.
Burner tubes
Frame brace
If you answered YES to a, b and c, the burners are
correctly aligned. If you answered NO, the burners are
misaligned. Contact your dealer. Do not use barbecue.
Guide screw
Figure 7
(b)
(a)
Slide the cooking box to the left within the frame. Put
washer on bolt. Insert the bolt through the cooking box
and frame with the head of the bolt outside the box.
Figure 8. Add the nut. Tighten by holding the bolt with
pliers while you tighten the nut with a wrench.
View from
behind
cooking
box
(c)
Figure 9
Thumb screws
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.
Figure 8
Frame brace
Figure 10
13
Manifold bracket
Step 10
Typical propane fixed piping system installation.
Figure 11.
Install gas supply
Gas supply
General Specifications for Piping
Inside wall
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.
Outside wall
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.
Quick Disconnect
Shut off
Locking shut off
NOTE: The LP gas supply at the barbecue must be
regulated to 10.5 inches of water column pressure.
■
A manual shut-off valve must be installed outdoors,
immediately ahead of the quick disconnect.
The quick disconnect is installed
above ground
Caution: If young children are in the area, a locking
valve should be considered.
■
■
■
An additional manual shut-off valve indoors should
be installed in the branch fuel line in an accessible
location near the supply line.
Gas line piping
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 propane gas when connections are
made.
■
Figure 11
The outdoor connector must be firmly attached to
rigid, permanent construction.
■
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.
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
injury or death, and damage to property.
14
Step 11
Step 13
Check that all burner valves are off
Install igniter
You will need: one burner control knob.
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.
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. Figure 12.
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 to the rear of the keyhole. Tighten the
igniter lock nut. Figure 14.
Note - If the igniter works loose, carefully tighten the
igniter lock nut with an adjustable wrench or pliers.
Figure 12
Step 12
Connect flexible hose to manifold
You will need: the 12 foot gas supply hose and a 3/4
inch wrench.
Figure 14
Thread fitting end of hose onto manifold. Figure 13 (a).
Tighten with wrench.
(a)
Keyhole in
frame brace
Igniter lock nut
Figure 13
15
Step 14
Check:
Check for gas leaks
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.
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 your dealer.
b) Valves to manifold connections. Figure 16 (b).
c) Hose to quick disconnect connection. Figure 16 (c).
WARNING: If there is a leak at connections b or c,
turn OFF the gas. DO NOT OPERATE THE
BARBECUE. Contact your dealer.
Warning: You should check for gas leaks every time
you disconnect and reconnect a gas fitting.
When leak checks are complete, turn gas supply OFF at
the source and rinse connections with water.
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.
(a)
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.
(b)
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.
(a)
(c)
Collar
Figure 16
(b)
Male fitting
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.
16
Step 15
Install Flavorizer Bars and Cooking Grates
Step 16
Install the bottom tray
You will need: five long Flavorizer Bars, eight short
Flavorizer Bars and two cooking grates.
You will need: bottom tray, catch pan holder, catch pan
and one drip pan.
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.
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
Finger grip
Figure 20
The open "U" of the cooking grates goes down. Set the
cooking grates onto the ledges in the cooking box.
Figure 18.
Slide the bottom tray onto the mounting rails under the
cooking box with finger grip toward you. Figure 21.
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.
17
Step 17
Step 18
Install Lid
Add tool holders, control panel and burner
control knobs
You will need: lid, two hinge pins and two hair pin
cotters.
You will need: two tool holders, control panel and three
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.
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. Place your thumbs over the
control panel push-in buttons, and push them into the
frame brace until they snap into place. Figure 23 (a).
Hair pin cotter
Push on the three burner control knobs. Figure 23 (b).
Hinge pin
Hole in
frame brace
(a)
Control panel
push-in buttons
Figure 22
(b)
Tool holders
Figure 23
18
Step 19
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)
(a)
(c)
(b)
Support rod
(a)
Figure 24
View from rear
of barbecue
Slot in frame
(view from below)
(c)
(d)
Figure 25
19
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 26 (a).
Set the warming rack into the slots at the rear of the
cooking box. Figure 26 (b).
Set the work table onto the left side rails. Figure 26 (c).
Set the accessory rack in place between the two frame
connectors. 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).
(a)
(b)
(e)
(c)
(f)
(d)
Figure 26
Caution: To keep the barbecue stationary, the tabs
on the locking casters should be in the down
position.
20
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 burner control knob down and turn
clockwise.)
DANGER
3) Turn gas supply valve on.
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.
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.
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 Weber-Stephen
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.
1
2
7
5
3
6
4
Figure 1
21
Manual Lighting
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.
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 flameup which can cause serious bodily injury
or death.
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
1) Open the lid. Figure 2.
Turn gas supply OFF at the source, then push down
and turn each burner control knob clockwise to OFF.
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
2
7
3
4
6
5
Figure 2
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.
22
Cooking
Periodic Cleaning
The Weber Genesis Gas Barbecue should not be
moved when operating or hot.
CAUTION: Turn your Weber Gas Barbecue OFF and
wait for it to cool before cleaning.
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.
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.
Note - The temperatures inside your cooking box, for the
first few uses, may be hotter than those shown in your
cookbook. Adjusting the burner controls may be
necessary.
Bottom tray - 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.
Caution: Replace thermometer in lid when not in use.
Do not leave thermometer in food while cooking.
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.
If burners go out during cooking, open lid, turn off
all burners and wait 5 minutes before relighting.
Thermometer - Wipe with warm soapy water, clean with
plastic scrub ball. Do not put in dishwasher or submerge
in water.
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.
Inside cooking box - Brush with a suitable barbecue
brush (brass bristle). Brush any debris off of burners with
barbecue brush. DO NOT ENLARGE BURNER PORTS
(OPENINGS). Wash inside box with warm soapy water.
Inside Lid - While lid is warm, wipe inside with paper
towel to prevent flaking due to grease build-up.
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.
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 postion. 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.")
23
Annual Maintenance
Check:
After a period of nonuse we recommend that you
perform the following maintenance procedures for your
safety.
WARNING: If there is a leak at connection (a),
retighten the 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 your dealer.
■
■
a) Hose to manifold connection. Figure 3 (a).
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 your dealer.
Inspect the burners for correct flame pattern. Clean
if necessary, following the procedures outlined in the
"General Maintenance" section of this manual.
When leak checks are complete, turn gas supply OFF at
the source and rinse connections with water.
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.
(a)
(b)
Warning: You should check for gas leaks every time
you disconnect and reconnect a gas fitting.
(c)
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.
Figure 3
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.
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".)
24
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
Venturi
Light blue
Dark blue
Flames
Venturi fin
Air shutter
Figure 6
Figure 4
If the flames do not appear to be uniform the length of
the burner tube, follow the burner cleaning procedures.
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.
Main Burner Cleaning Procedure
Brush the outside of the burner tubes and the burner
port section with a brass wire brush. This is to make
sure all the burner ports are fully open.
Caution: Do not enlarge the burner ports when
cleaning.
Weber Spider
Stopper Guard
Replacing Main Burners
a) Your Weber Gas Barbecue must be OFF and cool.
Figure 5
b) Turn gas OFF at source.
c) Remove control panel: take off the burner control
knobs. Put your fingers under the edge of the
control panel at the control panel push-in buttons
and pull toward you. Lift off the control panel.
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.
d) Unlatch the Spider Stopper Guards and remove.
Figure 7.
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
25
e) Remove the manifold bracket and unscrew the two
thumb screws that hold the manifold to the cooking
box. Pull the manifold and valve assembly out of the
burners and carefully set it down. Figure 8.
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 11.
View from behind
cooking box
Check fit
around valve
Venturi fin
Thumb screws
Figure 8
Check fit around burner
Figure 11
f)
Slide the burner assembly out from under the guide
screw and washer in the corners of the cooking box.
Figure 9.
CAUTION: If the Spider Stopper Guards do not fit
tightly, contact your dealer.
Guide screw
CAUTION: 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.
Figure 9
■
g) Lift and twist the burner assembly slightly, to
separate the crossover tube from the burners.
Figure 10. Remove the burners from the cooking
box.
Check that both the white and black ignition wires
are attached properly. Figure 12.
Crossover tube
White wire
Black wire
Figure 10
Figure 12
h) To reinstall the burners, reverse steps c) through g).
■
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 your dealer.
26
TROUBLESHOOTING & MAINTENANCE
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".)
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".)
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.
Experiencing flare-ups:
CAUTION: Do not line the bottom tray
with aluminum foil.
If problems cannot be corrected by using these methods, please contact your dealer.
27
1
33
34
®
®
35
2
3
4
5
6
7
36
37
38
39
40
41
42
43
44
8
9
45
46
47
10
11
48
12
13-14
15
16
49-53
54
17
10,14
18
55
19
20
W
21
W
22
E BE R
E BE R
23
24
25 26 27
28 29
30
30
31
32
Parts List
Contact:
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
32
Lid (assembly)
Lid handle
Warm-Up Basket
Warming rack
Short Flavorizer bars (8)
Long Flavorizer bars (5)
Cooking grates (2)
Work table
Tubing plugs (5)
1/4-20 x 2 inch bolts (5)
Swing table end bracket
Left frame
1/4-20 x 1/2 inch bolts (6)
1/4 inch nylon washers (11)
Caster frame
Swing table assembly
Support rod holder
Support rod
Casters (2)
Bottom tray
Catch pan holder
Catch pan
Drip pans (2)
Accessory rack
Frame connectors (2)
Wheel hubcaps (2)
Wheels (2)
Tool holders (3)
Wheel frame
Front panel
Plastic buttons (2)
Axle
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
Weber-Stephen Products Company
Customer Service Center
250 South Hicks Road
Palatine, IL 60067-6241
(708) 705-8660
(800) 446-1071
Hair pin cotters (2)
Hinge pins (2)
Thermometer
1/4-20 acorn nut
Cooking box
Burner control knobs (3)
Control panel
Igniter button
Control panel push-in buttons (2)
Crossover tube
Front and back burners (2)
Center burner
1/4-20 x 1/2 inch thumbscrews (2)
Spider Stopper Guards (3)
Manifold assembly
Manifold bracket
Igniter
Igniter lock nut
Gas catcher ignition chamber
Igniter wire (black)
Igniter wire (white)
Right frame
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 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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