Weber | A101.c | User's Manual | Weber A101.c User's Manual

Weber A101.c User's Manual
Owners Guide
DANGER
If you smell gas:
1. Shut off gas to the appliance.
2. Extinguish any open flames.
3. Open lid
4. If odor continues, keep away from the
appliance and immediately call your gas
supplier or your fire department.
Leaking gas may cause a fire or explosion
which can cause serious bodily injury or
death, or damage to property.
Natural Gas
®
®
WARNING
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 the
barbecue was dealer-assembled.
R
WE
B
E
WE
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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 the “Lighting”
Instructions section of this manual
YOU MUST READ THIS OWNERS GUIDE
BEFORE OPERATING YOUR GAS GRILL
A101.c
B067.e
C052.c
D001.e
55051 05/24/01
DANGER
Failure to follow the Dangers, Warnings and Cautions contained in this Owner’s Manual
may result in serious bodily injury or death, or in a fire or an explosion causing damage
to property.
WARNINGS
Do not store a spare or disconnected liquid propane cylinder under or near this barbecue.
Improper assembly may be dangerous. Please carefully follow the assembly instructions in
this manual.
After a period of storage, and/or nonuse, the Weber Gas Barbecue should be checked for gas
leaks and burner obstructions before use. See instructions in this manual for correct
procedures.
Do not operate the Weber gas barbecue if there is a gas leak present.
Do not use a flame to check for gas leaks.
Combustible materials should never be within 24 inches of the top, bottom, back or sides of
your Weber gas barbecue.
Do not put a barbecue cover or anything flammable on, or in the storage area under the
barbecue.
Your Weber Gas Barbecue should never be used by children. Accessible parts of the
barbecue may be very hot. Keep young children away while it is in use.
You should exercise reasonable care when operating your Weber gas barbecue. It will be hot
during cooking or cleaning and should never be left unattended, or moved while in operation.
Should the burners go out while in operation, turn all gas valves off. Open the lid and wait five
minutes before attempting to relight, using the lighting instructions.
Do not use charcoal or lava rock in your Weber gas barbecue.
Never lean over open grill or place hands or fingers on the front edge of the cooking box.
Should a grease fire occur, turn off all burners and leave lid closed until fire is out.
Do not enlarge valve orifices or burner ports when cleaning the valves or burners.
The Weber Gas Barbecue should be thoroughly cleaned on a regular basis.
Liquid propane gas is not natural gas. The conversion or attempted use of natural gas in a
liquid propane unit or liquid propane gas in a natural gas unit is dangerous and will void your
warranty.
Do not attempt to disconnect any gas fitting while your barbecue is in operation.
Use heat-resistant barbecue mitts or gloves when operating barbecue.
Combustion byproducts produced when using this product contain chemicals known to the
state of California to cause cancer, birth defects, or other reproductive harm.
LIQUID PROPANE GAS UNITS ONLY:
Use the regulator that is supplied with your Weber Gas Barbecue.
Do not attempt to disconnect the gas regulator or any gas fitting while your barbecue is in
operation.
A dented or rusty liquid propane cylinder may be hazardous and should be checked by your
liquid propane supplier. Do not use a liquid propane cylinder with a damaged valve.
Although your liquid propane cylinder may appear to be empty, gas may still be present, and
the cylinder should be transported and stored accordingly.
If you see, smell or hear the hiss of escaping gas from the liquid propane cylinder:
1. Move away from liquid propane cylinder.
2. Do not attempt to correct the problem yourself.
3. Call your fire department.
A-2
Warranty
Weber-Stephen Products Co. (Weber) hereby warrants
to the ORIGINAL PURCHASER of this Weber Gas Grill
that it will be free of defects in material and
workmanship from the date of purchase as follows:
Aluminum Castings,lifetime, 1 year paint
Porcelain Hood Section, 25 years
Burners, 10 years
Igniter, 3 years
Cooking Grates, 7 years no rust through
Flavorizer Bars, 1 year no rust through
Thermoplastic/
Thermoset Parts, 10 years Excluding fading
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 that prove defective under normal
use and service and which on examination shall
indicate, to Weber’s satisfaction, they are defective.
Before returning any parts, contact the Customer
service representative in your region using the contact
information sheet provided with your manual. If Weber
confirms the defect and approves the claim, Weber will
elect to replace such parts without charge. If you are
required to return defective parts, transportation
charges must be prepaid. Weber will return parts to the
purchaser, freight or postage prepaid.
This Limited Warranty does not cover any failures or
operating difficulties due to accident, abuse, misuse,
alteration, misapplication, vandalism, improper
installation or improper maintenance or service, or
failure to perform normal and routine maintenance,
including but not limited to damage caused by insects
within the burner tubes, as set out in this owner’s
manual.
Deterioration or damage due to severe weather
conditions such as hail, hurricanes, earthquakes or
tornadoes, discoloration due to exposure to chemicals
either directly or in the atmosphere, is not covered by
this Limited Warranty.
There are no other express warrants except as set forth
herein and any applicable implied warranties of
merchantability and fitness are limited in duration to the
period of coverage of this express written Limited
Warranty. Some regions do not allow limitation on how
long an implied warranty lasts, so this limitation may not
apply to you.
Weber is not liable for any special, indirect or
consequential damages. Some regions do not allow the
exclusion or limitation of incidental or consequential
damages, so this limitation or exclusion may not apply
to you.
Weber does not authorize any person or company to
assume for it any other obligation or liability in
connection with the sale, installation, use, removal,
return, or replacement of its equipment; and no such
representations are binding on Weber.
This Warranty applies only to products sold at retail.
WEBER-STEPHEN PRODUCTS CO.
Customer Service Center
1890 Roselle Road, Suite 308
Schaumburg, IL 60195
USA
A-3
Contents
Danger & Warnings ................................ A-2
Warranty ................................................. A-3
General Instructions ............................... A-5
Exploded View ........................................ A-6
Parts List ................................................ A-9
Assembly Instructions ............................ B-1
Installing Features .................................. C-1
Operating ............................................... D-1
Lighting ................................................... D-1
Manual Lighting ...................................... D-2
Cooking .................................................. D-3
Storage ................................................... D-3
Cleaning ................................................. D-3
Annual Maintenance .............................. D-4
General Maintenance ............................. D-5
Replacing Main Burners ......................... D-6
Crossover Ignition System Operations ... D-7
Troubleshooting ...................................... D-8
A-4
Storage
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.
•
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
WARNING: Only use this barbecue outdoors in a
well-ventilated area. Do not use in a garage,
building, breezeway or any other enclosed area.
WARNING: Never use your Weber Gas Barbecue
under an unprotected combustible roof or
overhang.
WARNING: Your Weber Gas Barbecue is not
intended to be installed in or on recreational
vehicles and/or boats.
WARNING: Do not use combustible materials
within 24 inches of the top, bottom, back or sides
of the grill.
WARNING: The entire cooking box gets hot
when in use. Do not leave unattended.
WARNING: Keep any electrical supply cord and
the fuel supply hose away from any heated
surface.
WARNING: Keep the cooking area clear of
flammable vapors and liquids, such as gasoline,
alcohol, etc., and combustible materials.
Gas Supply Testing
•
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 Standards CAN/
CGA-B149.1 (Installation Code for Natural Gas
Burning Appliances and Equipment).
•
A-5
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).
Genesis Silver-B Prem. NG 050401
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A-6
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Hinge Pin
Left Endcap
Shroud
Handle
Warm-Up Basket
Warming Rack
Cooking Grate
Flavorizer Bar
Cooking Box
1/4-20 keps nut
Slide Out Bottom Tray
Catch pan holder
Left Trim Piece
Work Surface
Left Frame
Hinge Rod
Left Swing-Up Work Surface
Caster Frame
1/4-20 x 2 inch bolt
1/4 Inch Nylon washer
Frame Connector
Caster
Bottom Shelf
Wheel
Hubcap
26.
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A-7
Hair Pin Cotter
Thermometer
Right Endcap
Burner Control Knob
Control Panel
Ignitor Button
Control Panel Hardware
Crossover tube
Front and Back Burners
Center Burner
Manifold Hardware
Manifold
Catch Pan
Disposable Drip Pan
Igniter
Right Frame
Right Trim Piece
1/4-20 x 1/2 inch bolt
Right Swing-Up Work Surface
Wheel Frame
Hose
Axle Rod
© 2001 Weber-Stephen Products Co., Weber, the silhouette, and the kettle configuration are registered trademarks
of Weber-Stephen Products Co., 200 East Daniels Road, Palatine, IL, 60067-6266, U.S.A. This product is covered by
one or more United States patents and patents in other nations globally. Printed in the U.S.A.
®
A-8
Screwdriver
Left Frame - 1
Phillips screwdriver
Hammer
Right Frame -1
7/16 open-end or an adjustable wrench
Wheel Frame - 1
Pliers
Caster Frame - 1
Block of wood
Lid -1
Frame Connectors - 2
®
®
Left Trim Piece - 1
Right Trim Piece - 1
Cooking Box - 1
Work Surface - 1
Left Swing-Up Work Surface - 1
Cooking grates - 2
Right Swing-Up Work Surface
Hinge Rod - 2
Control panel - 1
Bottom Shelf - 1
A-9
Warming Rack - 1
Burner Control Knobs - 3
Warm-Up Basket - 1
Hinge Pins (1/4-20 x 1 1/2 inch clevis pin) - 2
2 inch bolts (1/4-20 x 2 inch bolts) - 5
Flavorizer Bars - 5
1/2 inch bolts (1/4-20 x 1/2 inch bolts) - 9
Bottom tray - 1
Keps Nut (1/4-20 Keps Nut) - 1
Catch Pan Holder - 1
1/4 Inch Nylon Washers - 14
Catch Pan -1
Cotter Pin - 2
Disposable Drip Pans - 2
Hubcaps - 3
Thermometer -1
Control Panel Hardware
(Phillips screws/washers) - 2
Casters - 2
Axle Rod - 1
Wheels - 2
Hose - 1
A-10
Assembly Instructions
Assemble frame
You will need: left frame, right frame, two 1/2 inch
bolts, two nylon washers and a 7/16 inch or adjustable
wrench.
Note - Work on carpeted area (on grass or one of the
boxes) to protect the finish during frame assembly.
Lay the leg frame pieces as shown so the leg tabs
point up.
1) Connect the two frame pieces with the tabs inside
of the frame.
2) Slip washers on bolts, then insert bolts as shown
and tighten. (If you try to insert a bolt and there is
no hole, you have the left frame turned the wrong
way. Turn the left frame around.)
WE BE
WE B E R
Assemble wheel frame
You will need: axle rod, two wheel hubcaps, two
wheels, wheel frame, hammer and a block of wood.
Place one end of the axle rod on the block of wood (or
other protected surface). Tap one hubcap onto the end
of the axle rod. Slide one wheel onto the axle, WEBER
name facing out. Next, slide the other end of the axle
rod through the wheel frame. Add the other wheel,
WEBER name side facing out. Tap the hubcap onto
the axle rod to complete the axle.
R
(1)
(2)
B067.e
B-1
Continue frame assembly
You will need: caster frame, wheel frame, four 1/2 inch
bolts, four nylon washers and a 7/16 inch or adjustable
wrench.
Place the caster frame onto the tabs of the left frame,
so that the swing table locking latch (1) is to the rear.
Place the wheel frame onto the tabs of the right frame,
so that the swing table locking latch (2) is to the rear.
The leg tabs must be on the inside of the frames.
Add the washers to the bolts. Insert the bolts into the
holes as shown, do not tighten bolts on wheel
frame until a later step.
Complete frame assembly
You will need: partial frame assembly, two frame
connectors, four 2 inch bolts, four nylon
washers and a 7/16 inch or adjustable wrench.
Hold one frame connector between the caster frame
and wheel frame. Add the nylon washer to the bolt.
Insert the bolt through the frame and screw into frame
connector. Tighten bolt with wrench.
Repeat procedure with the other frame connector.
(1)
(2)
B-2
Insert casters
You will need: frame assembly and two casters.
Push the casters firmly into the inserts in the ends of
the caster frame.
Add cooking box (assembly)
You will need: frame assembly, cooking box
(assembly), 2 inch bolt, nylon washer, keps nut, pliers
and a 7/16 inch or adjustable wrench.
Place the cooking box (assembly) in the frame
assembly so the burner tubes(1) are under the frame
brace(2).
(1)
(2)
Slide the cooking box (assembly) to the left within the
frame assembly. Add the nylon washer to the bolt.
Insert the bolt through the cooking box and frame with
the head of the bolt outside the box. Add the keps nut.
Tighten by holding the bolt with pliers while you tighten
the nut with a wrench.
B-3
Your Weber Gas Grill Manifold assembly consisting of
gas manifold, valves and gas burners has been factory
assembled, pressure- and flame- tested. As a safety
precaution, we recommend you check the burner
alignment:
1) 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.
2) Do the valves fit into the ends of the burners?
3) Are the wing nuts under the burner assembly hand
tight? Do not tighten with pliers.
If you answered YES to 1, 2 and 3, the burners are
correctly aligned. If you answered NO, the burners are
misaligned. Contact the Customer Service
Representative in your region using the contact
information sheet provided with your manual. Do not
use grill.
Install manifold brackets
The manifold brackets(2) are already in place on the
manifold between the valves.
Place your hand underneath the manifold. Lift the
manifold and cooking box slightly and hook the
manifold bracket(2) onto the frame brace(1).
(1)
(2)
(1)
(3)
B-4
(2)
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.
1) Loosen the igniter lock nut.
2) Insert the top of the igniter up through the large
part of the keyhole in the frame brace. Slide the
igniter into the small part of the keyhole.
3) Tighten the igniter lock nut back onto the igniter.
Note - If the igniter works loose, carefully tighten the
igniter lock nut with an adjustable wrench or pliers.
The wire holder (1) is to keep ignition wires from
interfering with the swing-up table’s bracket. If the wire
holder becomes loose, reinstall or replace it
immediately.
(1)
(1)
(2)
(3)
B-5
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
confirm 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 ANISI 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.
 WARNING: Do not route the 12 foot hose under
a deck. The hose must be visible.
Gas Line Piping
■ If the length of the 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.
Gas supply
Inside wall
Outside wall
Shut off
Quick Disconnect
Locking shut off
B-6
Check that all burner valves are off
You will need: burner control knobs.
Valves are shipped in the OFF position, but you should
check to be sure that they are turned OFF. 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. If they do turn continue
turning them clockwise until they stop, then they are
off. Proceed to the next step.
Connect flexible hose to manifold
You will need: the 12 foot natural supply hose and a 3/
4 inch wrench.
Thread fitting end of hose onto manifold. Tighten with
wrench.
B-7
Check for gas leaks
Check:
1) Hose to manifold connection.
 WARNING: If there is a leak a connection(1),
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 the Customer Service Representative in
your region using the contact information sheet
provided with your manual.
2) Valves to manifold connection
3) Hose to quick disconnect connection
 WARNING: If there is a leak at connections(2)
or(3) turn OFF the gas. DO NOT OPERATE THE
BARBECUE. Contact the Customer Service
Representative in your region using the contact
information sheet provided with your manual.
When leak checks are complete, turn gas supply OFF
at the source and rinse connections with water.
 DANGER
Do not use an open flame to check for gas
leaks. Be sure there are no sparks or open
flames in the area while you check for
leaks. Sparks or open flames will result in
a fire or explosion which can cause
serious bodily injury or death and damage
to property.
 WARNING: You should check for gas leaks every
time you disconnect and reconnect a gas fitting.
Note - All factory-made connections have been
thoroughly checked for gas leaks. The burners have
been flame-tested. As a safety precaution however,
you should recheck all fittings for leaks before using
your Weber Gas Barbecue. Shipping and handling may
loosen or damage a gas fitting.
 WARNING: Perform these leak checks even if
your barbecue was dealer or store assembled.
You will need: a soap and water solution, and a rag or
brush to apply it.
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(1). Slide the
(1)
(1)
(2)
(2)
collar closed(2). If it does not engage or lock, repeat
procedure. Gas will not flow unless the quick
disconnect is properly engaged.
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.
(3)
B-8
Slide the bottom tray onto the mounting rails under the
cooking box with finger grip toward you(1).
 WARNING: 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.
Install the slide out bottom tray
You will need: the slide out bottom tray(1), catch pan
holder(2), catch pan and one disposable drip pan.
(1)
(2)
(1)
Hook the ends of the catch pan holder into the hole in
the slide out bottom tray. The front of the catch pan
holder must be on the same side as the finger
grip(1) of the bottom tray.
Put the disposable drip pan into the catch pan.
Slide the catch pan into the catch pan holder with its
finger grip towards you(1).
Install Lid
You will need: lid, two hair pin cotters(1) and two hinge
pins(2).
Place lid on top of the cooking box. Align the hinges at
the rear of the barbecue. Insert hinge pins through the
hinges from the outside. Insert hair pin cotters into the
small holes in the hinge pins.
(1)
(1)
(2)
B-9
Installing Features
Install the right end trim piece with tool holders
and right swing-up work surface
You will need: Right trim piece with tool holders, right
swing-up work surface, swing-up work surface rod, one
1/2 inch bolt, one nylon washer and a wrench
1.) Start the right end trim piece into the frame as
shown, do not push the trim piece in all of the
way and do not add bolt yet.
3.) Insert one end of the swing-up work surface rod
into the hole in the frame.
(1)
2.) Slide the swing-up work surface rod through the
holes at the top of the swing-up work surface.
C052.c
C-1
4.) While holding swing-up work surface in position,
insert the other end of the swing-up work surface
rod into the right end trim piece (1). Push the trim
piece into the frame as shown, making sure that
the tab on the back underside piece of the trim
piece is snapped into the slot in the rear frame (2).
5.) Add a washer to the bolt and insert it through the
front hole in the frame and the hole in the trim
piece. Tighten with a wrench.
View from underneath
(2)
(1)
View inside of control panel
C-2
To raise swing-up work surface: Lift table all the way
up and slide it to the left, then lower table until you feel
it lock in the up position.
Install the left end trim piece and swing-up work
surface
You will need: End trim piece, swing-up work surface,
swing-up work surface rod, two 1/2 inch bolts, two
nylon washers and a wrench
1.) Start the left end trim piece into the frame as
shown, do not push the trim piece in all of the
way and do not add bolts yet.
To lower swing-up work surface: Lift table up until it
disengages and slide it to the right. Then lower it all
the way down so that the locking pin on the right side
of the table fits into the locking bracket on the leg,
which will secure the table in the down position.
Do not use the swing-up work surface as a cutting
board.
2.) Slide the swing-up work surface rod through the
holes at the top of the swing-up work surface.
3.) Insert one end of the swing-up work surface rod
into the hole in the frame.
C-3
4.) While holding swing-up work surface in position,
insert the other end of the swing-up work surface
rod into the left end trim piece. Push the trim piece
into the frame.
To raise swing-up work surface: Lift table all the way
up and slide it to the right, then lower table until you
feel it lock in the up position.
To lower swing-up work surface: Lift table up until it
disengages and slide it to the left. Then lower it all the
way down so that the locking pin on the right side of
the table fits into the locking bracket on the leg, which
will secure the table in the down position.
Do not use the work surface as a cutting board.
5.) Add a washer to each bolt and insert it through the
hole in the frame and the hole in the trim piece on
both sides. Tighten with a wrench.
Install the work surface
You will need: work surface.
Place the work surface, so that the front and back
edges fit over the frame, in the area between the left
trim piece and the cooking box as shown.
Do not use the work surface as a cutting board.
(1)
(1) Make sure that the tabs on the side table are to the
right, next to the cooking box.
C-4
Install control panel and burner control knobs
You will need: control panel, two Phillips screws/
washers, a Phillips screwdriver, and burner control
knobs.
1) Set the control panel in place over both frame
braces. Hold the Crossover Ignition button up
while setting the control panel in place.
2) While looking under the right trim piece push the
control panel down and line up the holes in the
control panel with the white plastic plugs in the
frame brace. Insert screws and tighten with a
phillips screw driver until snug. Do not over
tighten.
3) Push each of the burner control knobs onto their
valve.
(1)
(2)
(3)
C-5
Install Flavorizer® Bars and Cooking Grates
You will need: five Flavorizer Bars and two cooking
grates.
Place the Flavorizer Bars side by side in the cooking
box.
Installing the warming rack
You will need: warming rack.
Set the warming rack into the slots at the rear of the
cooking box.
Install the thermometer
You will need: Thermometer.
Insert the thermometer into its holder on the right side
of the lid.
Set the cooking grates onto the ledges in the cooking
box with the rounded sides up.
®
®
Install the bottom shelf
You will need: Bottom shelf.
Set the bottom shelf in place between the two frame
connectors underneath the cooking box.
Installing the Warm-Up™ Basket
You will need: Warm-Up Basket
Insert one end of the Weber Warm-Up Basket into the
hole at the right side of the inside of the lid, and the
other end into the slot at the left side of the lid.
C-6
Operating
1) Open the lid.
2) Make sure all burner control knobs are turned
OFF. (Push each burner control knob down and turn
clockwise to ensure that they are in the off position.)
3) Turn the gas supply valve on.
WARNING: Do not lean over the open barbecue.
Keep your face and body at least one foot away
from the matchlight hole when lighting the
barbecue.
4) Push Front burner control knob down and turn to
START/HI.
5) Push the Crossover Ignition Button several times,
so it clicks each time.
6) Check that the burner is lit by looking through the
matchlight hole on the front of the cooking box. You
should see flame.
WARNING: If the burner does not light, turn the
Front burner control knob to OFF and wait 5
minutes to let the gas clear before you try again, or
try to light with a match.
7) After the FRONT burner is lit you can turn on the
other burner or burners.
Note - Always light the FRONT burner first. The other
burner or burners ignite from the FRONT burner.
Lighting
Summary lighting instructions are on the control panel.
DANGER
Failure to open the lid while igniting the
barbecue’s burners, or not waiting 5
minutes to allow the gas to clear if the
barbecue does not light, may result in an
explosive flame-up which can cause
serious bodily injury or death.
Crossover Ignition® System
Note - The Crossover Ignition System ignites the Front
burner with a spark from the igniter electrode inside
the Gas Catcher” Ignition Chamber. You generate the
energy for the spark by pushing the Crossover Ignition
Button until it clicks.
WARNING: Check hose before each use of
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. Contact the
Customer Service Representative in your region
using the contact information sheet provided with
your manual.
To Extinguish
Push down and turn each burner control knob
clockwise to the OFF position. Turn gas supply
OFF at the source.
1
2
7
5
3
6
4
*The grill illustrated may have slight differences than
the model purchased.
D001.e
D-1
WARNING: If the burner does not light, turn the
Front burner control knob to OFF and wait 5
minutes to let the gas clear before you try again or
try to light with a match.
7) After the FRONT burner is lit you can turn on the
other burner or burners.
Note - Always light the FRONT burner first. The other
burner or burners ignite from the FRONT burner.
Manual Lighting
DANGER
Failure to open lid while igniting the
barbecue’s burners, or not waiting 5
minutes to allow the gas to clear if the
barbecue does not light, may result in an
explosive flame-up which can cause
serious bodily injury or death.
1) Open the lid.
2) Make sure all burner control knobs are turned
OFF. (Push each burner control knob down and
turn clockwise to ensure they are in the off
position.)
3) Turn the gas supply valve on.
4) Strike a match and put the flame into the
matchlight hole in the front of the cooking box.
To Extinguish
Push down and turn each burner control knob
clockwise to the OFF position. Turn gas supply
OFF at the source.
1
2
7
4,6
3
5
*The grill illustrated may have slight differences than
the model purchased.
WARNING: Do not lean over the open barbecue.
Keep your face and body at least one foot away
from the matchlight hole when lighting the
barbecue.
5) Push Front burner control knob down and turn to
START/HI.
6) Check that the burner is lit by looking through the
matchlight hole on the front of the cooking box. You
should see a flame.
D-2
Cooking
Cleaning
WARNING: Do not move the Weber Gas
Barbecue when operating or while barbecue is hot.
You can adjust the FRONT and BACK burners as
desired. The control settings: High (H), Medium (M),
Low (L), or Off (O) are described in your Weber
cookbook. The cookbook uses these notations to
describe the settings of the FRONT and BACK
burners. For example, to sear steaks, you would set all
burners at H (high). Then to complete cooking, you
would set FRONT and BACK at M (medium). Refer to
your Weber cookbook for detailed cooking instructions.
WARNING: Turn your Weber Gas Barbecue OFF
and wait for it to cool before cleaning.
CAUTION: Do not clean your Flavorizer® Bars or
cooking grates in a self-cleaning oven.
For availability of replacement cooking grates and
Flavorizer Bars contact the Customer Service
Representative in your region using the contact
information sheet provided with your manual.
Outside surfaces - Use a warm soapy water solution
to clean, then rinse with water.
CAUTION: Do not use oven cleaner, abrasive
cleansers (kitchen cleansers) cleaners that contain
citrus products, or abrasive cleaning pads on
barbecue or cart surfaces.
Slide out Bottom tray - Remove excess grease, then
wash with warm soapy water, then rinse
Flavorizer® Bars and Cooking Grates - Clean with a
suitable brass bristle brush. As needed, remove from
grill and wash with warm soapy water, then rinse with
water.
Catch pan - Disposable foil trays are available, or you
can line the catch pan with aluminum foil. To clean the
catch pan, wash with warm soapy water, then rinse.
Thermometer - Wipe with warm soapy water; clean
with plastic scrub ball. Do not put in dishwasher or
submerge in water.
Inside cooking module - Brush any debris off of
burner tubes. DO NOT ENLARGE BURNER PORTS
(OPENINGS). Wash inside of cooking box with warm
soapy water and a water rinse.
Inside Lid - While lid is warm, wipe inside with paper
towel to prevent grease build-up. Flaking built-up
grease resembles paint flakes.
Stainless steel surfaces - Wash with a soft cloth and
a soap and water solution.
Thermoset surfaces - Wash with a soft cloth and a
soap and water solution.
Do not use cleaners that contain acid, mineral
spirits or xylene. Rinse well after cleaning.
Note: The temperature inside your cooking box for the
first few uses, while surfaces are still very reflective,
may be hotter than those shown in your cookbook.
Cooking conditions. Such as wind and weather, may
require the adjustment of the burner controls to obtain
the correct cooking temperatures.
CAUTION: Replace thermometer in lid when not
in use. Do not leave thermometer in food while
cooking.
If burners go out during cooking, open lid, turn off
all burners and wait five minutes before relighting.
Preheating - Your Weber Gas Barbecue is an energyefficient appliance. It operates at an economical low
BTU rate. To preheat: after lighting, close lid and turn
all burners to high (HH). Preheating to between 500°
and 550° F (260° and 290° C) will take 10 to 15
minutes depending on conditions such as air
temperature and wind.
Drippings and grease - The Flavorizer® Bars are
designed to “smoke” the correct amount of drippings
for flavorful cooking. Excess drippings and grease will
accumulate in the catch pan under the slide out bottom
tray. Disposable foil drip pans are available that fit the
catch pan.
WARNING: Check the bottom tray for grease
build-up before each use. Remove excess grease
to avoid a grease fire in the slide out bottom tray.
Thermoset work surfaces are not to be used as
cutting boards.
Storage
■ 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
“Maintenance” Section.)
■ Check that the areas under the control panel and
the slide out bottom tray are free from debris that
might obstruct the flow of combustion or ventilation air.
■ The Spider /Insect Screens should also be checked
for any obstructions. (See “Maintenance” Section.)
D-3
Contact the Customer Service Representative in
your region using the contact information sheet
provided with your manual.
2) Valves-to-manifold connections.
3) The hose-to quick-disconnect connection.
WARNING: If there is a leak at connections (2) or
(3), turn OFF the gas. DO NOT OPERATE THE
BARBECUE. Contact the Customer Service
Representative in your region using the contact
information sheet provided with your manual.
When leak checks are complete, turn gas supply OFF
at the source and rinse connections with water.
Annual Maintenance
After a period of nonuse, we recommend that you
perform the following maintenance procedures for your
safety.
WARNING: Check the hose before each use of
the 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. Contact the
Customer Service Representative in your region
using the contact information sheet provided with
your manual.
■ 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.
(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
leaks. Sparks or flames will result in a fire
or explosion, which can cause serious
bodily injury or death, and damage to
property.
(2)
WARNING: You should check for gas leaks every
time you disconnect and reconnect a gas fitting.
Note - All factory-made connections have been
thoroughly checked for gas leaks. The burners have
been flame tested. As a safety precaution however,
you should recheck all fittings for leaks before using
your Weber Gas Barbecue. Shipping and handling may
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: 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.
(3)
*The grill illustrated may have slight differences than
the model purchased.
Inspection and cleaning of the Spider/Insect
screens
To inspect the spider/insect screens, remove the
control panel. If there is dust or dirt on the screens,
remove the burners for cleaning the screens. Refer to
Maintenance, Replacing Main Burners. Brush the
spider/inspect screens, lightly, with a soft bristle brush
(i.e. an old toothbrush).
Caution: Do not clean the spider/insect screens
with hard or sharp tools. Do not dislodge the
spider/insect screens or enlarge the screen
openings.
Check:
1) Hose-to-manifold connection.
WARNING: If there is a leak at the hose-tomanifold connection(1), retighten the hose 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.
Lightly tap the burner to get debris and dirt out of the
burner tube. Once the spider/insect screens and
burners are clean replace the burners.
If the spider/insect screen becomes damaged or
cannot be cleaned, call Weber-Stephen Products
Customer Service for replacement parts.
D-4
Main Burner Flame Pattern
General Maintenance
The Weber Gas Barbecue burners have been factory
set for the correct air and gas mixture. The correct
flame pattern is shown.
1) Burner tube
2) Tips occasionally flicker yellow
3) Light blue
4) Dark blue
Weber Spider /Insect screens
Your Weber Gas Barbecue, as well as any outdoor gas
appliance, is a target for spiders and other insects.
They can nest in the venturi section Venturi(1). This
blocks the normal gas flow, and can cause the gas to
flow back out of the air shutter. This could result in a
fire in and around the air shutters, under the control
panel, causing serious damage to your barbecue.
(1)
(1)
(2)
(3)
(4)
If the flames do not appear to be uniform throughout
the burner tube, follow the burner cleaning procedures.
The burner tube air shutter is fitted with a stainless
steel screen(1) to prevent spiders and other insects
access to the burner tubes through the air shutter
openings.
Main Burner Cleaning Procedure
Turn off the gas supply. Remove the manifold.
Look inside each burner with a flashlight.
(1)
Clean the inside of the burners with a wire (a
straightened-out coat hanger will work). Check and
clean the air shutter opening at the ends of the
burners. Check and clean the valve orifices at the base
of the valves. Use a brass bristle brush to clean
outside of burners. This is to make sure all the burner
ports are fully open.
CAUTION: Do not enlarge the burner ports when
cleaning.
We recommend that you inspect the Spider/Insect
screens at least once a year. (See Section “Annual
Maintenance”.) Also inspect and clean the the
Spider/Insect screens if any of the following
symptoms should ever occur:
1) The smell of gas in conjunction with the burner
flames appearing yellow and lazy.
2) Barbecue does not reach temperature.
3) Barbecue heats unevenly.
4) One or more of the burners do not ignite.
DANGER
Failure to correct the above mentioned symptoms
may result in a fire, which can cause serious
bodily injury or death, and cause damage to
property.
D-5
CAUTION: The burner openings(1) must be
positioned properly over the valve orifices(2).
Check proper assembly before fastening manifold in
place.
Replacing Main Burners
1) Your Weber Gas Barbecue must be OFF and cool.
2) Turn gas OFF at source.
3) To remove control panel: take off the burner
control knobs. Remove the screws holding the
control panel in place. Lift off the control panel.
4) Unhook the manifold bracket(1) and unscrew the
two wing nuts(2) that hold the manifold to the
cooking box. Pull the manifold and valve assembly
out of the burners and carefully set it down.
(2)
(1)
(1)
(2)
5) Slide the burner assembly out from under the
guide screw and washer(1) in the corners of the
cooking box.
(1)
WARNING: After reinstalling the gas lines, they
should be leak checked with a soap and water
solution before using the barbecue. (See Step:
“Check for gas leaks.”)
6) Lift and twist the burner assembly slightly, to
separate the crossover tube(1) from the burners.
Remove the burners from the cooking box.
(1)
7) To reinstall the burners, reverse 3) through 7).
D-6
Crossover® Ignition System Operations
If the Crossover Ignition System fails to ignite the Left
burner, light the Left burner with a match. If the Left
burner lights with a match, then check the Crossover
Ignition System.
■ Check that both the white(1) and black(2) ignition
wires are attached properly.
(1)
(2)
■ Check that the Crossover Ignition button pushes the
igniter (button) down, and returns to the up position.
■ Check to see if the igniter is loose in the frame.
Tighten if necessary; See Step Install igniter” for
correct procedure.
If the Crossover Ignition System still fails to light,
Contact the Customer Service Representative in your
region using the contact information sheet provided
with your manual.
D-7
Troubleshooting
Problem
Check
Cure
Burners burn with a yellow or
orange flame, in conjunction with
the smell of gas.
Inspect Weber Spider/Insect
Screens for possible obstructions.
(Blockage of holes.)
Clean Weber Spider/Insect Screens.
(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
“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
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
“Cleaning”.)
Experiencing flare-ups:
CAUTION: Do not line the
bottom tray with aluminum foil.
If problems cannot be corrected by using these methods, please contact the Customer
Service Representative in your region using the contact information sheet provided with
your manual
D-8
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