Serial Number
Please use this number in registering your warranty
and any correspondence with the factory.
SKYLINE 3200
™
LP Gas Barbecue
WEBE
WEBE
R
Owner’s Manual
R
®
National PROPANEGAS Association
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.
FOR YOUR SAFETY
1. Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
2. An LP tank not connected for use shall
not be stored in the vicinity of this or
any other appliance.
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.
98696
12/97
DANGER
Failure to follow the Dangers, Warnings and Cautions contained in this Owner’s Manual
may result in serious bodily injury or death, or in a fire or an explosion causing damage
to property.
WARNINGS
 Do not store a spare or disconnected LP tank under or near this barbecue.
 Improper assembly may be dangerous. Please carefully follow the assembly instructions in this manual.
 After a period of storage, and/or nonuse, the Weber Gas Barbecue should be checked for gas leaks
and burner obstructions before using. See instructions in this manual for correct procedures.
 Do not operate the Weber Gas Barbecue if there is a gas leak present.
 Do not use a flame to check for gas leaks.
 Combustible materials should never be within 24 inches of the top, bottom, back or sides of your
Weber Gas Barbecue.
 Do not put a barbecue cover or anything flammable on or in the storage area under the barbecue.
 Your Weber Gas Barbecue should never be used by children.
 You should exercise reasonable care when operating your Weber Gas Barbecue. It will be hot during
cooking or cleaning, and should never be left unattended.
 Should the burners go out during operation, turn all gas valves off. Open the lid and wait five minutes
before attempting to relight, using the lighting instructions.
 Do not use charcoal or lava rock in your Weber Gas Barbecue.
 Never lean over open grill or place hands or fingers on the front edge of the cooking box.
 Should a grease fire occur, turn off all burners and leave lid closed until fire is out.
 Do not enlarge valve orifices or burner ports when cleaning the valves or burners.
 The Weber Gas Barbecue should be thoroughly cleaned on a regular basis.
 LP gas is not natural gas. The conversion or attempted use of natural gas in an LP unit or LP gas in a
natural gas unit is dangerous and will void your warranty.
 Do not attempt to disconnect any gas fitting while your barbecue is in operation.
 Use heat-resistant barbecue mitts or gloves when operating barbecue.
LP GAS UNITS ONLY:
 Use the regulator that is supplied with your Weber Gas Barbecue.
 Do not attempt to disconnect the gas regulator or any gas fitting while your barbecue is in operation.
 A dented or rusty LP tank may be hazardous and should be checked by your liquid propane supplier.
Do not use an LP tank with a damaged valve.
 Although your LP tank may appear to be empty, gas may still be present, and the tank should be
transported and stored accordingly.
 If you see, smell or hear the hiss of escaping gas from the LP tank:
1. Get away from LP tank.
2. Do not attempt to correct the problem yourself.
3. Call your fire department.
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;
Recycled Work Surfaces, 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 Weber-Stephen Products Co.
Customer Service Center. If Weber confirms the
defect and approves the claim, Weber will elect
to replace such parts without charge. If you are
required to return defective parts, transportation
charges must be prepaid. Weber will return parts
to the purchaser, freight or postage prepaid.
This Warranty applies only to products sold
at retail.
WEBER-STEPHEN PRODUCTS CO.
Customer Service Center
250 South Hicks Road
Palatine, IL 60067-6241
(800) 446-1071
This Limited Warranty does not cover any failures
or operating difficulties due to accident, abuse,
misuse, alteration, misapplication, vandalism,
improper installation or improper maintenance or
service, or failure to perform normal and routine
maintenance, including but not limited to damage
caused by insects within the burner tubes, as set
out in this owner's manual.
LP Tank
The LP tank manufacturer is responsible for the
materials, workmanship and performance of the tank. If
the tank has a defect, malfunctions, or you have a
question regarding the tank, call the tank manufacturer's customer service center. The phone number is
on the warning decal which is permanently attached to
the tank. If the tank manufacturer has not resolved the
issue to your satisfaction, then call Weber-Stephen
Products Co., Customer Service Center.
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
© 1997 Weber. Weber, , Genesis, Flavorizer and Crossover are
registered U.S. trademarks; 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.
Printed in the U.S.A.
4
Contents
Troubleshooting & Maintenance
Annual Maintenance ........................................ 31
General Maintenance.................................. 32-34
Troubleshooting .......................................... 35-36
Parts Listing .............................................................. 39
WARNINGS ................................................................ 2
Warranty & Patents.................................................. 3-4
General Instructions.................................................... 6
Assembly ............................................................... 7-23
Operating Instructions
Lighting ....................................................... 24-26
Cooking ............................................................ 27
Storage and/or Nonuse .................................... 27
Cleaning ........................................................... 27
LP Tank Information.................................... 28-30
b
c
e
a
d
f
g
k
FEATURES:
j
a) Convenient tables and racks.
a
i
b) Heavy gauge porcelain-on-steel lid seals in heat.
h
c) Rapid read thermometer for precision cooking
measures grill temperature, and can be removed and
inserted into the food.
d) Stainless 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. Uncontrolled flare-ups are
eliminated (versus lava rock systems on other grills).
The stainless steel Flavorizer Bars are easy to clean.
IMPORTANT NEW FEATURES:
Your Weber Gas Barbecue is equipped with a new and
improved LP tank connection, that has additional
safety features. They are:
e) Weber Warm-Up Basket for additional cooking or
warming space.
f)
1. The connection of the barbecue to the LP tank can be
made without the use of tools.
Separate burners for temperature control.
2. The new connection will not permit the flow of gas until
a positive gas connection is made.
g) Side burner for making sauces, gravies, etc.,while
main grill is in use.
3. If an accidental fire occurs at the LP tank connection,
the flow of gas is stopped by a temperature activated
shutoff.
h) Fuel scale indicates LP gas supply.
i)
j)
Crossover Ignition System with Gas Catcher Ignition
Chamber.
4. If the LP supply hose becomes damaged, cut,
punctured, or accidentally fire damaged, the barbecue
connection is equipped with an excess flow control
that will limit the flow of gas if leakage or a fire occurs.
Catch pan catches excess grease.
k) Locking casters for additional portability.
5
Storage
General Instructions
■
The gas must be turned OFF at the LP tank when the
Weber Gas Barbecue is not in use.
■
When the Weber Gas Barbecue is stored indoors, the
gas supply must be disconnected and the LP tank
stored outdoors in a well-ventilated space.
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.
■
LP tanks must be stored outdoors in a well-ventilated
area out of the reach of children. Disconnected LP
tanks must not be stored in a building, garage or any
other enclosed area.
Liquid Propane (LP) gas supply is easy to use and gives
you more cooking control than charcoal fuel.
■
When the LP tank is not disconnected from the Weber
Gas Barbecue, the appliance and LP tank must be
kept outdoors in a well-ventilated space.
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.
■
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.
■
■
Operating area
WARNING: Only use this barbecue outdoors in a
well ventilated area. Do not use in a garage, building,
breezeway or any other enclosed area.
The pressure regulator supplied with the Weber Gas
Barbecue must be used. This regulator is set for 10.5
inches of water column (pressure).
This Weber Gas Barbecue is designed for use with
liquid propane (LP) gas only. Do not use with natural
(piped in city) gas. The valves, orifices, hose and
regulator are for LP gas only.
■
Do not use with charcoal fuel.
■
Check that the area under the control panel and the
bottom tray are free from debris that might obstruct
the flow of combustion or ventilation air.
■
The area around the LP tank must be free and clear
from debris.
For Installation in Canada
These instructions, while generally acceptable, do not
necessarily comply with the Canadian Installation codes,
particularly with piping above and below ground. In
Canada the installation of this appliance must comply with
local codes and/or Standard CAN/CGA-B149.2 (Installation
Code for Propane Burning Appliances and Equipment).
6
■
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.
■
Never store an extra (spare) LP tank under or near
the Weber Gas Barbecue.
Step 1
Assembly
Check package contents
Tools needed
Regular screwdriver
Cooking box
(assembly)
Phillips screwdriver
Hammer
7/16 inch or an adjustable wrench
Lid
(assembly)
®
®
Pliers
Block of wood
LP tank
Supplies needed
Your LP tank is shipped empty for safety. After setting the
LP fuel scale you will need to fill it. (See Step "Fill LP tank.")
You will need a soap and water solution to check for gas
leaks. (See Step "Check for gas leaks.")
LP tank filler adapter
Note - The hardware size of nuts, bolts and screws is given.
For example "1/4-20 x 2 inch bolt" means a bolt 1/4 inch in
diameter with 20 threads to the inch, 2 inches long. On a
small screw for example, "6-32 x 1/2 inch screw" means a
number 6 screw, with 32 threads to the inch, 1/2 inch long.
Bottom tray
While we give much attention to our products,
unfortunately an occasional error may occur. If a part is
missing, do not go back to the store. Call the Weber
Customer Service Center toll free 1-800-446-1071 to
receive immediate assistance. Have your owner ’s
manual and serial number of the barbecue available
for reference.
Work table
Accessory rack
Swing table
7
Control panel
Right frame
Front panel
Caster frame
Left frame
Two casters
Wheel frame
Two cooking grates
Two frame connectors
Warming rack
Tank panel assembly
Warm-Up Basket
Five long Flavorizer Bars
Thermometer
Wire condiment basket
with tool holders
WE BE
R
Two wheels
WE B E R
Eight short Flavorizer Bars
Left hand slide bar assembly
Two aluminum drip pans
Assembly consists of:
Left hand slide bar
Catch pan
Support
Axle
Slide
8
Fuel scale assembly
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)
Catch pan holder
Six 1/4-20 x 1/2 inch bolts
(actual size)
Manifold bracket
Two 1/4-20 wing nuts
(actual size)
Side burner assembly
Two 10-24 x 1 3/4 machine screws
(actual size)
Two 10-24 hex nuts
(actual size)
Burner grate
Eighteen 1/4 inch nylon washers
(actual size)
Two side burner locks
Note: The locks are
taped to the inside
of the side burner lid.
1/4-20 keps nut
Side burner knob
1/4-20 x 1 1/4 inch bolt
(actual size)
Spacer bracket
1/4-20 hex nut
(actual size)
Two hair pin cotters
Check contents of hardware packs
Three burner control knobs
Two swing table end brackets
Five tubing plugs
(two are spares)
Two Phillips screws/washers
Two wheel hubcaps
(actual size)
9
Step 3
Assemble wheels
Assemble 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 nylon washers,
two 1/4-20 x 1/2 inch bolts 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 on 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.
Put the frame pieces so the leg tabs are up. Put the right
frame to your right and left frame to your left. Figure 2.
Slip the two frame halves together with the tabs inside,
until the tabs of the right frame are inside the left frame
and the holes align. Figure 2 (a).
WE BE
WE B E R
Step 2
R
Slip washers over bolts; insert and tighten bolts. (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.)
Figure 2 (b).
Figure 1
(a)
Frame tabs
Leg tabs
Right frame
Left frame
(b)
Figure 2
10
Step 4
Step 5
Continue frame assembly
Complete frame assembly
You will need: frame assembly, wheel frame assembly,
front panel, caster 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. The fuel scale decal should face away as shown.
Figure 3.
Hold one frame connector between the caster and wheel
frame. Add nylon washer to the bolts. Put the bolts through
the frame and screw into frame connector. Tighten.
Repeat procedure with the other frame connector. Figure 4.
The leg tabs must be on the inside of the frames.
Add front panel with the hole down and to your right. Add
the washers to the bolts, insert in the holes as shown.
Only start the bolts at the wheel frame, figure 3 (a) & (b),
and tighten the bolts at the caster frame.
Note - Fuel scale decal on wheel frame must be on the
same side as the front panel.
Dimples to
the inside
Caster
frame
Fuel scale
decal
Figure 4
Wheel
frame
Step 6
Insert casters
You will need: frame assembly and two casters.
(b)
(a)
Push the casters firmly into the inserts in the ends of the
caster legs. Figure 5.
Only start
these bolts
Figure 3
Figure 5
11
Step 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. Tighten by holding the bolt with pliers while
you tighten the nut with the 7/16 inch wrench.
Install side burner locks
Note: The locks are taped to the inside of the side
burner lid.
You will need: frame assembly, two side burner locks and
a 7/16 inch wrench.
Turn frame assembly right side up.
Spacer
bracket
Loosen the right rear 1/4 x 20 bolt. Install the side burner
lock. The “U” shape cut out of the lock slips down over the
bolt. Tighten with a wrench. Figure 6 (a).
(a)
Frame cross piece
(b)
Loosen the right front 1/4 x 20 bolt. The side burner lock
fits between the front panel and the frame. The “U” shape
cut out slips up over the bolt. Tighten with a wrench.
Figure 6 (b).
(a)
Keps
nut
Bolt
Nylon
washer
Figure 8
(b)
Figure 6
Step 8
Add cooking box
You will need: frame assembly, cooking box assembly,
spacer bracket, 1/4-20 x 2 inch bolt, 1/4 inch nylon
washer, 1/4-20 keps nut, pliers and a 7/16 inch wrench.
Uncoil the hose.
Set the cooking box into the frame so the burner tubes are
under the frame brace. Figure 7.
Burner tubes
Frame brace
Figure 7
12
Tab
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:
Step 9
a) Do the valves fit into the ends of the burners? Figure 9(a).
You will need: tank panel assembly, 1/4-20 x 1 1/4 inch
bolt, 1/4-20 hex nut, nylon washer and a 7/16 inch wrench.
Install tank panel assembly
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).
Insert the tank panel tabs into the slots in the frame brace.
Slide up until the notch at the bottom of the tank panel fits
over the cross brace. Figure 10 (a).
c) Are the wing nuts under the burner assembly hand
tight? Do not tighten with pliers. Figure 9 (c).
Add the washer to the bolt. Put the bolt through panel and
frame brace, add hex nut and tighten with the 7/16 inch
wrench. Figure 10 (b).
Slot in 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 Weber-Stephen Customer Service.
Do not use your barbecue.
(a)
Frame brace
Guide screw
(a)
(b)
Tabs on tank panel
(c)
(b)
Figure 10
Figure 9
Wing nuts
Cross brace
13
Step 10
Step 11
Add fuel scale
Install igniter
You will need: fuel scale, two 1/4-20 wing nuts and two
nylon washers.
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.
Slip the bolts on the back of the fuel scale assembly through
the two small holes in the tank panel. Make sure indicator
rod of fuel scale is on the left side of the wheel frame.
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 12 (b). Loosen the igniter
lock nut and slide the igniter into the small part of the
keyhole. Figure (c). Tighten the igniter lock nut. Figure 12.
Add washers, then wing nuts and tighten. Figure 11.
Note - If the igniter works loose, carefully tighten the igniter
lock nut with an adjustable wrench or pliers.
Frame brace
(a)
(b)
Figure 11
Keyhole
in frame
brace
E
E
Small part of
keyhole in
frame brace
F
Igniter
lock nut
F
(c)
View from front left
View from front right
Figure 12
Frame brace
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.
Figure 13
14
Step 13
Step 14
Install side burner
Install manifold bracket
You will need: side burner assembly, burner grate, and
manifold bracket.
You will need: manifold bracket
Hook the bracket onto the manifold at the center burner
valve. Figure 15. Place your hand underneath the bracket.
Lift the bracket, manifold and cooking box slightly as a unit
and hook onto the frame brace.
WARNING: Make sure gas supply is OFF.
Slide the side burner assembly into the open end of the
right frame. Route the side burner hose around the tank
panel so it will not interfere with scale indicator rod.
Manifold bracket
The side burner hose is connected in the following
manner:
Frame brace
Slide back the collar of the quick disconnect on the manifold.
Push the male fitting of the side burner hose into the quick
disconnect, and maintain pressure. Slide the collar closed.
Figure 14a. Figure 14b shows the quick disconnect
engaged.Install burner grate. Check to be sure the side
burner valve is OFF. Push side burner control knob down
and turn clockwise. Figure 14.
Figure 15
Figure 14
Male fitting
a)
Manifold side view
Quick disconnect
engaged
b)
Side burner hose
Manifold side view
15
Step 15
Step 16
Set LP fuel scale
Fill LP tank
You will need: LP tank (empty).
Note - The LP tank manufacturer is responsible for the
materials, workmanship and performance of the tank. If
the tank has a defect, malfunctions, or you have a
question regarding the tank, call the tank manufacturer's
customer service center. The phone number is on the
warning decal which is permanently attached to the tank.
If the tank manufacturer has not resolved the issue to your
satisfaction, then call Weber-Stephen Products Co.,
Customer Service Center.
Note - For accuracy, the fuel scale must be set with an
empty tank.
We utilize various LP tank manufacturers. Some of the
tanks we receive have differing top collar assemblies.
(The top collar is the metal protective ring around the
valve.) One series of tanks mounts with the valve facing
the front. The other tanks mount with the valve facing
away from the fuel scale. These types of tanks are
illustrated in Figure 16.
To fill, take the LP tank and filler adapter to an RV center,
or look-up gas propane in the phone book for other
sources of LP gas.
Loosen the tank lock wing nut. Tighten so the lock is held
up out of the way. Figure 16 (a). Lift and hook the tank
onto the fuel scale. With an empty LP tank, adjust the fuel
scale setting to E by turning the scale setting (top) wing
nut. Figure 16 (b).
WARNING: We recommend that your LP tank be
filled at an authorized LP gas dealer by a qualified
attendant, who fills the tank by weight.
IMPROPER FILLING IS DANGEROUS.
CAUTION: Do not remove adjustment wing nut from
tank scale.
Tell your LP dealer that this is a new LP tank. The air must
be removed from a new LP tank before the initial filling.
Your LP tank dealer is equipped to do this.
After adjusting tank scale, push tank down a couple of
times to check that the tank scale is set on “E”.
WARNING: If you exchange your LP tank, make
sure you get a similar tank in return. Your LP tank is
equipped with a quick-disconnect valve and an OPD
(Overfilling Prevention Device). Other LP tanks are not
compatible with your barbecue connection.
The LP tank must be installed, transported and stored in
an upright position. LP tank should not be dropped or
handled roughly.
Scale setting
wing nut
Tank lock
wing nut
(a)
Never store or transport the LP tank where temperatures
can reach 125° Fahrenheit (too hot to hold by hand – for
example: do not leave the LP tank in a car on a hot day).
(b)
E
E
F
F
For full instructions on safe handling of LP tanks, see
section "Operating Instructions".
Figure 16
16
Route the hose so it will not interfere with the scale
indicator rod.
Step 17
Connect LP tank
The hose and regulator are connected in the following
manner:
WARNING; Make sure that the LP tank valve is
closed. Close by turning clockwise.
Slide back the collar of the quick disconnect on the tank
valve. Push the male fitting of the regulator into the quick
disconnect, and maintain pressure. Slide the collar closed.
Figure 18 (a). Figure 18 (b) shows the quick disconnect
engaged and various components of the tank and
regulator. Regulator vent hole should be at 3, 6, or 9
o'clock. It should not be pointed up. Figure 18 (c).
Hook the LP tank onto the fuel scale. Loosen the tank lock
wing nut. Swing the tank lock down. Tighten the wing nut.
Figure 17.
Tank lock
wing nut
E
F
(a)
Collar
Figure 17
Male
fitting
(b)
Hose
Valve handwheel
close clockwise
Tank valve
Regulator
Pressure
relief valve
Tank
Regulator
vent
Quick disconnect
engaged
(c)
Turn so regulator vent
does not collect water
Figure 18
17
Step 18
WARNING: Do not ignite burners while leak checking.
Check for gas leaks
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.
 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.
Check:
a) Hose to manifold connection. Figure 21 (a).
b) Regulator to tank connection. Figure 21 (b).
c) Manifold to side burner hose connection.Figure 21 (c).
WARNING: If there is a leak at connections a, b or c,
retighten the fitting with a wrench and recheck for
leaks with soap and water solution.
WARNING: You should check for gas leaks every
time you disconnect and reconnect a gas fitting.
If a leak persists after retightening the fitting, turn OFF
the gas. DO NOT OPERATE THE BARBECUE. Contact
Weber-Stephen Customer Service.
Note - All factory made connections have been thoroughly
checked for gas leaks. The burners have been flame
tested. As a safety precaution you should recheck all
fittings for leaks before using your Weber Genesis Gas
Barbecue. Shipping and handling may have loosened or
damaged a gas fitting.
d) Side burner hose to side burner connection.
Figure 21 (d).
e) Valves to manifold connections. Figure 21 (e).
f)
WARNING: Perform these leak checks even if your
barbecue was dealer or store assembled.
Hose to regulator connection. Figure 21 (f).
WARNING: If there is a leak at connections d, e or f,
turn OFF the gas. DO NOT OPERATE THE BARBECUE.
Contact Weber-Stephen Customer Service.
You will need: a soap and water solution and a rag or
brush to apply it.
When leak checks are complete, turn gas supply OFF at
the source and rinse connections with water.
Note - Since some leaks test solutions, including soap
and water, may be slightly corrosive, all connections
should be rinsed with water after checking for leaks.
(a)
(b)
Make sure side burner is OFF. Remove valve control knob
and screws. Remove porcelain top. Figure 19.
(c)
Figure 19
To perform leak checks: open tank valve by turning the
tank valve handwheel counterclockwise. Figure 20.
(d)
E
(f)
F
(e)
Figure 20
Figure 21
18
Step 19
Step 20
Install Flavorizer Bars and Cooking Grates
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 22.
Finger grip on front
edge of bottom tray
Front side of catch
pan holder
Figure 24
Hook the ends of the catch pan holder into the hole in the
bottom tray. Figure 25. The front of the catch pan holder
must be on the same side as the finger grip of the
bottom tray.
Figure 22
The open "U" of the cooking grates goes down. Set the
cooking grates onto the ledges in the cooking box. Figure 23.
Finger grip
Figure 25
Slide the bottom tray onto the mounting rails under the
cooking box with finger grip toward you. Figure 26.
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 23
Bottom tray
Figure 26
Put the foil drip pan into the catch pan.
Slide the catch pan into the catch pan holder with its finger
grip towards you.
19
Step 21
Step 22
Install the lid
Install control panel and burner control knobs
You will need: lid, two hinge pins and two hair pin cotters.
You will need: control panel, two Phillips screws/washers,
a Phillips screwdriver, and three burner control knobs.
Set the lid in place from the rear of the barbecue. Close
and align the hinge at the rear. Insert hinge pins from the
outside through the hinge. Insert hair pin cotters into the
small holes in the hinge pins. Figure 27.
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 28 (a).
Hair pin cotter
Push on the burner control knobs. Figure 28 (b).
Insert in
frame brace
Hinge pin
Crossover
Ignition Button
(a)
Control panel
Phillips screws/
washers
Figure 27
(b)
Figure 28
20
Step 23
Step 24
Secure side burner
Install the condiment basket
Pull the right hand swing table up. Stand to the right side
of the barbecue. Slightly pull back both side burner locks.
Slide the side burner toward the control panel. The locks
will snap into the slots in the front and back of the side
burner. Figure 29.
You will need: condiment basket and end bracket.
Insert one wire end of the condiment basket into the hole
in the side frame. Figure 30 (a). Insert the opposite wire
end of the condiment basket into the hole in the end
bracket. Hold the end bracket at an angle so the lower tab
is inside the frame tube. Push the bracket into the frame.
Figure 30 (b). Check to see that the lower tab of the
bracket is hooked in the slot in the frame. Figure 30 (c).
CAUTION: Make sure both locks have snapped
into place.
Note: The side burner is shown with the cover removed to
show the side burner locks.
To fully seat the bracket, you may have to tap it lightly with
a hammer.
WARNING: If the end bracket is in any way cracked
or damaged, do not use the condiment basket. Call
our Customer Service Center to order a new part.
Wire end
(a)
(b)
View from top
View from side
of barbecue
(c)
Figure 29
Slot in frame
(view from below)
Figure 30
21
Step 25
Insert one end of the hinge rod into the hole in the frame.
Figure 32 (a).
Install swing table
Insert the other end into the hole in the swing table end
bracket. Figure 32 (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 32 (c).
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 31 (a). Swing the
rod up so you can slide the rod all the way inside the
locking tab. Figure 31 (b). The rod should swing freely
inside the locking tab. Figure 31 (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.
WARNING: The load limit for the swing table is
30 pounds.
Hinge rod
(a)
(b)
(b)
(c)
Support rod
(a)
View from rear
of barbecue
Figure 31
Slot in frame
(view from below)
(c)
Figure 32
22
Step 26
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 33.
Complete accessory installation
You will need: work table, accessory rack, Warm-Up
Basket, warming rack, thermometer, three tubing plugs
and a hammer.
Notch to the front
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 35 (a).
Slide bar
Set the work table onto the left side rails. Figure 35 (b).
Set the accessory rack between the two frame connectors.
Figure 35 (c).
Set the warming rack into the slots at the rear of the
cooking box. Figure 35 (d).
Insert the thermometer into its holder. Figure 35 (e).
Insert tubing plugs into the ends of the frame. To fully seat
the plugs, you may have to tap them lightly with a hammer.
Figure 35 (f).
View from front
of barbecue
Figure 33
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 34.
(a)
(d)
(e)
(b)
Support rod
(f)
View from rear
of barbecue
(c)
Slide
Figure 35
CAUTION: To keep the barbecue stationary, the tabs
on the locking casters should be in the down position.
Unlocked position
Locked position
Figure 34
23
OPERATING INSTRUCTIONS
Lighting
WARNING: The burner control knobs must be in the
OFF position before turning on the LP tank valve. If
they are not in the OFF position, when you turn on the
LP tank valve, the excess flow control will activate,
limiting the flow of gas from the LP tank. If this should
occur, turn OFF the LP tank valve and burner control
knobs and start over.
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 flameup which can cause serious bodily injury
or death.
 DANGER
When the excess flow control is
activated, a small amount of gas is still
flowing to the burners. After turning OFF
the tank and burner control knobs, wait
at least 5 minutes for the gas to clear
before attempting to light the barbecue.
Failure to do so may result in an
explosive flame-up which can cause
serious bodily injury or death.
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 manifold assembly. Order from WeberStephen Products Co., Customer Service Center or
authorized dealer.
4) Turn the tank on by turning the tank valve
counterclockwise.
5) Push Front burner control knob down and turn to
START/HI.
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.
Crossover Ignition System
1
6) Push the Crossover Ignition Button several times, so it
clicks each time.
7) Check that the burner is lit by looking through the
matchlight hole on the front of the cooking box.
3
8
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.
4
7
5
6
8) After the FRONT burner is lit you can turn on the other
burners.
2
Note - Always light the FRONT burner first. The other
burners ignite from the FRONT burner.
Figure 1
1) Open the lid. Figure 1.
2) Check that the fuel scale reads more than “E”.
Note - E = empty; F = full.
To Extinguish
3) Make sure all burner control knobs are turned OFF.
(Push each burner control knob down and turn
clockwise.)
Turn gas supply OFF at the source, then push down
and turn each burner control knob clockwise to OFF.
24
Manual Lighting
4) Turn the tank on by turning the tank valve
counterclockwise.
5) Strike a match and put the flame into the matchlight
hole in the front of the cooking box.
 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.
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.
6) Push Front burner control knob down and turn to
START/ HI.
7) Check that the burner is lit by looking through the
matchlight hole on the front of the cooking box.
1) Open the lid. Figure 2.
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.
2) Check that fuel scale reads more than “E”.
Note - E = empty; F = full.
3) Make sure all burner control knobs are turned OFF.
(Push each burner control knob down and turn
clockwise.)
8) After the FRONT burner is lit you can turn on the other
burners.
WARNING: The burner control knobs must be in the
OFF position before turning on the LP tank valve. If
they are not in the OFF position, when you turn on the
LP tank valve, the excess flow control will activate,
limiting the flow of gas from the LP tank. If this should
occur, turn OFF the LP tank valve and burner control
knobs and start over.
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.
 DANGER
When the excess flow control is
activated, a small amount of gas is still
flowing to the burners. After turning OFF
the tank and burner control knobs, wait
at least 5 minutes for the gas to clear
before attempting to light the barbecue.
Failure to do so may result in an
explosive flame-up which can cause
serious bodily injury or death.
1
Manual Lighting
3
8
4
7
5
6
2
Figure 2
25
Lighting the side burner
Lighting the side burner if the main burners are lit.
Figure 4.
The side burner has a separate ignition system from the
main cooking box.
1) Open the side burner lid.
2) Push down and turn the side burner control to HI.
 DANGER
3) Press the side burner igniter button several times so it
clicks each time.
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.
1
2
Lighting only the side burner. Figure 3.
3
1) Open the side burner lid.
Figure 4
2) Check that the fuel scale reads more than “E”.
3) Check that the side burner valve is OFF (push down
and turn clockwise), and all main burner control valves
are OFF (push down and turn clockwise).
CAUTION: Side burner flame may be difficult to see
on a bright sunny day.
4) Turn the LP tank valve on (turn counterclockwise).
WARNING: If the side burner does not light:
5) Push down and turn the side burner control valve to HI.
a)
6) Push the side burner igniter button several times so it
clicks each time.
b) Wait 5 minutes to let the gas clear before you try
again or try to light with a match.
1
5
3
6
Figure 3
CAUTION: Side burner flame may be difficult to see
on a bright sunny day.
WARNING: If the side burner does not light:
a)
Turn OFF the side burner control valve.
b) Wait 5 minutes to let the gas clear before you try
again or try to light with a match.
26
Turn OFF the side burner control valve.
Storage and/or Nonuse continued
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.
■
LP tanks must be stored outdoors in a well- ventilated
area out of reach of children. Disconnected LP tanks
must not be stored in a building, garage or any other
enclosed area.
■
When the LP tank is not disconnected from the Weber
Gas Barbecue, the appliance and LP tank must be
kept outdoors in a well-ventilated space.
■
The Weber Gas Barbecue should be checked for
gas leaks and any obstructions in the burner tubes
before using. (See Sections "General 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.")
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.
Periodic Cleaning
Preheating
WARNING: Turn your Weber Gas Barbecue OFF and
wait for it to cool before cleaning.
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.
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.
Drippings and grease
Outside surfaces - Use a warm soapy water solution.
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.
CAUTION: Do not use oven cleaner, abrasive
cleansers (kitchen cleansers) cleaners that contain
citrus products or abrasive cleaning pads on barbecue
or cart surfaces.
WARNING: Check the bottom tray for grease buildup before each use. Remove excess grease to avoid a
grease fire in the bottom tray.
Bottom tray - Remove excess grease and then wash with
warm soapy water.
Flavorizer Bars and Cooking Grates- Clean with a
suitable brass bristle brush. As needed, remove from grill
and wash with warm soapy water.
Storage and/or Nonuse
■
The gas must be turned off at the LP tank when the
Weber Gas Barbecue is not in use.
■
When the Weber Gas Barbecue is stored indoors, the
gas supply must be DISCONNECTED and the LP
tank stored outdoors in a well-ventilated space.
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.
27
Connecting the filled LP tank
Refilling the LP tank
WARNING: Make sure that the LP tank valve is
closed. Close by turning clockwise.
We recommend that you refill before the scale indicator
reaches "E".
 DANGER
Note - If you run out of fuel, check the indicator setting
and/or adjust the fuel scale indicator setting with the scale
setting wing nut, while the tank is empty so you do not run
out again.
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.
Removal of the LP tank
1) Close tank valve (turn clockwise). Figure 5 (a).
2) Slide the collar back on the quick disconnect to
disengage the fitting. Figure 5 (b).
3) Loosen tank lock wing nut and turn tank lock up out of
the way.
You will need: LP tank, a soap and water solution and a
rag or brush to apply it.
4) Lift tank off.
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
To refill take LP tank and tank filler adapter to a "Gas
Propane" dealer.
a) Lift and hook the tank onto the fuel scale.
WARNING: We recommend that your LP tank be
filled at an authorized LP gas dealer, by a qualified
attendant, who fills the tank by weight. IMPROPER
FILLING IS DANGEROUS.
b) Loosen the tank lock wing nut. Swing the tank lock
down. Tighten the wing nut. Figure 6.
WARNING: If you exchange your LP tank, make
sure you get a similar tank in return. Your LP tank is
equipped with a quick-disconnect valve and an OPD
(Overfilling Prevention Device). Other LP tanks are not
compatible with your barbecue connection.
Scale setting wing nut
Tank lock
wing nut
Figure 6
(a)
Tank valve
Collar
(b)
Figure 5
28
c) Connect the hose to the tank. Route the hose so it
does not interfere with the scale indicator rod. Slide
back the collar of the quick disconnect on the tank
valve. Figure 7 (a). Push the male fitting of the
regulator into the quick disconnect, and maintain
pressure. Slide the collar closed. Figure 7 (b). If it does
not engage or lock, repeat procedure. Gas will not flow
unless the quick disconnect is properly engaged.
f)
Check for leaks by wetting the fitting with the soap
and water solution and watching for bubbles. If
bubbles form or if a bubble grows there is a leak.
If leak does not stop, turn off the gas and contact
Weber-Stephen Customer Service. Do not use the
barbecue.
g) When leak checks are complete, turn gas supply OFF
and rinse connections with water.
(a)
LP Tank
The LP tank manufacturer is responsible for the materials,
workmanship and performance of the tank. If the tank has
a defect, malfunctions, or you have a question regarding
the tank, call the tank manufacturer's customer service
center. The phone number is on the warning decal which is
permanently attached to the tank. If the tank manufacturer
has not resolved the issue to your satisfaction, then call
Weber-Stephen Products Co., Customer Service Center.
Male fitting
Regulator
Collar
(b)
Quick disconnect
engaged
Figure 7
d) Mix soap and water.
e) Open the tank valve. Figure 8.
Figure 8
29
Liquid Propane (LP) Tank(s)
Safe handling tips for LP Gas
■
Liquid Propane (LP) gas is a petroleum product as are
gasoline and natural gas. LP gas is a gas at regular
temperatures and pressures. Under moderate pressure,
inside a tank, LP gas is a liquid. As the pressure is
released the liquid readily vaporizes and becomes gas.
■
LP gas has an odor similar to natural gas. You should
know this odor.
■
LP gas is heavier than air. Leaking LP gas may collect
in low areas that prevent dispersion.
■
To fill, take the LP tank to an RV center, or look up gaspropane in the phone book for other sources of LP gas.
■
The LP tank and connections supplied with your
Weber Gas Barbecue have been designed and tested
to meet government, American Gas Association and
Underwriters Laboratories requirements.
■
Replacement LP tanks supplied by Weber satisfy the
requirements. Check to be sure the tank has a D.O.T.
certification, and has been tested within five years.
Your LP gas supplier can do this for you. Figure 9.
If you have questions about spare LP tanks, please
call Weber-Stephen Customer Service.
D.O.T. Certification (example)
WARNING: We recommend that your LP tank be
filled at an authorized LP gas dealer, by a qualified
attendant, who fills the tank by weight. IMPROPER
FILLING IS DANGEROUS.
DOT 4BA240
WARNING: If you exchange your LP tank, make
sure you get a similar tank in return. Your LP tank is
equipped with a quick-disconnect valve and an OPD
(Overfilling Prevention Device). Other LP tanks are not
compatible with your barbecue connection.
■
■
■
1/97
Air must be removed from a new LP tank before the
initial filling. Your LP dealer is equipped to do this.
Date tested
The LP tank must be installed, transported and stored
in an upright position. LP tanks should not be dropped
or handled roughly.
20 lb LP tank
Figure 9
Never store or transport the LP tank where temperatures
can reach 125° F (too hot to hold by hand - for example:
do not leave the LP tank in a car on a hot day).
Note - A refill will last about 20 hours of cooking time at
normal use. The fuel scale will indicate the propane
supply so you can refill before running out. You do not
have to run out before you refill.
■
Treat "empty" LP tanks with the same care as when
full. Even when the LP tank is empty of liquid there
still may be gas pressure in the tank. Always close
the tank valve before disconnecting.
■
Do not use a damaged LP tank. Dented or rusty LP
tanks or LP tanks with a damaged valve may be
hazardous and should be replaced with a new one
immediately. See "LP tank requirements".
■
The joint where the hose connects to the LP tank must
be leak tested each time the LP tank is reconnected.
For example, test each time the LP tank is refilled.
■
Be sure the regulator is mounted with the small vent
hole pointed downward so it will not collect water. This
vent should be free of dirt, grease, bugs etc.
30
■
All LP tank supply systems must include a collar to
protect the tank valve.
■
The LP tank must be a 20 lb size (18 1/4 inches high,
12 1/4 inches in diameter).
■
The LP tank must be constructed and marked in
accordance with the specifications for LP gas cylinders
of the U.S. Department of Transportation (D.O.T.).
Annual Maintenance
d) Side burner hose to side burner connection.
Figure 10 (d).
After a period of nonuse we recommend that you perform
the following maintenance procedures for your safety.
e) Valves to manifold connection. Figure 10 (e).
f)
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 manifold assembly. Order from WeberStephen Products Co., Customer Service Center or
authorized dealer.
Hose to regulator connection. Figure 10 (f).
WARNING: If there is a leak at connections d, e or f,
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)
■ 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.
(c)
 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.
(d)
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.
(f)
(e)
Make sure main burners are in the OFF position.
Make sure side burner is OFF. Remove valve control knob
and screws. Remove enamel top.
To perform leak checks: 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 10
Inspection and Cleaning of the Weber Spider
Stopper Guards
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.
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 do, 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".)
Check:
a) Hose to manifold connections. Figure 10 (a).
b) Regulator to tank connection. Figure 10 (b).
c) Manifold to side burner hose connection. Figure 10 (c).
WARNING: If there is a leak at connections a, b or c,
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.
31
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 13.
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 11. This could result in a
fire in and around the air shutters, under the control panel,
causing serious damage to your barbecue.
Tips occasionally yellowish
Burner inside
cooking box
Light blue
Venturi
Dark blue
Flames
Figure 13
Air shutter
Venturi fin
If the flames do not appear to be uniform the length of the
burner tube, follow the burner cleaning procedures.
Figure 11
Main Burner Cleaning Procedure
The Weber Spider Stopper Guard is factory installed. It fits
tightly around the air shutter section of the burner tube
and the valve, thereby preventing spiders and other
insects access to the burner tubes through the air shutter
openings. Figure 12.
Turn off the gas supply. Remove the manifold. (See
Section “Replacing the main burners”.)
Look inside each burner with a flashlight. Figure 14.
Weber Spider
Stopper Guard
Figure 14
Clean the inside of the burners with a wire (a straightened
out coat hanger will work). Figure 15. 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 12
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.
Figure 15
3. Barbecue heats unevenly.
CAUTION: Do not enlarge the burner ports when
cleaning.
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.
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.
32
g) Lift and twist the burner assembly slightly, to separate
the crossover tube from the burners. Figure 19.
Remove the burners from the cooking box.
d) Unlatch the Spider Stopper Guards and remove.
Figure 16.
Crossover tube
Figure 19
Figure 16
h) To reinstall burners, reverse steps c) through g).
 CAUTION: The burner openings must be positioned
properly over the valve orifices. Figure 20a.
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 17.
Check proper assembly before fastening manifold in
place. Figure 20b.
Valve
View from behind
cooking box
Wing nuts
Burner
Figure 17
f)
Slide the burner assembly out from under the guide
screw and washer in the corners of the cooking box.
Figure 18.
(b)
Guide screw
Figure 18
Figure 20
33
(a)
i)
Crossover Ignition System Operations
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 21.
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 22.
Venturi fin
White wire
Check fit around
valve
Black wire
Check fit around burner
Figure 22
Figure 21
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".)
■
Check that the Crossover Ignition button pushes the
igniter (button) down, and returns to the up position.
■
Check to see if the igniter is loose in the frame.
Tighten if necessary; see Step “Install igniter” for
correct procedure.
If the Crossover Ignition System still fails to light, contact
Weber-Stephen Customer Service.
34
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".)
Burners do not light. -orBurners have a small flickering flame in the
HIGH position. -orBarbecue temperature only reaches 250˚ to
300˚ degrees in the HIGH position.
The excess flow safety device,
To reset the excess flow safety
which is part of the barbecue to tank device turn all burner control
connection, may have activated.
knobs and the tank valve OFF.
Disconnect the regulator from the
tank. Turn burner control knobs
to HIGH. Wait at least 1 minute.
Turn burner control knobs OFF.
Reconnect the regulator to the
tank. Turn tank valve on slowly.
Refer to “Lighting Instructions”.
Burner does not light, or flame is low in
HIGH position.
Is LP fuel low or empty?
Refill LP tank.
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.
Experiencing flare-ups:
CAUTION: Do not line the bottom tray
with aluminum foil.
Burner flame pattern is erratic. Flame is low Are burners clean?
when burner is on HIGH. Flames do not run
the whole length of the burner tube.
Inside of lid appears to be “peeling.”
(Resembles paint peeling.)
Clean burners. (See Section
"General Maintenance".)
The lid is porcelain-on-steel, not
Clean thoroughly. (See Section
paint. It cannot “peel.” What you are "Periodic Cleaning".)
seeing is baked on grease that has
turned to carbon and is flaking off.
THIS IS NOT A DEFECT.
Fuel scale shows that there is gas in the LP Check adjustment of fuel scale.
tank, but tank is empty.
Fuel scale must be adjusted with
an empty tank.
If problems cannot be corrected by using these methods, please contact Weber-Stephen Customer Service.
35
Side Burner Troubleshooting
WARNING: Before attempting any troubleshooting
steps, all gas controls and supply valves should be in
the OFF position.
Problem
Check
Cure
Side burner does not light.
Is gas supply off?
Turn supply on.
Flame is low in HIGH position.
Is fuel hose bent or kinked?
Straighten hose.
Flame is very yellow in conjunction with
the smell of gas,
Inspect the Weber Spider Stopper
Guard for possible obstructions.
(Blockage of holes.)
Clean Weber Spider Stopper
Guard. (See Section "Annual
Maintenance.")
Does burner light with a match?
If match lights burner, check
igniter (see below).
OR
Burner makes popping noise in conjunction
with the smell of gas.
Push button ignition does not work.
Side Burner Maintenance
Venturi/Burner
WARNING: All gas controls and supply valves
should be in the OFF position.
Check igniter: Remove side burner cover. To remove side
burner cover, remove control knob and screws that hold
cover to bottom. Figure 23. Make sure wire is connected
between igniter and electrode. Check that igniter lock nut
is tight. Figure 24.
Igniter wire
Note - If the igniter works loose, carefully tighten the
igniter lock nut with an adjustable wrench or pliers.
Electrode
Igniter
Adjust igniter electrode. Gap should be 1/8 to 3/16 inch
from tip of electrode to burner. Figure 25. Spark should be
a white/blue color, not yellow.
Figure 24
1/8 to 3/16 inch gap
Figure 23
Figure 25
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4
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49
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12
13
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55
15
16-17
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57
58
59
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19-20,17
12
21
22
60-61
23
62
63
24
W
25
E BE R
W
E BE R
26 27 28 29
30
31
32 33 34
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35
36
Parts List
While we give much attention to our products,
unfortunately an occasional error may occur. If a part is
missing, do not go back to the store. Call the Weber
Customer Service Center toll free 1-800-446-1071 to
receive immediate assistance. Have your owner’s manual
and serial number of the barbecue available for reference.
All items are single quantities unless otherwise specified.
Parts can be ordered directly from Weber-Stephen
Products Company by phone or mail.
Note - Do not return parts to Weber-Stephen Products Co.
without first contacting the Customer Service Center by
mail or phone. Returning the part may not be necessary.
Weber-Stephen Products Company
Customer Service Center
250 South Hicks Road
Palatine, IL 60067-6241
(800) 446-1071
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2
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27
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Left endcap
Shroud 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)
Spacer bracket
Swing table end bracket
Left frame
Swing table
1/4-20 x 1/2 inch bolts (6)
1/4 inch nylon washers (18)
Slide bar assembly
10-24 x 1 3/4 inch machine screws (2)
10-24 hex nuts (2)
Caster frame
Casters (2)
Bottom tray
Catch pan holder
Catch pan kit
Frame connectors (2)
Accessory rack
Wheel hub caps (2)
Wheels (2)
Axle
Front panel
Wheel frame
1/4-20 hex nut
Side burner locks (2)
Tank panel assembly
1/4-20 x 1 1/4 inch bolt
Right endcap
Hair pin cotters (2)
Hinge pins (2)
Thermometer
Thermometer holder
1/4-20 keps nut
Cooking box
Burner control knobs (3)
Control panel
Igniter button
Phillips screws/washers (2)
Crossover tube
Front or Back burner
Center burner
1/4-20 stainless steel wing nuts (2)
Spider Stopper Guards (4)
Manifold assembly
Manifold bracket
Side burner assembly
Condiment rack with tool holders
Right frame
Control panel inserts (2)
Igniter assembly
Fuel scale
1/4-20 wing nuts (2)
LP tank
Filler adapter
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.
39
A FINAL WORD
OF THANKS
you for choosing a Weber Barbecue.
TOurhankfamily
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