Page 3 - WARRANTY; LP Tank
3 WARRANTY Weber-Stephen Products Co. (Weber) herebywarrants to the ORIGINAL PURCHASER ofthis Weber Gas Barbecue that it will be free ofdefects in material and workmanship from thedate of purchase as follows: Aluminum Castings, 10 years,Stainless Steel Flavorizer Bars, 5 years,Cooking Grill, 3 years...
Page 4 - PATENTS AND TRADEMARKS
© 1996 Weber-Stephen Products Co. Weber, , Flavorizer andCrossover are registered U.S. trademarks; Gas Catcher is atrademark of Weber-Stephen Products Co., 200 East Daniels Road,Palatine, IL 60067-6266, U.S.A. Weber is also a registeredtrademark (Reg. TM., Marca Registrada, Marque Desposee,Schutzmar...
Page 5 - Contents; WARNINGS
5 Contents WARNINGS ..................................................................2 Warranty & Patents .................................................. 3-4General Instructions .................................................... 6Assembly ......................................................
Page 6 - General Instructions; Storage
6 General Instructions The Weber Gas Barbecue is a portable outdoor cookingappliance. With your Weber Gas Barbecue you can grilland barbecue with results that are difficult to duplicatewith indoor kitchen appliances. The Weber Gas Barbecue is portable so you can easilychange its location in your yar...
Page 7 - Check package contents; Assembly; Tools needed
7 Step 1 Check package contents Cooking box(assembly) Wheel frame Caster frame Bottom connectors (2) Back panel Top frame rail #1’s (2) Top frame rail #2’s (2) Splash guards (2) Assembly Tools needed Hammer 7/16 inch open end or an adjustable wrench Pliers Block of wood Phillips screwdriver Regular ...
Page 9 - Check contents of hardware packs
9 Wheel hubcaps (3)(one is a spare) (actual size) Plastic button (actual size) Casters (2) Match holder bracket 1/4-20 x 5/8 screw (actual size) Check contents of hardware packs Glides (4) 1/4-20 x 3 1/2 inch bolts (4) (actual size) 1/4-20 x 1 3/4 inch bolt (actual size) 1/4-20 x 1/2 inch bolts (6) ...
Page 10 - Assemble wheel frame; Insert casters; Figure 1
10 Step 2 Assemble wheel frame You will need: wheel frame, two wheels, two wheelhubcaps, hammer and a block of wood. Note: Work on a carpeted area (on grass, or on one ofthe boxes) to protect the finish during the frameassembly. Set one end of wheel frame on the block of wood (orother hard, protecte...
Page 11 - Continue frame assembly; Figure 3
11 Step 4 Continue frame assembly You will need: Wheel frame, caster frame, two bottomconnectors, four 1/4-20 x 3 1/2 inch bolts, four nylonwashers and a 7/16 inch or adjustable wrench. Turn caster frame and wheel frame upside down, andspace apart. Figure 3. Note: Fuel scale decal on wheel frame mus...
Page 12 - Assemble front top frame rail; Install match holder bracket; Figure 6
12 Step 6 Assemble front top frame rail You will need: one top frame rail #1, one top frame rail #2, one 1/4-20 x 1/2 inch bolt, frameassembly and 7/16 inch or adjustable wrench. Put top frame rail #1 to your right and top frame rail #2to your left. Figure 6. Insert top frame rail #1 into topframe r...
Page 13 - Assemble back top frame rail; Figure 7
(a) Fuel scaledecal onfront side Top frame railassembly Cut out View fromthe back Frontcasterframe Front wheelframe Position the top frame rail assembly with the tabs to theinside of the cart. Figure 7 (a). Insert the tabs into the front caster frame and frontwheel frame, the round tubing of the top...
Page 14 - Bolt front top frame rail assembly; Figure 9
14 Step 8 Bolt front top frame rail assembly You will need: two 1/4-20 x 1/2 inch bolts, two nylonwashers, frame assembly and 7/16 or adjustablewrench. Slip a washer over the bolt. Insert the bolt from theinside of the frame assembly into the caster frame.Figure 10 (a). Align the hole in the tab of ...
Page 16 - Add tank panel; Add fuel scale
16 Step 10 Add tank panel You will need: tank panel assembly, 1/4-20 x 1 3/4 inch bolt, 1/4-20 hex nut, two 1/4 inchnylon washers, pliers, and a 7/16 inch or adjustablewrench. Insert the tank panel tabs into the slots in the wheelframe brace. Slide up until the notch at the bottom ofthe tank panel f...
Page 17 - Add cooking box assembly
17 Figure 15 Figure 16 (a) Flanges Cooking box assembly Control panel Step 12 Add cooking box assembly You will need: frame assembly and cooking boxassembly. Note: This assembly takes two people to lift thecooking box assembly into the frame. Uncoil the hose. Set the cooking box into the frame so th...
Page 18 - Remove the control panel and the front panel
Front edge of thecontrol panel 18 Step 13 Remove the control panel and the front panel Take off all 6 burner control knobs. Pull up on the ignition buttons until they stay in the upposition. Figure 17. Put your fingers under the front edge of the controlpanel and lift up and pull evenly toward you. ...
Page 19 - Check burner alignment; Set LP fuel scale; facing front; facing away; CAUTION: Do not remove adjustment wing nut
19 Step 14 Check burner alignment Your Weber Gas Barbecue burner assembly has beenfactory assembled, pressure and flame tested. As asafety precaution we recommend you check the burneralignment. Figure 21. a) Are the mounting clips that hold the manifold and burner assembly in place? Figure 21 (a). b...
Page 20 - Fill LP tank; WARNING: We recommend that your LP tank be; Check that burners are off
20 Step 16 Fill LP tank Note - The LP tank manufacturer is responsible for thematerials, workmanship and performance of the tank. Ifthe tank has a defect, malfunctions, or you have aquestion regarding the tank, call the tankmanufacturer's customer service center. The phonenumber is on the warning de...
Page 21 - Connect LP tank; WARNING: Make sure that the LP tank valve is
21 The hose and regulator are connected in the followingmanner: Slide back the collar of the quick disconnect on the tankvalve. Push the male fitting of the regulator into thequick disconnect, and maintain pressure. Slide the collarclosed. Figure 26 (a). Figure 26 (b) shows the quickdisconnect engag...
Page 22 - Check for gas leaks; DANGER; WARNING: Do not ignite burners while leak; WARNING: You should check for gas leaks every
Manifold Figure 28 22 Step 19 Check for gas leaks DANGER Do not use an open flame to check forgas leaks. Be sure there are no sparks oropen flames in the area while you checkfor leaks. This will result in a fire orexplosion which can cause serious bodilyinjury or death and damage to property. Check ...
Page 23 - Rear
23 Step 20 Install Flavorizer Bar/cooking grill support You will need: two Flavorizer Bar/cooking grill supports. Slide one Flavorizer Bar/cooking grill support behind thebracket in the rear of the cooking box assembly. Figure 29 (a). Slide the second Flavorizer Bar/cooking grill supportbehind the b...
Page 24 - Install splash guards
24 Step 22 Install splash guards You will need: two splash guards Position splash guard, flanges to the rear, at the back ofthe cooking box assembly. Figure 31 (a). Insert bothwire ends into the mounting holes in the cooking box.Figure 31. Note: You will have to bend the splash guards slightlyto fit...
Page 25 - Install Cooking Grills and Griddle; CAUTION: The drain hole of the griddle needs to
25 The open “U” of the cooking grill goes down. Set bothcooking grills in place next to the griddle. Figure 35. Figure 34 Figure 35 Step 23 Install Cooking Grills and Griddle You will need: two cooking grills and one griddle. Set the griddle on top of the Flavorizer Bar/cooking grillsupport. Figure ...
Page 26 - Install left work surface and glides; Install right work surface and glides; WARNING: The load limit for the work surface is
26 Step 24 Install left work surface and glides You will need: left work surface, two nylon (plastic)glides, two Phillips head 1/4-20 x 1 inch machinescrews and a Phillips screwdriver. Set the left work surface over the top of the cooking boxand the top frame rails. Figure 36. The left work surfacew...
Page 28 - Install bottom tray; CAUTION: Do not line the bottom tray with; View from front of the Cooking Box
28 Step 27 Install bottom tray You will need: Bottom tray, catch pan holder, catchpan, and one drip pan. Figure 41 Figure 42 Figure 43 Figure 44 Note: It may be easier to install the catch pan holderby removing the catch pan from the holder. Hook the ends of the catch pan holder into the hole inthe ...
Page 29 - Add accessory rack
29 Step 28 Add accessory rack You will need: accessory rack. Set the bottom rack between the two bottomconnectors. Figure 45. Figure 45
Page 30 - OPERATING INSTRUCTIONS; Failure to open sliding work surfaces; W h e n t h e e x c e s s f l o w c o n t r o l i s
30 1) Open the sliding work surfaces and splash guards. Figure 1. 2) Check that the fuel scale reads more than “E”. Note - E = empty; F = full. 3) Make sure all burner control knobs are OFF. (Push each burner control knob down and turn clockwise.) WARNING: The burner control knobs must be in the O...
Page 31 - F a i l u r e t o o p e n s l i d i n g w o r k s u r f a c e s; To Extinguish; When the excess flow control is activated,
31 Manual Lighting EACH HEAT ZONE OPERATES INDEPENDENTLY. 1) Open the sliding work surfaces and splash guards. Figure 2. 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 turnclockwi...
Page 32 - First Time Use; Using the Cooking Grates; High
32 Cooking The Weber Gas Barbecue should not be movedwhen operating or hot. You can adjust the LEFT and RIGHT burners asdesired. 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 thesettings of the LEFT an...
Page 33 - Periodic Cleaning; CAUTION: Turn your Weber Gas Barbecue OFF; Maintenance; Storage and/or Nonuse
33 Periodic Cleaning CAUTION: Turn your Weber Gas Barbecue OFF and wait for it to cool before cleaning. CAUTION: Do not clean your Flavorizer Bars or cooking grills in a self-cleaning oven.Replacementcooking grills and griddles and Flavorizer Bars areavailable through your retailer. Outside surf...
Page 34 - Refilling the LP tank; Connecting the filled LP tank; Do not use an open flame to check for
34 Scale setting wing nut Tank lockwing nut Tank valve Collar (a) (b) Figure 4 Refilling the LP tank We recommend that you refill before the scale indicatorreaches "E". Note - If you run out of fuel, check the indicator settingand/or adjust the fuel scale indicator setting with thescale sett...
Page 36 - Safe handling tips for LP Gas; WARNING: We recommend that your LP tank be; Figure 8
36 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 cylinder, LP gas is a liquid. As the pressure is released the liquid readily vaporizes and becom...
Page 37 - Annual Maintenance; WARNING: Check hose before each use of
37 WARNING: You should check for gas leaks every time you disconnect and reconnect a gas fitting. Note: All factory made connections have beenthoroughly checked for gas leaks. The burners havebeen flame tested. As a safety precaution you shouldrecheck all fittings for leaks before using your Weber...
Page 38 - General Maintenance; Burner Inspection; Failure to correct these symptoms
The Weber Spider Stopper Guard is factory installed. Itfits tightly around the air shutter section of the burner tubeand the valve, thereby preventing spiders and otherinsects access to the burner tubes through the air shutteropenings. Figure 12. We recommend that you inspect the Weber SpiderStopper...
Page 39 - CAUTION: Do not enlarge the burner ports when; Replacing the Burners
Main Burner Flame Pattern The Weber Gas Barbecue burners have been factory setfor the correct air and gas mixture. The correct flamepattern is shown in Figure 13. If the flames do not appear to be uniform the length of theburner tube, follow the burner cleaning procedures. Main Burner Cleaning Proce...
Page 41 - Crossover Ignition System Operations; CAUTION: If the Spider Stopper Guards do not fit; CAUTION: The burner openings must be
41 Crossover Ignition System Operations If the Crossover Ignition System fails to ignite the Frontburner, light the Front burner with a match. If the Frontburner lights with a match, then check the CrossoverIgnition System. ■ Check that both the white and black ignition wires are attached properly. ...
Page 42 - Cure; WARNING: The spare or; TROUBLESHOOTING
42 Problem Burners burn with a yellow or orange flame, in conjunction with the smell of gas. Burners do not light. -or-Burners have a small flickering flame inthe HIGH position. -or-Barbecue temperature only reaches 250˚ to300˚ degrees in the HIGH position. Burner does not light, or flame is low inH...
Page 45 - Parts List
45 1 Cooking grills (2)2 Griddle 3 Flavorizer bars (11) 4 Left work surface 5 Glides (4) 6 Phillips head 1/4-20 x 1 inch machine screws (4) 7 Cooking box (assembly) 8 Burner control knobs (6) 9 Igniter (3) 10 Igniter lock nut (3)11 Igniter wire (black) (3)12 Igniter wire (white) (3)13 Gas catcher ig...
Page 48 - A F; INAL
A F INAL W ORD OF T HANKS hank you for choosing a Weber Barbecue. Our family here at Weber has worked hard to produce the highest quality products for your satisfaction. While we give much attention to our products, an occasional error may occur. Our knowledgeable Customer Service staff is prepared ...