Page 3 - WARRANTY
3 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,Cooking Grates, 3 years,Stainless Steel Flavorizer Bars, 5 years,All Rem...
Page 4 - PATENTS AND TRADEMARKS
4 © 1996 Weber. Weber, , Genesis, Flavorizer and Crossover arer e g i s t e r e d U. S . t r a d e m a r k s ; Pe r m a - M o u n t , G a s C a t c h e r,FlameCheck, Steam-N-Chips, Spider Stopper, and Warm-Up areU.S. trademarks of Weber-Stephen Products Co., 200 East DanielsRoad, Palatine, IL 60067-...
Page 5 - Contents; WARNINGS
5 Contents WARNINGS ................................................................ 2 Warranty & Patents .................................................. 3-4General Instructions .................................................... 6Assembly .......................................................
Page 6 - General Instructions; For Installation in Canada; WARNING: Only use this barbecue outdoors in a; Gas supply testing
6 General Instructions Your Weber Gas Barbecue is a stationary outdoorcooking appliance. With the Weber Gas Barbecue youcan grill, barbecue, roast and bake with results that aredifficult to duplicate with indoor kitchen appliances. Theclosed lid and Flavorizer Bars produce that "outdoor"flav...
Page 7 - Notice Before Installation; WE RECOMMEND THAT THIS INSTALLATION BE DONE BY A PROFESSIONAL.; DANGER; Do not use an open flame to check for
7 General Specifications for Piping American National Standards Institute (ANSI)Recommendations for gas supply installations:Connections: ■ This barbecue is designed to operate at 7 inches ofwater column pressure (.2526 psi). ■ A manual shut-off valve must be installed outdoors,immediately ahead of ...
Page 9 - Recommended concrete pad requirements
9 Recommended concrete pad requirements We recommend a pad a minimum of 40 inches left toright, 20 inches front to back and 4 inches deep (1.85cubic feet). Figure 4. Note - Cubic feet is determined by multiplying lengthtimes width times depth and dividing by 1728. 20” 4” 40” Figure 4 If you use a co...
Page 10 - Typical base installation for a wood deck
10 Method 3 A 3/8 inch machine screw anchor, using a 3/8-16 x 1 1/2 inch machine screw and a flat washer.Figure 8. Note - Use a 3/4 inch diameter concrete drill bit for drillingthe hole for the screw base. The machine screw anchorrequires a setting tool. 3/8-16 x 1 1/2 machine screw 3/8 inch flat wa...
Page 11 - Assembly; Tools needed; Check package contents
11 Assembly Tools needed Screwdrivers, regular and Phillips Hammer Two 7/16 inch, one 5/8, 11/16, and 3/4 inch open end ortwo adjustable wrenches Pliers Level Electric drill Supplies needed You will need a soap and water solution to check for gasleaks. (See Step "Check for gas leaks.") Note ...
Page 14 - Check contents of hardware packs
14 Check contents of hardware packs Three burner control knobs FlameCheck Button Three tool holders Eight tubing plugs(two are spares) Manifold bracket Four 10-24 x 1 3/4 inch machine screws (actual size) Four 10-24 hex nuts (actual size) Two hinge pins(hardware size: 1/4 x 1 1/2 inch clevis pin) (a...
Page 16 - Assemble base; Figure 1; Finish base assembly; Figure 2
16 Step 2 Assemble base You will need: left/right base panels, front/back basepanels, four 1/4-20 x 1/2 inch bolts, eight nylon washersand four 1/4-20 hex nuts. Position a left/right base panel with a front/back basepanel (flanges down) with left/right base panel on theoutside. Align the bottom hole...
Page 17 - Level the base; Figure 3; Figure 5
17 Step 4 Level the base You will need: base assembly, level, 5/8 inch and 3/4 inchwrenches. Using the 3/4 inch wrench, loosen the locking nuts(square nuts). Figure 3. Locking nut Mount plate Figure 3 Turn the base assembly over or right side up. (Flangesare now up.) Set the base in position on your...
Page 18 - Assemble the frame; tabs inside; Figure 6; Continue frame assembly; inside; Figure 7
18 Step 5 Assemble the frame You will need: left frame, right frame, two nylonwashers, two 1/4-20 x 1/2 inch bolts and a 7/16 inchwrench. Note - Work on carpeted area (on grass, or on one ofthe boxes) to protect the finish during frame assembly. Put the frame pieces so the leg tabs are up. Put the r...
Page 19 - Complete frame assembly; Figure 8; Insert bottom tubing plugs; Figure 9; Check the frame assembly
19 Step 7 Complete frame assembly You will need: partial frame assembly, one frameconnector with bushings, one frame connector withoutbushings, four 1/4-20 x 2 inch bolts, four nylon washersand a 7/16 inch wrench. Hold the frame connector with the bushings between thetwo upright frames above the fro...
Page 20 - Secure frame assembly to anchored base; CAUTION: The base must be anchored at all four; Install left end panel
20 Step 10 Secure frame assembly to anchored base You will need: completed frame assembly, four 1/4-20 x 11/2 inch bolts, eight nylon washers, four 1/4-20 hex nuts,four plastic buttons and a 7/16 inch wrench. CAUTION: The base must be anchored at all four anchor points prior to mounting the frame to...
Page 21 - Install side burner locks
21 Repeat the procedure with the other two back panels.When in place they should be flush with each other.Figure 14. Left upright Figure 14 Rightupright Step 14 Install side burner locks You will need: frame assembly, two side burner locks anda 7/16 inch wrench. Loosen the right rear 1/4 x 20 bolt. ...
Page 22 - Add cooking box
22 Step 15 Add cooking box You will need: frame assembly, cooking box assembly,1/4-20 x 2 inch bolt, nylon washer, 1/4-20 keps nut,pliers and a 7/16 inch wrench. Set the cooking box into the frame so the burner tubesare under the frame brace. Figure 17. Burner tubes Frame brace Figure 17 Your Weber ...
Page 23 - Install side burner; WARNING: No sealant is required on the side; Install manifold bracket
23 Step 16 Install side burner You will need: side burner assembly, 5/8 inch, 11/16inch and 3/4 inch or two adjustable wrenches. WARNING: No sealant is required on the side burner fitting. Do not use pipe dope, tape or anyother type of sealant on the fitting or hose. Use an 11/16 inch wrench to remo...
Page 24 - Check that all burner valves are off; WARNING: This barbecue is NOT portable. It
24 Figure 23 Step 19 Check that all burner valves are off You will need: one burner control knob. (Valves are shipped in the OFF position, but you shouldcheck to be sure.) Put the knob on each valve. Check bypushing down and turning clockwise. If they do not turnthey are off, proceed to the next sho...
Page 25 - Purge air from gas lines; Be sure there are no sparks or open; Install igniter
25 Step 21 Purge air from gas lines You will need: one burner control knob and FlameCheckbutton. It is necessary to bleed the air out of newly installed gaslines. Turn gas supply ON at the source. Put on theFlameCheck button and the front burner control knob.Push the front burner control knob down a...
Page 26 - Check for gas leaks
26 Step 22 Check for gas leaks 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 le...
Page 27 - Install brace panel and right end panel; Set notched accessory tray in place
27 Step 23 Install brace panel and right end panel You will need: brace panel, right end panel, 1/4-20 x 1 1/2 inch bolt, 1/4-20 hex nut, 1/4-20 x 1/2 inchbolt, 1/4-20 wing nut, three nylon washers, gas linebracket and a 7/16 inch wrench. Position the right end panel with the flange at the topfacing...
Page 28 - Install cooking grates
28 Step 25 Insert Flavorizer Bars andSteam-N-Chips Smoker You will need: five long Flavorizer Bars, seven shortFlavorizer Bars, Steam-N-Chips Smoker body and flue. Place the three long Flavorizer Bars in the rear of thecooking box. Insert the remaining two bars through theSteam-N-Chips Smoker flue a...
Page 29 - Install left hand swing table; left hand; WARNING: If swing table end bracket is in any
29 Step 27 Install left hand swing table You will need: swing table end bracket, two 10-24 hexnuts, two 10-24 x 1 3/4 inch machine screws, left hand slide bar assembly , swing table, four nylon washers, screwdriver and pliers. Allow the slide bar to hang down. Push the support rodinto the lower supp...
Page 30 - Install right hand swing table; right
30 Position slide bar assembly on the outside of the casterframe. Put a nylon washer on each 1 3/4 inch screw,insert screws through frame and slide bar assembly andadd nylon washers and hex nuts. Tighten nuts using ascrewdriver and pliers. Figure 37. Figure 37 View from front of barbecue Notch to th...
Page 32 - Install the lid; Install the bottom tray; The front of the catch pan
32 Step 30 Install the lid You will need: lid, two hinge pins and two hair pin cotters. Set the lid in place from the rear of the barbecue. Closeand align the hinge at the rear. Insert hinge pins from theoutside through the hinge. Insert hair pin cotters into thesmall holes in the hinge pins. Figure...
Page 33 - Secure the side burner; Caution: Make sure both locks have snapped
33 Step 31 Install the control panel, burner control knobs,FlameCheck button and tool holders You will need: control panel, three burner control knobs,FlameCheck button and three tool holders. Hook the tool holders over the frame rail. Figure 47. Set the control panel in place over both frame braces...
Page 35 - Lighting; WARNING: Check gas supply line before each use; WARNING: Do not lean over open barbecue. Keep; To Extinguish; OPERATING INSTRUCTIONS; Failure to open lid while igniting the
35 Lighting Summary lighting instructions are on the control panel. Crossover Ignition System Note - The Crossover Ignition System ignites the Frontburner with a spark from the igniter electrode inside theGas Catcher Ignition Chamber. You generate the energyfor the spark by pushing the Crossover Ign...
Page 36 - WARNING: If the burner does not light, turn the
36 5) Open the center glass door. Strike a match and put the flame into the matchlight hole in the front of the cooking box. 6) Push down and hold the FlameCheck button down. Note - Gas is supplied to the burner only when theFlameCheck button is depressed. Observe if front burner has ignited by look...
Page 37 - Lighting the side burner; Cooking
37 Lighting the side burner The side burner has a separate ignition system from themain cooking box. The side burner will only operate when the Frontburner is lit. 1) Open the side burner lid. Figure 3. 2) Push down and turn the side burner control valve ON. 3) Push the side burner igniter button se...
Page 39 - Do not use any flammable fluid in the; Figure 4
39 Using the Steam-N-ChipsSmoker The Steam-N-Chips Smoker cooks with both WeberFireSpice Wood Chips and Chunks. For best results withfaster cooking foods like steaks, burgers and chops, etc.,we recommend using the FireSpice Chips because theyignite and create smoke faster. For longer cooking foodssu...
Page 40 - Annual Maintenance
40 Annual Maintenance After a period of nonuse, we recommend that youperform the following maintenance procedures, for your safety. WARNING: Check gas supply line before each use of barbecue for nicks or cracking. If the gas supplyline is found to be unserviceable, do not usebarbecue. Replace using ...
Page 41 - WARNING: If there is a leak at connections; General Maintenance; Weber Spider Stopper Guards; Failure to correct these symptoms
41 Inspection and Cleaning of the Weber SpiderStopper Guards To inspect the Spider Stopper Guards, remove thecontrol panel, and look to see if they have dust or dirt ontheir outside surfaces. If they do, brush off the outsidesurface of the Spider Stopper Guards with a soft bristlebrush (an old tooth...
Page 42 - Turn off the gas supply.; Replacing Main Burners
42 e) Unlatch the Spider Stopper Guards and remove. Figure 13. f) Use an adjustable wrench to remove thethermocouple from the FlameCheck valve. g) Remove the manifold bracket and unscrew the two thumb screws that hold the manifold to the cookingbox. Pull the manifold and valve assembly out of thebur...
Page 43 - CAUTION: If the Spider Stopper Guards do not fit
43 ij) To reinstall burners, reverse steps c) through i). Venturi fin Check fit around burner Figure 18 Check fit aroundvalve 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 m...
Page 44 - THIS IS NOT A DEFECT.; TROUBLESHOOTING
44 Problem Burners burn with a yellow or orange flame, inconjunction with the smell of gas. Burner does not light, or flame is low in HIGH position. Experiencing flare-ups: CAUTION: Do not line the bottom tray with aluminum foil. Burner flame pattern is erratic. Flame is lowwhen burner is on HIGH. F...
Page 45 - Side Burner Maintenance; Side Burner Troubleshooting
45 Side Burner Maintenance WARNING: All gas controls and supply valves should be in the OFF position. Check igniter: Remove side burner cover. To removeside burner cover, remove control knob and screws thathold cover to bottom. Figure 21. Make sure wire isconnected between igniter and electrode. Che...
Page 47 - Parts List
47 1 Lid (assembly) 2 Weber Warm-Up Basket 3 Warming rack 4 Steam-N-Chips Smoker body 5 Steam-N-Chips Smoker flue 6 Steam-N-Chips Smoker water pan 7 Stainless Steel Short Flavorizer Bars (7) 8 Stainless Steel Long Flavorizer Bars (5) 9 Narrow cooking grate 10 Wide cooking grate11 Serving tray 12 Wor...
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 ...
