Weber 98642 - Manual

6 General Instructions Your Weber Gas Barbecue is a portable outdoor cookingappliance. With the Weber Gas Barbecue you can grill,barbecue, roast and bake with results that are difficult toduplicate with indoor kitchen appliances. The closed lid andFlavorizer Bars produce that "outdoor" flavo...

Step 1 Check package contents Cooking box (assembly) Lid (assembly) LP tank LP tank filler adapter Bottom tray Work table Two accessory trays Swing table 7 Assembly Tools needed Regular screwdriver Phillips screwdriver Hammer 7/16 inch or an adjustable wrench Pliers Block of wood Supplies needed You...

Two wheel hubcaps(actual size) Two hinge pins(hardware size: 1/4 x 1 1/2 inch clevis pin)(actual size) Five 1/4-20 x 2 inch bolts(actual size) Six 1/4-20 x 1/2 inch bolts(actual size) Two 1/4-20 wing nuts(actual size) Two 10-24 x 1 3/4 machine screws(actual size) Two 10-24 hex nuts(actual size) Eigh...

10 Step 2 Assemble wheels You will need: axle, two wheel hubcaps, two wheels,wheel frame, hammer and a block of wood. Place one end of the axle on the block of wood (or otherprotected surface). Tap on one hubcap. Put one wheel on the axle, WEBER side toward thehubcap. Slide the axle through the fram...

11 Step 4 Continue 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. Place the caster frame onto the tabs of the left frame withthe dimple to the inside. Figure 3. Place the wheel fra...

Step 7 Install side burner locks Note: The locks are taped to the inside of the sideburner lid. You will need: frame assembly, two side burner locks anda 7/16 inch wrench. Turn frame assembly right side up. Loosen the right rear 1/4 x 20 bolt. Install the side burnerlock. The “U” shape cut out of th...

13 Your Weber Gas Barbecue burner assembly has beenfactory assembled, pressure and flame tested. As a safetyprecaution we recommend you check the burner alignment: a) Do the valves fit into the ends of the burners? Figure 9(a). b) Are the ends of the burners under the washers at the left rear and le...

14 Step 11 Install igniter Note - The igniter wires are already attached to the GasCatcher Ignition Chamber and the igniter. This was done tofactory test the ignition system. The igniter lock nut is on the igniter. Insert the top of the igniter up through the large part of thekeyhole in the frame br...

16 Step 15 Set LP fuel scale You will need: LP tank (empty). Note - For accuracy, the fuel scale must be set with anempty tank. We utilize various LP tank manufacturers. Some of thetanks we receive have differing top collar assemblies.(The top collar is the metal protective ring around thevalve.) On...

17 Route the hose so it will not interfere with the scaleindicator rod. 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 the quickdisconnect, and maintain pressure. Slide the colla...

18 Step 18 Check for gas leaks Figure 19  DANGER Do not use an open flame to check for gasleaks. Be sure there are no sparks or openf l a m e s i n t h e a r e a w h i l e yo u ch e ck fo rleaks. This will result in a fire or explosionwhich can cause serious bodily injury ordeath and damage to prop...

20 Step 21 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...

21 Step 23 Secure side burner Pull the right hand swing table up. Stand to the right sideof the barbecue. Slightly pull back both side burner locks.Slide the side burner toward the control panel. The lockswill snap into the slots in the front and back of the sideburner. Figure 29.  CAUTION: Make su...

23 Step 25 Complete accessory installation You will need: work table, two accessory trays, Warm-UpBasket, warming rack, thermometer, three tubing plugs anda hammer. Insert one end of the Weber Warm-Up Basket into the holein the right end of the lid and the other end into the slot inthe left end of t...

24 Lighting Summary lighting instructions are on the control panel. 2 1 7 3 4 5 6 8 Figure 1 Crossover Ignition System  WARNING: The burner control knobs must be in the OFF position before turning on the LP tank valve. Ifthey are not in the OFF position, when you turn on theLP tank valve, the exces...

26 Lighting the side burner The side burner has a separate ignition system from themain cooking box. 6 3 5 1 Figure 3 Lighting the side burner if the main burners are lit.Figure 4. 1) Open the side burner lid. 2) Push down and turn the side burner control to HI. 3) Press the side burner igniter butt...

27 Cooking  WARNING: Do not move the Weber Gas Barbecue when operating or hot. You can adjust the FRONT, CENTER and BACK burnersas desired. The control settings High (H), Medium (M), Low(L), or Off (O) are described in your Weber cookbook. Thecookbook uses these notations to describe the settings o...

28 Scale setting wing nut Tank lockwing nut Tank valve Collar (a) (b) Figure 5 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 the scalesett...

30 Safe handling tips for LP Gas ■ Liquid Propane (LP) gas is a petroleum product as aregasoline and natural gas. LP gas is a gas at regulartemperatures and pressures. Under moderate pressure,inside a tank, LP gas is a liquid. As the pressure isreleased the liquid readily vaporizes and becomes gas. ...

31 d) Side burner hose to side burner connection. Figure 10 (d). e) Valves to manifold connection. Figure 10 (e). f) 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 Servi...

32 General Maintenance Weber Spider Stopper Guards Your Weber Gas Barbecue, as well as any outdoor gasappliance, is a target for spiders and other insects. Theycan nest in the venturi section of the burner tubes. Thisblocks the normal gas flow, and can cause the gas to flowback out of the air shutte...

34 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 areattached properly. F...

35 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 in theHIGH position. -or-Barbecue temperature only reaches 250˚ to300˚ degrees in the HIGH position. Burner does not light, or flame is low inH...

36 Problem Side burner does not light. Flame is low in HIGH position. Flame is very yellow in conjunction withthe smell of gas, OR Burner makes popping noise in conjunctionwith the smell of gas. Push button ignition does not work. Check Is gas supply off? Is fuel hose bent or kinked? Inspect the Web...

39 1 Lid (assembly) 2 Lid handle 3 Warm-Up Basket 4 Warming rack 5 Short Flavorizer Bars (8) 6 Long Flavorizer Bars (5) 7 Cooking grates (2) 8 Work table 9 Tubing plugs (5) 10 1/4-20 x 2 inch bolts (5) 11 Spacer bracket12 Swing table end bracket13 Left frame 14 Swing table 15 1/4-20 x 1/2 inch bolts...

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 ...