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mDANGER 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. mWARNINGS m Do not store a spare or disconnected LP tank under or near this barbecue. m Improper assembly may be dangerous. Please carefully follow the assembly instructions in this manual. m After a period of storage, and/or nonuse, the Weber Gas Barbecue should be checked for gas leaks and burner ob
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WARRANTY Weber-Stephen Products Co. (Weber) hereby There are no other express warrants except as warrants to the ORIGINAL PURCHASER of this set forth herein and any applicable implied Weber Gas Barbecue that it will be free of warranties of merchantability and fitness are defects in material and workmanship from the limited in duration to the period of coverage of date of purchase as follows: this express written Limited Warranty. Some states do not allow limitation on how long an Aluminum Casti
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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. U.S.A. Genesis Gas Barbecues are covered under the following patent nos.: U.S.A. #4,677,964; 4,727,853; #4,777,927; #4,829,978; #4,860,724; #4,941,817; #4,966,125; #5,070,776; #D293,067; #D316,355; Canada:
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Contents Troubleshooting & Maintenance WARNINGS................................................................ 2 LP Tank Information .................................... 26-28 Warranty & Patents.................................................. 3-4 Annual Maintenance......................................... 29 General Instructions.................................................... 6 General Maintenance.................................. 30-32 Assembly ...........................................
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Storage General Instructions n The gas must be turned OFF at the LP tank when the Your Weber Gas Barbecue is a portable outdoor cooking Weber Gas Barbecue is not in use. appliance. With the Weber Gas Barbecue you can grill, n When the Weber Gas Barbecue is stored indoors, the barbecue, roast and bake with results that are difficult to duplicate with indoor kitchen appliances. The closed lid and gas supply must be disconnected and the LP tank Flavorizer Bars produce that "outdoor" flavor in the f
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® ® ® ® ® ® ® ® Step 1 Assembly Check package contents Tools needed Regular screwdriver Cooking box (assembly) Phillips screwdriver Hammer 7/16 inch open-end 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 LP tank filler adapter leaks. (See Step "Check for gas leaks.") Note -
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R R E E B B E E W W Left frame Five long Flavorizer Bars Eight short Flavorizer Bars Right frame Tank panel assembly Wheel frame Front panel Caster frame Catch pan holder Two frame connectors Catch pan Work table Two drip pans Swing table assembly Manifold bracket Support rod Thermometer Axle Two wheels Two accessory trays Fuel scale assembly Warming rack Two casters Warm-Up Basket 8 R R E E B B E E W W
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Check contents of hardware packs Two plastic buttons (actual size) Three burner control knobs 1/4-20 keps nut Three tool holders Two 1/4-20 wing nuts (actual size) Five tubing plugs (two are spares) Eighteen 1/4 inch nylon washers Swing table end bracket Two hair pin cotters Two hinge pins Two wheel hubcaps (hardware size: 1/4 x 1 1/2 inch clevis pin) (actual size) Five 1/4-20 x 2 inch bolts Two Phillips screws/washers (actual size) 1/4-20 x 1 1/4 inch bolt (actual size) Six 1/4-20 x 1/2 inch b
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R E B E W Step 2 Step 3 Assemble wheels Assemble frame You will need: axle, two wheel hubcaps, two wheels, You will need: left frame, right frame, two 1/4-20 x 1/2 inch wheel frame, hammer and a block of wood. bolts, two nylon washers and a 7/16 inch wrench. Place one end of the axle on the block of wood (or other Note - Work on carpeted area (on grass or one of the protected surface). Tap on one hubcap. boxes) to protect the finish during frame assembly. Put one wheel on the axle, WEBER side to
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Step 4 Step 5 Continue frame assembly Complete frame assembly You will need: caster frame, wheel frame, four 1/4-20 x 1/2 You will need: partial frame assembly, two frame inch bolts, four nylon washers and a 7/16 inch wrench. 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 Hold one frame connector between the leg and wheel onto the tabs of the
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Step 7 Step 8 Add front panel Add cooking box You will need: front panel and two plastic buttons. You will need: frame assembly, cooking box (assembly), 1/4-20 x 2 inch bolt, 1/4 inch nylon washer, 1/4-20 keps nut, Turn frame assembly right side up. pliers and a 7/16 inch wrench. Align the panel with the holes in the frame and insert the Uncoil the hose. plastic buttons through the front panel and frame. Figure 6. Set the cooking box in the frame so the burner tubes are Plastic buttons under th
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Your Weber Gas Barbecue burner assembly has been Step 9 factory assembled, pressure and flame tested. As a safety Install manifold bracket precaution we recommend you check the burner alignment: You will need: manifold bracket a) Do the valves fit into the ends of the burners? Figure 9 (a). Hook the bracket onto the manifold at the center burner valve. Place your hand underneath the bracket. Lift the b) Are the ends of the burners under the washers at the manifold, bracket and cooking box sligh
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E F Step 10 Step 11 Install tank panel assembly Add fuel scale assembly You will need: tank panel assembly, 1/4-20 x 1 1/4 inch bolt, You will need: fuel scale assembly, two 1/4-20 wing nuts 1/4-20 hex nut, nylon washer and a 7/16 inch wrench. and two nylon washers. Insert the tank panel tabs into the slots in the frame brace. Slip the bolts on the back of the fuel scale assembly through Figure 11. the two small holes in the tank panel. Make sure indicator rod of fuel scale is on the left side o
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E F E E F F Step 12 Step 13 Install igniter Set LP fuel scale Note - The igniter wires are already attached to the Gas You will need: LP tank (empty). Catcher Ignition Chamber and the igniter. This was done to Note - For accuracy, the fuel scale must be set with an factory test the ignition system. empty tank. The igniter lock nut is on the igniter. We utilize various LP tank manufacturers. Some of the Insert the top of the igniter up through the large part of tanks we receive have differing t
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E F Step 14 Step 15 Fill LP tank Check that all burner valves are off Note - The LP tank manufacturer is responsible for the You will need: one burner control knob. materials, workmanship and performance of the tank. Valves are shipped in the OFF position, but you should If the tank has a defect, malfunctions, or you have a check to be sure. Put the knob on each valve. Check by question regarding the tank, call the tank manufacturer's pushing down and turning clockwise. If they do not turn, cus
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Route the hose so it will not interfere with the scale Step 17 indicator rod. Check for gas leaks The hose and regulator are connected in the following manner: m DANGER Slide back the collar of the quick disconnect on the tank Do not use an open flame to check for gas valve. Push the male fitting of the regulator into the quick leaks. Be sure there are no sparks or open disconnect, and maintain pressure. Slide the collar closed. flames in the area while you check for Figure 18 (a). Figure 18 (b)
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Check: Step 18 a) Hose to manifold connection. Figure 20 (a). Install Flavorizer Bars and Cooking Grates b) Regulator to tank connection. Figure 20 (b). You will need: five long Flavorizer Bars, eight short Flavorizer Bars and two cooking grates. mWARNING: : If there is a leak at connection (a) , retighten the fitting with a wrench and recheck for Set the long Flavorizer Bars side to side in the lower leaks with soap and water solution. position, then set the short Flavorizer Bars front to back
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Step 19 Step 20 Install the bottom tray Install Lid You will need: bottom tray, catch pan holder, catch pan and You will need: lid, two hinge pins and two hair pin cotters. one drip pan. Set the lid in place. Align the hinges at the rear of the barbecue. Insert hinge pins from the outside. Insert hair pin cotters into the small holes in the hinge pins. Figure 26. Hair pin cotter Hinge pin Finger grip on front Front side of catch edge of bottom tray pan holder Figure 23 Hook the ends of the cat
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Step 21 Step 22 Install the condiment basket Add control panel and burner control knobs You will need: condiment basket and end bracket. You will need: control panel, two Phillips screws/washers, a Phillips screwdriver, and three burner control knobs. Insert one wire end of the condiment basket into the hole in the side frame. Figure 27 (a). Insert the opposite wire Set the control panel in place over both frame braces. end of the condiment basket into the hole in the end Hold the Crossover Igni
