Weber Gas Grill 55009 User Manual

Owners Guide  
DANGER  
If you smell gas:  
1. Shut off gas to the appliance.  
2. Extinguish any open flames.  
3. Open lid  
Liquid Propane Gas  
4. If odor continues, keep away from the  
appliance and immediately call your gas  
supplier or your fire department.  
Leaking gas may cause a fire or explosion  
which can cause serious bodily injury or  
death, or damage to property.  
®
®
WARNING  
1. Do not store spare liquid propane  
cylinder within 10 feet (3m) of this  
appliance.  
2. Do not store or use gasoline or other  
flammable liquids or vapors within 25  
feet (8m) of this appliance.  
WARNING: Follow all leak-check  
procedures carefully in this manual prior  
to barbecue operation. Do this even if the  
barbecue was dealer-assembled.  
NOTICE TO INSTALLER:These  
instructions must be left with the owner  
and the owner should keep them for future  
use.  
YOU MUST READ THIS OWNERS GUIDE  
BEFORE OPERATING YOUR GAS GRILL  
THIS GAS APPLIANCE IS DESIGNED FOR  
OUTDOOR USE ONLY.  
WARNING: Do not try to light this  
appliance without reading the “Lighting”  
Instructions section of this manual  
A003.f  
B005.d  
C003.e  
D005.f  
55009 04/09/01  
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Warranty  
Weber-Stephen Products Co. (Weber) hereby warrants There are no other express warrants except as set forth  
to the ORIGINAL PURCHASER of this Weber Gas Grill herein and any applicable implied warranties of  
that it will be free of defects in material and  
workmanship from the date of purchase as follows:  
merchantability and fitness are limited in duration to the  
period of coverage of this express written Limited  
Warranty. Some regions do not allow limitation on how  
long an implied warranty lasts, so this limitation may not  
apply to you.  
Weber is not liable for any special, indirect or  
consequential damages. Some regions do not allow the  
exclusion or limitation of incidental or consequential  
damages, so this limitation or exclusion may not apply  
to you.  
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.  
Aluminum Castings, lifetime,1 year paint  
Porcelain Hood Section, 25 years  
Burners, 10 years  
Igniter, 3 years  
Cooking Grates, 3 years no rust  
through  
Flavorizer Bars, 1 year no rust through  
Thermoplastic/  
Thermoset Parts, 10 years Excluding  
fading  
All Remaining Parts, 5 years,  
when assembled and operated in accordance with the  
printed instructions accompanying it.  
This Warranty applies only to products sold at retail.  
Weber may require reasonable proof of your date of  
purchase. THEREFORE, YOU SHOULD RETAIN  
YOUR SALES SLIP OR INVOICE.  
WEBER-STEPHEN PRODUCTS CO.  
Customer Service Center  
1890 Roselle Road, Suite 308  
Schaumburg, IL 60195  
USA  
This Limited Warranty shall be limited to the repair or  
replacement of parts that 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 the Customer  
service representative in your region using the contact  
information sheet provided with your manual. 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 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 Cylinder  
The LP cylinder manufacturer is responsible for the  
materials, workmanship and performance of the  
cylinder. If the cylinder has a defect, malfunctions, or  
you have a question regarding the cylinder, call the  
cylinder manufacturer’s customer service center. The  
phone number is on the warning decal, which is  
permanently attached to the cylinder. If the cylinder  
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.  
A-3  
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Contents  
Danger & Warnings ................................ A-2  
Warranty................................................. A-3  
General Instructions ............................... A-5  
Exploded View........................................ A-6  
Parts List ................................................ A-9  
Assembly Instructions ............................ B-1  
Installing Features .................................. C-1  
Operating ............................................... D-1  
Lighting................................................... D-1  
Manual Lighting ...................................... D-2  
Lighting the side burner.......................... D-3  
Cooking .................................................. D-4  
Storage and/or Nouse ............................ D-4  
Cleaning ................................................. D-4  
Refilling the LP Cylinder ......................... D-5  
Safe handling tips for LP Gas Cylinders.. D-7  
Annual Maintenance .............................. D-8  
General Maintenance ............................. D-9  
Replacing Main Burners......................... D-10  
Crossover Ignition System Operations ... D-11  
Troubleshooting ...................................... D-12  
Side Burner Troubleshooting .................. D-13  
A-4  
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Storage  
General Instructions  
The gas must be turned OFF at the LP cylinder  
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.  
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  
cylinder stored outdoors in a well-ventilated space.  
LP cylinders must be stored outdoors in a well-  
ventilated area out of the reach of children.  
Disconnected LP cylinders must not be stored in a  
building, garage or any other enclosed area.  
When the LP cylinder is not disconnected from the  
Weber Gas Barbecue, the appliance and LP  
cylinder must be kept 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, if you move.  
Liquid Propane (LP) gas supply is easy to use and  
gives you more cooking control than charcoal fuel.  
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.  
Operating  
WARNING: Only use this barbecue outdoors in a  
well-ventilated area. Do not use in a garage,  
building, breezeway or any other enclosed area.  
WARNING: Never use your Weber Gas Barbecue  
under an unprotected combustible roof or  
overhang.  
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.  
WARNING:Your Weber Gas Barbecue is not  
intended to be installed in or on recreational  
vehicles and/or boats.  
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 areas around the LP cylinder must be free  
and clear from debris.  
WARNING: Do not use combustible materials  
within 24 inches of the top, bottom, back or sides  
of the grill.  
WARNING:The entire cooking box gets hot  
when in use. Do not leave unattended.  
WARNING: Keep any electrical supply cord and  
the fuel supply hose away from any heated  
surface.  
WARNING: Keep the cooking area clear of  
flammable vapors and liquids such as gasoline,  
alcohol, etc., and combustible materials.  
WARNING: Never store an extra (spare) LP  
cylinder under or near the Weber Gas Barbecue.  
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).  
A-5  
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Genesis Silver-C LP 032301  
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A-6  
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1.  
2.  
3.  
4.  
5.  
6.  
7.  
8.  
Hinge Pin  
Left Endcap  
Shroud  
Handle  
29.  
30.  
31.  
32.  
33.  
34.  
35.  
36.  
37.  
38.  
39.  
40.  
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46.  
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48.  
49.  
50.  
51.  
52.  
53.  
54.  
55.  
Right Endcap  
Burner Control Knobs  
Control Panel  
Ignitor Button  
Control Panel Hardware  
Side Burner  
Crossover tube  
Front and Back Burners  
Center Burner  
Manifold Support Bracket  
Manifold, Hose and regulator (assembled)  
Manifold Hardware  
Disposable Drip Pan  
Back Panel  
Left Frame  
1/4-20 x 1/2 inch bolts  
Right Frame  
Igniter  
Right End Trim Piece  
Wheel Frame  
Axle  
Wing Nuts  
Cylinder Panel  
Fuel Guage  
Warm-UpBasket  
Warming Rack  
Cooking Grates  
Flavorizer® Bars  
Cooking Box  
9.  
10.  
11.  
12.  
13.  
14.  
15.  
16.  
17.  
18.  
19.  
20.  
21.  
22.  
23.  
24.  
25.  
26.  
27.  
28.  
1/4-20 keps nut  
Slide Out Bottom Tray  
Catch pan holder  
Catch pan  
Left end trim piece  
Work Surface  
Front Panel  
Swing-Up Work Surface Rod  
Swing-Up Work Surface  
Caster Frame  
1/4-20 x 2 inch bolts  
Nylon Washers  
Bottom Shelf  
Frame Connectors  
Casters  
Wheels  
Hubcap  
Hair Pin Cotter  
Thermometer  
Liquid Propane Cylinder  
Cylinder Glides  
1/4-20 x 1 3/4 bolts  
A-7  
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© 2001 Weber-Stephen Products Co., Weber, the silhouette, and the kettle configuration are registered trademarks  
®
of Weber-Stephen Products Co., 200 East Daniels Road, Palatine, IL, 60067-6266, U.S.A. This product is covered by  
one or more United States patents and patents in other nations globally. Printed in the U.S.A.  
A-8  
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You will need:  
Screwdriver  
Left Frame - 1  
Right Frame - 1  
Wheel Frame - 1  
Caster Frame - 1  
Phillips screwdriver  
Hammer  
7/16 open-end or an adjustable wrench  
Pliers  
Block of wood  
Lid - 1  
Frame Connectors - 2  
Sideburner - 1  
®
Work Surface - 1  
Cooking Box - 1  
Swing-Up Work Surface - 1  
Hinge Rod - 1  
Left Trim Piece - 1  
Right Trim Piece - 1  
Bottom Shelf - 1  
Cooking grates - 2  
Control panel - 1  
A-9  
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Warming Rack - 1  
Burner Control Knobs - 3  
Warm-Up Basket - 1  
Flavorizer Bars - 5  
Hinge Pins (1/4 x 1 1/2 inch clevis pin) - 2  
2 inch bolts (1/4 x 20 x 2 inch bolts) - 5  
1 3/4 inch bolts (1/4 x 20 x 1 3/4 inch bolts) - 2  
1/2 inch bolts (1/4 x 20 x 1/2 inch bolts) - 8  
Cylinder Panel - 1  
Front Panel - 1  
Back Panel - 1  
Bottom tray - 1  
Keps Nut (1/4 x 20 Keps Nut) - 1  
Wing Nut (1/4 x 20 Wing Nut) - 2  
Catch Pan Holder - 1  
Nylon Washers - 17  
Catch-Pan - 1  
Hair Pin Cotter - 2  
Hubcaps - 3  
Disposable Drip Pans - 2  
Thermometer - 1  
Wheels - 2  
Control Panel Hardware - 2  
(Phillips screws/washers)  
Cylinder Glides - 2  
Casters - 2  
Fuel Guage - 1  
Liquid Propane Cylinder - 1  
Axle Rod - 1  
A-10  
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Click here to view  
addendum sheet  
Assembly Instructions  
Assemble wheel frame  
Assemble frame  
You will need: axle rod, two wheel hubcaps, two  
wheels, wheel frame, hammer and a block of wood.  
Place one end of the axle rod on the block of wood (or  
other protected surface). Tap one hubcap onto the end  
of the axle rod. Slide one wheel onto the axle, WEBER  
name facing out. Next, slide the other end of the axle  
rod through the wheel frame. Add the other wheel,  
WEBER name side facing out. Tap the hubcap onto  
the axle rod to complete the axle.  
You will need: left frame, right frame, two 1/2 inch  
bolts, two nylon washers and a 7/16 inch or adjustable  
wrench.  
Note - Work on carpeted area (on grass or one of the  
boxes) to protect the finish during frame assembly.  
Lay the leg frame pieces as shown so the leg tabs  
point up.  
1) Connect the two frame pieces with the tabs inside  
of the frame.  
2) Slip washers on bolts, then insert bolts as shown  
and tighten. (If you try to insert a bolt and there is  
no hole, you have the left frame turned the wrong  
way. Turn the left frame around.)  
E R  
W
B
E
E
B
W
E
R
(1)  
(2)  
B-1  
B005.d  
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Continue frame assembly  
Add back panel  
You will need: caster frame and wheel frame.  
Place the caster frame onto the tabs of the left frame,  
so that the swing table locking bracket (1) is to the rear.  
Place the wheel frame onto the tabs of the right frame,  
so that the swing table locking bracket is to the rear  
(2). The leg tabs must be on the inside of the frames.  
You will need: frame assembly, back panel, two 1/2  
inch bolts, two nylon washers, and a 7/16 or adjustable  
spanner.  
Place the back panel against the inside frame  
assembly as shown in illustration.  
Add washer to bolt. Insert bolt through the back panel  
and into the frame. Insert bolt on other end through the  
back panel and the frame. Tighten bolts.  
(1)  
Add front panel  
You will need: frame assembly, front panel, two 1/2  
inch bolts, two nylon washers, and a 7/16 or adjustable  
spanner.  
Place the front panel with the matchlight hole(1) down  
and to your right against the inside frame assembly as  
shown in illustration.  
Add washer to bolt. Insert bolt through the front panel  
and into the frame. Insert bolt on other end through the  
front panel and the frame. Tighten bolts.  
Complete frame assembly  
You will need: partial frame assembly, two frame  
connectors, four 2 inch bolts, four nylon  
washers and a 7/16 inch or adjustable wrench.  
Hold one frame connector between the caster frame  
and wheel frame. Add the nylon washer to the bolt.  
Insert the bolt through the frame and screw into frame  
connector. Tighten bolt with wrench.  
(1)  
Repeat procedure with the other frame connector.  
B-2  
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Insert casters  
You will need: frame assembly and two casters.  
Push the casters firmly into the inserts in the ends of  
the caster frame.  
Slide the cooking box (assembly) to the left within the  
frame assembly. Add the nylon washer to the bolt.  
Insert the bolt through the frame and cooking box with  
the head of the bolt outside the box. Add the keps nut.  
Tighten by holding the bolt with pliers while you tighten  
the nut with a wrench.  
Add cooking box (assembly)  
You will need: frame assembly, cooking box  
(assembly), 2 inch bolt, nylon washer, keps nut, pliers  
and a 7/16 inch or adjustable wrench.  
Uncoil the hose.  
Place the cooking box (assembly) in the frame  
assembly so the burner tubes(1) are under the frame  
brace(2).  
Your Weber Gas Grill manifold assembly, consisting of  
gas manifold, valves, hose, regulator and gas burners  
has been factory assembled, pressure and flame  
tested. As a safety precaution, we recommend you  
check the burner alignment:  
1) 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.  
(1)  
(2)  
2) Do the valves fit into the ends of the burners?  
3) Are the wing nuts under the burner assembly  
tight?  
If you answered YES to 1, 2 and 3, the burners are  
correctly aligned. If you answered NO, the burners are  
misaligned. Contact the Customer Service  
Representative in your region using the contact  
information sheet provided with your manual. Do not  
use grill.  
(2)  
(1)  
(3)  
B-3  
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Install manifold brackets  
The manifold brackets(2) are already in place on the  
manifold between the valves.  
Place your hand underneath the manifold. Lift the  
manifold and cooking box slightly and hook the  
manifold bracket(2) onto the frame brace(1).  
Slide the cylinder panel up until notch at bottom of  
panel fits over the cross brace(1). Add nylon washer to  
bolt and insert through the hole in the wheel frame at  
the bottom right of the cylinder panel, make sure that  
the bolt slips through the hole in the cylinder panel.  
Add nylon cylinder glide to bolt end and tighten bolt  
with the wrench, while holding the cylinder glide with  
the pliers. Repeat procedure with the hole on the  
bottom left side of the cylinder panel.  
(2)  
(1)  
Install cylinder panel  
(1)  
You will need: Cylinder panel, two 1 3/4inch bolts, two  
nylon cylinder glides, two nylon washers a 7/16 inch or  
adjustable wrench and pliers.  
Insert the cylinder panel tabs(1) into the slots in the  
frame brace(2).  
(2)  
Add fuel gauge  
You will need: fuel gauge, two wing nuts and two nylon  
washers.  
1) Slip the bolts on the back of the fuel gauge  
through the two small holes in the cylinder panel.  
2) Add washers to the bolts, then wing nuts, and  
tighten with your fingers.  
(1)  
(1)  
(2)  
B-4  
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Install igniter  
Install the slide out bottom tray  
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.  
The igniter lock nut is on the igniter.  
You will need: the slide out bottom tray(1), catch pan  
holder(2), catch pan and one disposable drip pan.  
1) Loosen the igniter lock nut.  
2) Insert the top of the igniter up through the large  
part of the keyhole in the frame brace. Slide the  
igniter into the small part of the keyhole.  
3) Tighten the igniter lock nut back onto the igniter.  
Note - If the igniter works loose, carefully tighten the  
igniter lock nut with an adjustable wrench or pliers.  
(1)  
(2)  
(1)  
Hook the ends of the catch pan holder into the hole in  
the slide out bottom tray. The front of the catch pan  
holder must be on the same side as the finger  
grip(1) of the bottom tray.  
(2)  
(1)  
Slide the bottom tray onto the mounting rails under the  
cooking box with finger grip toward you(1).  
ƽ WARNING: 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.  
(3)  
Check that all burner valves are off  
You will need: burner control knobs.  
(1)  
Valves are shipped in the OFF position, but you should  
check to be sure that they are turned OFF. 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. If they do turn continue  
turning them clockwise until they stop, then they are  
off. Proceed to the next step.  
Put the disposable drip pan into the catch pan.  
Slide the catch pan into the catch pan holder with its  
finger grip towards you(1).  
B-5  
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Install Lid  
Install control panel and burner control knobs  
You will need: control panel, two Phillips screws/  
washers, a Phillips screwdriver, and burner control  
knobs.  
1) Set the control panel in place over both frame  
braces. Hold the Crossover Ignition button up while  
setting the control panel in place.  
You will need: lid, two hair pin cotters(1) and two hinge  
pins(2).  
Place lid on top of the cooking box. Align the hinges at  
the rear of the barbecue. Insert hinge pins through the  
hinges from the outside. Insert hair pin cotters into the  
small holes in the hinge pins.  
2) Line up the holes in the control panel with the  
holes in the white plastic plugs in the frame brace.  
Insert screws and tighten with a Phillips  
screwdriver until snug. Do not overtighten.  
3) Push each of the burner control knobs onto their  
valve.  
(1)  
(2)  
(1)  
(2)  
(3)  
B-6  
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Installing Features  
Install the right trim piece with tool holders  
Install the left end trim piece and swing-up work  
You will need: Right trim piece with tool holders  
Push the Right trim piece into the frame as shown(1),  
making sure that the tabs on the underside of the trim  
piece are snapped into the slots in the frame.(2)  
surface  
You will need: End trim piece, swing-up work surface,  
swing-up work surface rod, two 1/2 inch bolts, two  
nylon washers and a wrench  
1.) Start the left end trim piece into the frame as  
shown, do not push the trim piece in all of the  
way and do not add bolts yet.  
(1)  
(2)  
2.) Slide the swing-up work surface rod through the  
holes at the top of the swing-up work surface.  
C003.e  
C-1  
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3.) Insert one end of the swing-up work surface rod  
into the hole in the frame.  
5.) Add a washer to each bolt and insert it through the  
hole in the frame and the hole in the trim piece on  
both sides. Tighten with a wrench.  
To raise swing-up work surface: Lift table all the way  
up and slide it to the right, then lower table until you  
feel it lock in the up position.  
To lower swing-up work surface: Lift table up until it  
disengages and slide it to the left. Then lower it all the  
way down so that the locking pin on the right side of  
the table fits into the locking bracket on the leg, which  
will secure the table in the down position.  
4.) While holding swing-up work surface in position,  
insert the other end of the swing-up work surface  
rod into the left end trim piece. Push the trim piece  
into the frame.  
Do not use the work surface as a cutting board.  
C-2  
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Install the work surface  
You will need: work surface.  
Place the work surface, so that the front and back  
edges fit over the frame, in the area between the left  
trim piece and the cooking box as shown.  
Do not use the work surface as a cutting board.  
Set the side burner in place in the frame. The side  
burner locking clip on the right should latch under the  
right trim piece.  
(1)  
Tilt the side burner slightly, toward the control panel.  
Latch the side burner locking clip on the left, under the  
control panel.  
(1) Make sure that the tabs on the side table are to the  
right, next to the cooking box.  
Install side burner  
You will need: side burner,  
WARNING: Make sure gas supply is off.  
Start the side burner hose into the opening between  
the control panel and right trim piece route the hose  
between the cylinder panel and wheel frame.  
Push side burner control knob onto the valve  
C-3  
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Connect the side burner hose as follows:  
Set the cooking grates onto the ledges in the cooking  
box with the rounded sides up.  
1)  
Slide back the collar of the quick disconnect  
on the manifold.  
2)  
Push the male fitting of the side burner hose  
into the quick disconnect, and maintain  
pressure. Slide the collar closed.  
(1)  
Installing the warming rack  
You will need: warming rack.  
Set the warming rack into the slots at the rear of the  
cooking box.  
(2)  
Quick disconnect will be engaged.  
Check to be sure that the side burner valve is OFF.  
Push the side burner control knob down and turn it  
clockwise. If it doesn’t turn, the valve is OFF. If it does  
turn, continue turning it clockwise until it stops, then  
the burner is OFF.  
Installing the Warm-Up™ Basket  
You will need: Warm-Up Basket  
Insert one end of the Weber Warm-Up Basket into the  
hole at the right side of the inside of the lid, and the  
other end into the slot at the left side of the lid.  
Install Flavorizer® Bars and Cooking Grates  
You will need: five Flavorizer Bars and two cooking  
grates.  
Place the Flavorizer Bars side by side in the cooking  
box.  
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Install the thermometer  
Install the bottom shelf  
You will need: Thermometer.  
Insert the thermometer into its holder on the right side  
of the lid.  
You will need: Bottom shelf.  
Set the bottom shelf in place between the two frame  
connectors underneath the cooking box.  
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Fill liquid propane cylinder  
Note - The liquid propane cylinder manufacturer is  
responsible for the materials, workmanship and  
performance of the cylinder. If the cylinder has a  
defect, malfunctions, or you have a question regarding  
the cylinder, call the cylinder manufacturers customer  
service center. The phone number is on the warning  
decal, which is permanently attached to the cylinder. If  
the cylinder manufacturer has not resolved the issue to  
your satisfaction, then contact the Customer Service  
Representative in your region using the contact  
information sheet provided with your manual.  
To fill, take the liquid propane cylinder and filler  
adapter to an RV center or look up gas-propane in the  
phone book for other sources of liquid propane gas.  
WARNING:We recommend that your liquid  
propane cylinder be filled at an authorized liquid  
propane gas dealer by a qualified attendant, who  
fills the tank by weight.  
2) Loosen the cylinder lock wing nut. Swing the  
cylinder lock down. Tighten the wing nut.  
IMPROPER FILLING IS DANGEROUS.  
Tell your liquid propane dealer that this is a new liquid  
propane cylinder. The air must be removed from a new  
liquid propane cylinder before the initial filling. Your  
liquid propane cylinder dealer is equipped to do this.  
The liquid propane cylinder must be installed,  
transported and stored in an upright position, and  
should not be dropped or handled roughly.  
To Connect the hose to the cylinder:  
3) Remove the plastic dust cover from the valve.  
4) Screw the regulator coupling onto the tank valve,  
clockwise, or to the right. Hand-tighten only.  
Never store or transport the liquid propane cylinder  
where temperatures can reach 125° Fahrenheit (too  
hot to hold by hand for example: do not leave the  
liquid propane cylinder in a car on a hot day).  
For full instructions on safe handling of liquid propane  
cylinders, see Section Operating.  
Connecting the Liquid Propane Cylinder  
WARNING: Make sure that the LP cylinder valve  
is closed. Close by turning valve clockwise.  
Note: This is a new type of connection. It tightens  
clockwise and will not allow gas to flow unless the  
connection is tight. The connection requires tightening  
by hand only.  
WARNING: Do not use a wrench to tighten the  
connection. Using a wrench could damage the  
regulator coupling and could cause 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. Sparks or flames will result in a fire  
or explosion which can cause serious  
bodily injury or death, and damage to  
Checking the fuel level in your tank  
Check the fuel level by viewing the color indicator level  
line on the side of the tank scale.  
1) Empty  
2) Medium  
property.  
We utilize various LP tank manufacturers. Some of  
the tanks have differing top collar assembles. (The top  
collar is the metal protective ring around the valve.)  
One series of tanks mount with the valve facing front.  
The other tanks mount with the valve facing away from  
the fuel scale. These types of tanks are illustrated  
below.  
3) Full  
(2)  
(1)  
(3)  
You will need: LP cylinder, a soap and water solution  
and a rag or brush to apply it.  
1) Turn the LP cylinder so the opening of the valve is  
either to the front, side or rear of the Weber Gas  
Barbecue. Lift and hook the cylinder onto the fuel  
gauge.  
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Check for gas leaks  
WARNING: Do not ignite burners when 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.  
Check:  
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. Sparks or open flames will result in  
a fire or explosion, which can cause  
serious bodily injury or death and damage  
to property.  
1) Hose to manifold connection.  
WARNING: If there is a leak at connection (1),  
retighten the fitting with a wrench and recheck for  
leaks with soap and water solution.  
If a leak persists after re-tightening the fitting, turn  
OFF the gas. DO NOT OPERATE THE BARBECUE.  
Contact the Customer Service Representative in  
your region using the contact information sheet  
provided with your manual.  
WARNING:You should check for gas leaks every  
time you disconnect and reconnect a gas fitting.  
Note - All factory-made connections have been  
thoroughly checked for gas leaks. The burners have  
been flame-tested. As a safety precaution however,  
you should recheck all fittings for leaks before using  
your Weber Gas Barbecue. Shipping and handling may  
loosen or damage a gas fitting.  
2) Regulator to cylinder connection.  
3) Manifold to side burner hose connection.  
4) Side burner hose to side burner connection.  
5) Valves to manifold connections.  
6) Hose to regulator connection.  
WARNING: Perform these leak checks even if  
your barbecue was dealer or store assembled.  
You will need: a soap and water solution, and a rag or  
brush to apply it.  
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.  
Make sure side burner is OFF.  
WARNING: If there is a leak at connections  
(2,3,4,5 or 6), turn OFF the gas. DO NOT OPERATE  
THE BARBECUE. Contact the Customer Service  
Representative in your region using the contact  
information sheet provided with your manual.  
When leak checks are complete, turn gas supply OFF  
at the source and rinse connections with water.  
(1)  
(2)  
To perform leak checks: open cylinder valve by turning  
the cylinder valve hand-wheel counterclockwise.  
(3)  
(4)  
(6)  
(5)  
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addendum sheet  
Operating  
ƽ WARNING:The burner control knobs must be in  
Lighting  
the OFF position before turning on the liquid  
propane cylinder tank valve. If they are not in the  
OFF position, when you turn on the LP cylinder  
valve, the “excess gas flow control” feature will  
activate, limiting the flow of gas from the LP  
cylinder. If this should occur, turn OFF the LP  
cylinder valve and burner control knobs.Then start  
over.  
Summary lighting instructions are on the control panel.  
ƽ DANGER  
Failure to open the lid while igniting the  
barbecue’s burners, or not waiting 5  
minutes to allow the gas to clear if the  
barbecue does not light, may result in an  
explosive flame-up which can cause  
serious bodily injury or death.  
ƽ DANGER:  
When the “excess gas flow control” feature is  
activated, a small amount of gas I still flowing to  
the burners. After turning OFF the cylinder 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.  
3) Turn the cylinder on by turning the cylinder valve  
ƽ 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 hose. Contact the  
Customer Service Representative in your region  
using the contact information sheet provided with  
your manual.  
counterclockwise.  
ƽ WARNING: Do not lean over the open barbecue.  
Keep your face and body at least one foot away  
from the matchlight hole when lighting the  
barbecue.  
4) Push Front burner control knob down and turn to  
START/HI.  
5) Push the Crossover Ignition Button several times,  
so it clicks each time.  
1
6) Check that the burner is lit by looking through the  
matchlight hole on the front of the cooking box.You  
should see a flame.  
ƽ 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
7
7) After the FRONT burner is lit you can turn on the  
other burner or burners.  
Note - Always light the FRONT burner first. The other  
burner or burners ignite from the FRONT burner.  
3
6
4
5
*The grill illustrated may have slight differences than  
the model purchased.  
To Extinguish  
Push down and turn each burner control knob  
clockwise to the OFF position.Turn gas supply  
OFF at the source.  
1) Open the lid.  
2) Make sure all burner control knobs are turned  
OFF. (Push control knob down and turn clockwise  
to ensure that it is in the OFF position.)  
D-1  
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3) Turn the cylinder on by turning the cylinder valve  
counterclockwise.  
Manual Lighting  
4) Strike a match and put the flame into the  
matchlight hole in the front of the cooking box.  
ƽ 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.  
ƽ DANGER  
Failure to open the lid while igniting the  
barbecue’s burners, or not waiting 5 minutes  
to allow the gas to clear if the barbecue does  
not light, may result in an explosive flame-  
up which can cause serious bodily injury or  
death.  
5) Push Front burner control knob down and turn to  
START/HI.  
6) Check that the burner is lit by looking through the  
matchlight hole on the front of the cooking box.You  
should see a flame  
ƽ 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.  
1) Open the lid.  
2) Make sure all burner control knobs are turned OFF.  
(Push each knob down and turn clockwise to  
ensure they are in the off position.)  
ƽ WARNING:The burner control knobs must be in  
the OFF position before turning on the liquid  
propane cylinder valve. If they are not in the OFF  
position, when you turn on the LP cylinder valve,  
the “excess gas flow control” feature will activate,  
limiting the flow of gas from the LP cylinder. If this  
should occur, turn OFF the LP tank valve and  
burner control knobs.Then start over.  
7) After the FRONT burner is lit you can turn on the  
other burner.  
Note - Always light the FRONT burner first. The other  
burner or burners ignite from the FRONT burner.  
To Extinguish  
ƽ DANGER  
Push down and turn each burner control knob  
clockwise to the OFF position.Turn gas supply  
OFF at the source.  
When the “excess gas flow control”  
feature is activated, a small amount of gas  
is still flowing to the burners. After turning  
OFF the cylinder 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
2
7
3
4,6  
5
*The grill illustrated may have slight differences than  
the model purchased.  
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Lighting the side burner if the main burners are lit.  
1) Open the side burner lid.  
2) Push down and turn the side burner control to HI.  
3) Press the side burner igniter button several times so  
Lighting the Side Burner  
The side burner has a separate ignition system from  
the main cooking box.  
it clicks each time.  
ƽ CAUTION: Side burner flame may be difficult to  
see on a bright sunny day.  
ƽ DANGER  
Failure to open the lid while igniting the side  
burner, or not waiting 5 minutes to allow the  
gas to clear if the side burner does not light,  
may result in an explosive flame-up which  
can cause serious bodily injury or death.  
1
2
Lighting only the side burner.  
1) Open the side burner lid.  
3
2) Check that the side burner valve is turned OFF.  
(Push each knob down and turn clockwise to  
ensure they are in the off position.), and all main  
burner control valves are OFF (push down and  
turn clockwise).  
3) Turn the LP tank valve on (turn counter-clockwise).  
4) Push down and turn the side burner control valve  
to HI.  
ƽ WARNING: If the side burner does not light:  
1) Turn OFF the side burner control valve.  
2) Wait 5 minutes to let the gas clear before  
you try again or try to light with a match.  
5) Push the side burner igniter button several times  
so it clicks each time.  
ƽ CAUTION: Side burner flame may be difficult to  
see on a bright sunny day.  
1
2, 4  
5
ƽ WARNING: If the side burner does not light:  
1) Turn OFF the side burner control valve.  
2) Wait 5 minutes to let the gas clear before  
you try again or try to light with a match.  
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The Weber Gas Barbecue should be checked for  
gas leaks and any obstructions in the burner tubes  
before using. (See Sections: General Maintenance  
and Annual Maintenance.)  
Check that the areas under the control panel and  
the slide out bottom tray are free from debris that  
might obstruct the flow of combustion or ventilation air.  
The Spider /Insect Screens should also be checked  
for any obstructions. (See Section: Annual  
Maintenance.)  
Cooking  
ƽ WARNING: Do not move the Weber Gas  
Barbecue when operating or while barbecue is hot.  
You can adjust the FRONT 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 and BACK  
burners. For example, to sear steaks, you would set all  
burners at H (high). Then to complete cooking, you  
would set FRONT and BACK at M (medium). Refer to  
your Weber cookbook for detailed cooking instructions.  
Cleaning  
ƽ WARNING:Turn your Weber Gas Barbecue OFF  
and wait for it to cool before cleaning.  
Note: The temperature 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. Such as wind and weather, may  
require the adjustment of the burner controls to obtain  
the correct cooking temperatures.  
ƽ CAUTION: Do not clean your Flavorizer® Bars or  
cooking grates in a self-cleaning oven.  
For availability of replacement cooking grates and  
Flavorizer Bars contact the Customer Service  
Representative in your region using the contact  
information sheet provided with your manual.  
Outside surfaces - Use a warm soapy water solution  
to clean, then rinse with water.  
ƽ CAUTION: Do not use oven cleaner, abrasive  
cleansers (kitchen cleansers) cleaners that contain  
citrus products, or abrasive cleaning pads on  
barbecue or cart surfaces.  
Slide out Bottom tray - Remove excess grease, then  
wash with warm soapy water, then rinse  
Flavorizer® Bars and Cooking Grates - Clean with a  
suitable brass bristle brush. As needed, remove from  
grill and wash with warm soapy water, then rinse with  
water.  
ƽ 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 five minutes before relighting.  
Preheating - Your Weber Gas Barbecue is an energy-  
efficient appliance. It operates at an economical low  
BTU rate. To preheat: after lighting, close lid and turn  
all burners to high (HH). 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.  
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, then rinse.  
Thermometer - Wipe with warm soapy water; clean  
with plastic scrub ball. Do not put in dishwasher or  
submerge in water.  
Drippings and grease - The Flavorizer® Bars are  
designed to smokethe correct amount of drippings  
for flavorful cooking. Excess drippings and grease will  
accumulate in the catch pan under the slide out bottom  
tray. Disposable foil drip pans are available that fit the  
catch pan.  
Inside cooking module - Brush any debris off of  
burner tubes. DO NOT ENLARGE BURNER PORTS  
(OPENINGS). Wash inside of cooking box with warm  
soapy water and a water rinse.  
ƽ WARNING: Check the bottom tray for grease  
build-up before each use. Remove excess grease  
to avoid a grease fire in the slide out bottom tray.  
Inside Lid - While lid is warm, wipe inside with paper  
towel to prevent grease build-up. Flaking built-up  
grease resembles paint flakes.  
Stainless steel surfaces - Wash with a soft cloth and  
a soap and water solution.  
Thermoset surfaces - Wash with a soft cloth and a  
soap and water solution.  
Do not use cleaners that contain acid, mineral  
spirits or xylene. Rinse well after cleaning.  
Storage and/or Nonuse  
The gas must be turned off at the liquid propane  
cylinder 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  
cylinder stored outdoors in a well-ventilated space.  
LP cylinder must be stored outdoors in a well -  
ventilated area out of reach of children. Disconnected  
LP cylinder must not be stored in a building, garage or  
any other enclosed area.  
Thermoset work surfaces are not to be used as  
cutting boards.  
When the LP cylinder is not disconnected from the  
Weber Gas Barbecue, the appliance and LP tank must  
be kept outdoors in a well-ventilated space.  
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The LP cylinder supplied with your barbecue is  
equipped with an OPD (Overfilling Prevention  
Device) and a QCC1 or Type 1 (CGA810) cylinder  
connection.The cylinder connection is compatible  
with the barbecue connection.  
This is a secondary device to prevent the overfilling of  
your LP cylinder. The proper filling methods for the  
filling of your cylinder are by weight or volume, as  
described in NFPA 58. Please make sure your filling  
station fills your LP cylinder by weight or volume. Ask  
your filling station to read purging and filling  
instructions on the LP cylinder before attempting to fill.  
ƽWARNING: Do not exchange the LP tank  
provided with your barbecue, unless the exchange  
LP tank is equipped with an OPD. Otherwise you  
will lose the OPD (Overfilling Prevention Device)  
feature. If there is not an LP tank available for  
exchange equipped with an OPD, we recommend  
that you have your LP tank filled at an authorized  
LP gas dealer by a qualified attendant.  
Refilling the Liquid  
Propane Cylinder  
We recommend that you refill the LP cylinder before it  
is completely empty.  
Removal of the LP cylinder  
1) Close cylinder valve (turn clockwise).  
2) Unscrew regulator coupling by turning  
counterclockwise, by hand only.  
3) Loosen cylinder lock wing nut and turn cylinder  
lock up out of the way.  
4) Lift cylinder off.  
To refill, take LP cylinder to a Gas Propanedealer.  
ƽ WARNING:We recommend that your LP cylinder  
be filled at an authorized LP gas dealer, by a  
qualified attendant, who fills the cylinder by  
weight. IMPROPER FILLING IS DANGEROUS.  
ƽ CAUTION:When transporting the LP cylinder  
make sure the plastic dust cover is in place over  
the valve.This will keep dust and dirt from the  
threaded portion of the valve.  
(1)  
(3)  
Raises up while filling  
then stops when full.  
(2)  
Important LP Cylinder Information  
Failure to follow these DANGER statements exactly  
may result in a fire causing death or serious injury.  
ƽDANGER  
ƽNEVER store a spare LP Cylinder under or near  
this barbecue.  
ƽNEVER fill the tank beyond 80% full.  
Your Weber gas grill is equipped with a cylinder  
supply system designed for vapor withdrawal.  
ƽWARNING: Only use this grill outdoors in a well-  
ventilated area. Do not use in a garage, building,  
breezeway or any other enclosed area.  
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To Connect the hose to the cylinder:  
Connecting the Liquid Propane Cylinder  
ƽ WARNING: Make sure that the LP cylinder valve  
is closed. Close by turning valve clockwise.  
3) Remove the plastic dust cover from the valve.  
4) Screw the regulator coupling onto the tank valve,  
clockwise, or to the right. Hand-tighten only.  
ƽ 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. Sparks or flames will result in a fire  
or explosion which can cause serious  
bodily injury or death, and damage to  
property.  
We utilize various LP tank manufacturers. Some of the  
tanks have differing top collar assembles. (The top  
collar is the metal protective ring around the valve.)  
One series of tanks mount with the valve facing front.  
The other tanks mount with the valve facing away from  
the fuel scale. These types of tanks are illustrated  
below.  
Note: This is a new type of connection. It tightens  
clockwise and will not allow gas to flow unless the  
connection is tight. The connection requires tightening  
by hand only.  
ƽ WARNING: Do not use a wrench to tighten the  
connection. Using a wrench could damage the  
regulator coupling and could cause a leak.  
5) Mix soap and water.  
You will need: LP cylinder, a soap and water solution  
and a rag or brush to apply it.  
1) Turn the LP cylinder so the opening of the valve is  
either to the front, side or rear of the Weber Gas  
Barbecue. Lift and hook the cylinder onto the fuel  
gauge.  
6) Turn on the cylinder valve.  
7) 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 there is a leak, turn off the gas and tighten the fitting.  
Turn the gas back on and recheck with the soap and  
water solution.  
2) Loosen the cylinder lock wing nut. Swing the  
cylinder lock down. Tighten the wing nut.  
If leak does not stop, Contact the Customer Service  
Representative in your region using the contact  
information sheet provided with your manual. Do not  
use the barbecue.  
8) When leak checking is complete, turn gas supply  
OFF at the source and rinse connections with  
water.  
Liquid Propane Cylinder  
The liquid propane cylinder 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 manufacturers 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 contact the Customer Service  
Representative in your region using the contact  
information sheet provided with your manual.  
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Liquid Propane (LP) Cylinder(s)  
Safe handling tips for  
Liquid Propane Gas  
Cylinders  
The joint where the hose connects to the LP cylinder  
must be leak tested each time the LP cylinder is  
reconnected. For example, test each time the LP  
cylinder is refilled.  
Be sure the regulator is mounted with the small vent  
hole pointed downward so that it will not collect water.  
This vent should be free of dirt, grease, bugs etc.  
The LP cylinder and connections supplied with your  
Weber Gas Barbecue have been designed and tested  
to meet government, American Gas Association, and  
Underwriters Laboratories requirements.  
Liquid Propane Cylinder requirements  
Replacement LP cylinders supplied by Weber satisfy  
the above requirements. Check to be sure other  
cylinders have a D.O.T. certification(1), and date  
tested(2) is within five years.Your LP gas supplier can  
do this for you.  
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  
becomes gas.  
LP gas has an odor similar to natural gas.You  
should be aware of this odor.  
LP gas is heavier than air. Leaking LP gas may  
collect in low areas and prevent dispersion.  
To fill, take the LP cylinder to an RV center, or look  
up gas-propanein the phone book for other sources  
of LP gas.  
ƽ WARNING:We recommend that your LP cylinder  
be filled at an authorized LP gas dealer, by a  
qualified attendant, who fills the tank by weight.  
IMPROPER FILLING IS DANGEROUS.  
(1)  
DOT 4BA240  
ƽ WARNING: If you exchange your LP cylinder,  
make sure you get a similar tank in return.Your LP  
cylinder is equipped with a quick closing coupling  
or type 1 valve and an OPD (Overfilling Prevention  
Device). Other LP cylinders may not be compatible  
with your barbecue connection.  
Air must be removed from a new LP cylinder before  
the initial filling.Your LP dealer is equipped to do this.  
The LP cylinder must be installed, transported and  
stored in an upright position. LP cylinders should not  
be dropped or handled roughly.  
Never store or transport the LP cylinder where  
temperatures can reach 125° F (too hot to hold by  
hand - for example: do not leave the LP cylinder 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.  
00/01  
(2)  
If you have questions about spare LP cylinders  
contact the Customer Service Representative in  
your region using the contact information sheet  
provided with your manual.  
All LP tank supply systems must include a collar to  
protect the cylinder valve.  
The LP cylinder must be a 20-lb. size (18 1/4 inches  
high, 12 1/4 inches in diameter).  
The LP cylinder must be constructed and marked in  
accordance with the specifications for LP gas cylinders  
of the U.S. Department of Transportation (D.O.T.).  
Treat emptyLP cylinders with the same care as  
when full. Even when the LP tank is empty of liquid  
there still may be gas pressure in the cylinder. Always  
close the cylinder valve before disconnecting.  
ƽ CAUTION:When transporting the LP cylinder  
make sure the plastic dust cover is in place over  
the valve.This will keep dust and dirt from the  
threaded portion of the valve.  
Do not use a damaged LP cylinder. Dented or rusty  
LP cylinders or LP cylinders with a damaged valve  
may be hazardous and should be replaced with a new  
one immediately.  
For Canada Only  
Liquid Propane Cylinder requirements  
ƽ WARNING: Replacement LP tanks must match  
the regulator connection supplied with this  
barbecue.  
Note:Your retailer can help you match a replacement  
tank to your barbecue  
All LP tank supply systems must include a collar to  
protect the cylinder valve.  
The LP cylinder must be a 20-lb. size (18 1/4 inches  
high, 12 1/4 inches in diameter).  
The LP cylinder must be constructed and marked in  
accordance with the specifications for LP gas  
cylinders, T.C.  
D-7  
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your region using the contact information sheet  
provided with your manual.  
2) Regulator to tank connection.  
3) Manifold to side burner hose connection.  
4) Side burner hose to side burner connection  
5) Valves to manifold connection.  
Annual Maintenance  
After a period of nonuse, we recommend that you  
perform the following maintenance procedures for your  
safety.  
ƽ WARNING: Check the hose before each use of  
the 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 hose. Contact the  
Customer Service Representative in your region  
using the contact information sheet provided with  
your manual.  
Inspect the burners for correct flame pattern. Clean  
if necessary, following the procedures outlined in the  
General Maintenancesection of this manual.  
Check all gas fittings for leaks.  
6) Hose to regulator connection.  
ƽ WARNING: If there is a leak at connections  
(2,3,4,5 0r 6), turn OFF the gas. DO NOT OPERATE  
THE BARBECUE. Contact the Customer Service  
Representative in your region using the contact  
information sheet provided with your manual.  
When leak checks are complete, turn gas supply OFF  
at the source and rinse connections with water.  
(1)  
(2)  
ƽ 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. Sparks or flames will result in a fire  
or explosion, which can cause serious  
bodily injury or death, and damage to  
property.  
(3)  
(4)  
ƽ WARNING:You should check for gas leaks every  
time you disconnect and reconnect a gas fitting.  
Note - All factory-made connections have been  
thoroughly checked for gas leaks. The burners have  
been flame tested. As a safety precaution however,  
you should recheck all fittings for leaks before using  
your Weber Gas Barbecue. Shipping and handling may  
have loosened or damaged a gas fitting.  
(6)  
(5)  
ƽ WARNING: Perform these leak checks even if  
your barbecue was dealer- or store-assembled.  
You will need: a soap and water solution and a rag or  
brush to apply it.  
*The grill illustrated may have slight differences than  
the model purchased.  
Inspection and cleaning of the Spider/Insect  
screens  
To perform leak checks: Make sure all Burners are in  
the off position. Turn on gas supply.  
ƽ 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.  
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.  
Check:  
To inspect the spider/insect screens, remove the  
control panel. If there is dust or dirt on the screens,  
remove the burners for cleaning the screens. Refer to  
Maintenance, Replacing Main Burners. Brush the  
spider/inspect screens, lightly, with a soft bristle brush  
(i.e. an old toothbrush).  
ƽCaution: Do not clean the spider/insect screens  
with hard or sharp tools. Do not dislodge the  
spider/insect screens or enlarge the screen  
openings.  
1) Hose to manifold connections.  
ƽ WARNING: If there is a leak at connection (1), re-  
tighten the fitting with a wrench and recheck for  
leaks with a soap and water solution.  
If a leak persists after re-tightening the fitting, turn  
OFF the gas. DO NOT OPERATE THE BARBECUE.  
Contact the Customer Service Representative in  
Lightly tap the burner to get debris and dirt out of the  
burner tube. Once the spider/insect screens and  
burners are clean replace the burners.  
If the spider/insect screen becomes damaged or  
cannot be cleaned, call Weber-Stephen Products  
Customer Service for replacement parts.  
D-8  
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Main Burner Flame Pattern  
The Weber Gas Barbecue burners have been factory  
set for the correct air and gas mixture. The correct  
flame pattern is shown.  
1) Burner tube  
2) Tips occasionally flicker yellow  
3) Light blue  
General Maintenance  
Weber Spider /Insect screens  
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(1) of the burner  
tubes. This blocks the normal gas flow, and can cause  
the gas to flow back out of the air shutter. This could  
result in a fire in and around the air shutters, under the  
control panel, causing serious damage to your  
barbecue.  
4) Dark blue  
(1)  
(1)  
(2)  
(3)  
(4)  
If the flames do not appear to be uniform throughout  
the burner tube, follow the burner cleaning procedures.  
Main Burner Cleaning Procedure  
Turn off the gas supply. Remove the manifold.  
Look inside each burner with a flashlight.  
The burner tube air shutter is fitted with a stainless  
steel screen(1) to prevent spiders and other insects  
access to the burner tubes through the air shutter  
openings.  
(1)  
Clean the inside of the burners with a wire (a  
straightened-out coat hanger will work). 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.  
We recommend that you inspect the Spider/Insect  
screens at least once a year. (See Section Annual  
Maintenance.) Also inspect and clean the the  
Spider/Insect screens if any of the following  
symptoms should ever occur:  
CAUTION: Do not enlarge the burner ports when  
cleaning.  
1) The smell of gas in conjunction with the burner  
flames appearing yellow and lazy.  
2) Barbecue does not reach temperature.  
3) Barbecue heats unevenly.  
4) One or more of the burners do not ignite.  
ƽ DANGER  
Failure to correct the above mentioned symptoms  
may result in a fire, which can cause serious  
bodily injury or death, and cause damage to  
property.  
D-9  
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6) Lift and twist the burner assembly slightly, to  
separate the crossover tube(1) from the burners.  
Remove the burners from the cooking box.  
Replacing Main Burners  
1) Your Weber Gas Barbecue must be OFF and cool.  
2) Turn gas OFF at source.  
3) To remove control panel: take off the burner  
control knobs. Remove the screws holding the  
control panel in place. Lift off the control panel.  
4) Unhook the manifold bracket(1) and unscrew the  
two wing nuts(2) that hold the manifold to the  
cooking box. Pull the manifold and valve assembly  
out of the burners and carefully set it down.  
(1)  
(1)  
7) To reinstall the burners, reverse 3) through 7).  
ƽ CAUTION:The burner openings(1) must be  
positioned properly over the valve orifices(2).  
Check proper assembly before fastening manifold in  
place.  
(2)  
(2)  
5) Slide the burner assembly out from under the  
guide screw and washer(1) in the corners of the  
cooking box.  
(1)  
(1)  
ƽ 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.)  
D-10  
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Crossover® Ignition System Operations  
If the Crossover Ignition System fails to ignite the Left  
burner, light the Left burner with a match. If the Left  
burner lights with a match, then check the Crossover  
Ignition System.  
Check that both the white(1) and black(2) ignition  
wires are attached properly.  
(1)  
(2)  
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 igniterfor  
correct procedure.  
If the Crossover Ignition System still fails to light,  
Contact the Customer Service Representative in your  
region using the contact information sheet provided  
with your manual.  
D-11  
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Troubleshooting  
Problem  
Check  
Cure  
Burners burn with a yellow or  
Inspect Spider/Insect Screens for  
Clean Spider/Insect Screens. (See  
orange flame, in conjunction with possible obstructions. (Blockage of Section Annual Maintenance)  
the smell of gas.  
holes.)  
The excess flow safety device,  
which is part of the barbecue to  
cylinder connection, may have  
activated.  
To reset the excess flow safety  
device turn all burner control knobs  
and the cylinder valve OFF.  
Disconnect the regulator from the  
cylinder. Turn burner control knobs to  
HIGH. Wait at least 1 minute. Turn  
burner control knobs OFF. Reconnect  
the regulator to the cylinder. Turn  
cylinder valve on slowly. Refer to  
Lighting Instructions.  
Burners do not light. -or- Burners  
have a small flickering flame in  
the HIGH position. -or-  
Barbecue temperature only  
reaches 250˚ to 300˚ in the HIGH  
position.  
Burner does not light, or flame is  
low in HIGH position.  
Is LP fuel low or empty?  
Refill LP cylinder.  
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.  
Experiencing flare-ups:  
Are you preheating barbecue in the All burners on high for 10 to 15  
prescribed manner?  
minutes for preheating.  
Are the cooking grates and  
Flavorizer bars heavily coated with  
burned-on grease?  
Clean thoroughly. (See Section  
Cleaning)  
ƽ CAUTION: Do not line the  
bottom tray with aluminum foil.  
Is the bottom tray dirtyand not  
allowing grease to flow into catch  
pan?  
Clean bottom tray  
Burner flame pattern is erratic.  
Flame is low when burner is on  
HIGH. Flames do not run the  
whole length of the burner tube.  
Are burners clean?  
Clean burners. (See Section  
General Maintenance.)  
Inside of lid appears to be  
peeling.(Resembles paint  
peeling.)  
The lid is porcelain-on-steel, not  
Clean thoroughly. (See Section  
paint. It cannot peel. What you are Cleaning.)  
seeing is baked on grease that has  
turned to carbon and is flaking off.  
THIS IS NOT A DEFECT.  
If problems cannot be corrected by using these methods, please contact the Customer  
Service Representative in your region using the contact information sheet provided with  
your manual.  
D-12  
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Side Burner Troubleshooting  
ƽ WARNING: Before attempting any troubleshooting steps, all gas controls and supply  
valves should be in the OFF position.  
Problem  
Side Burner does not light.  
Check  
Is gas supply off?  
Cure  
Turn supply on.  
Is the fuel hose bent or kinked?  
Straighten hose.  
Flame is low in HIGH position.  
Inspect the Spider/Insect Screens  
for possible obstructions.  
(Blockage of holes.)  
Clean Spider/Insect Screens. (See  
section Annual Maintenance)  
Flame is very yellow in  
conjunction with the smell of gas,  
OR  
Burner makes popping noise in  
conjunction with the smell of gas.  
If match lights burner, checkigniter  
(see below).  
Push button ignition does not  
work.  
Does burner light with a match?  
Side Burner maintenance  
ƽ WARNING: All gas controls and supply valves  
should be in the OFF position.  
Check igniter:  
4) 1/8 to 3/16 inch gap between electrode and burner  
(4)  
Make sure wire is connected between igniter and  
electrode. Check that igniter lock nut is tight.  
Note: If the igniter works loose, carefully tighten the  
igniter lock nut with an adjustable wrench or pliers.  
Adjust igniter electrode to burner. Gap should be 1/8 to  
3/16 inch from tip of electrode to burner. Spark should  
be a white/blue color, not yellow.  
1) Igniter  
2) Igniter Wire  
3) Venturi/Burner  
(2)  
(1)  
(3)  
D-13  
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Addendum Sheet  
You may have a different style manifold bracket and Spider Stopper Guard listed in your  
instruction manual. If you do, please follow these steps below in place of the steps  
included in the manual.  
Assembly Instructions  
* See Section B *  
Install manifold bracket  
You will need: manifold bracket  
Hook the bracket(2) onto the manifold at the center  
burner valve. Place your hand underneath the bracket.  
Lift the manifold and cooking box slightly, then hook the  
* See Section A *  
tab of the bracket on the frame brace(1).  
Manifold Support Bracket - 1  
(2)  
(1)  
* See Section D *  
Operating  
The Weber Spider Stopper™ Guard(1) 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.  
General Maintenance  
Weber Spider Stopper™ Guards  
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 (Venturi(1), air shutter(2),  
venturi fin(3) ) of the burner tubes. This blocks the  
normal gas flow, and can cause the gas to flow back out  
of the air shutter. This could result in a fire in and around  
the air shutters, under the control panel, causing serious  
damage to your barbecue.  
(1)  
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
ADD US 09/30/00  
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1) The smell of gas in conjunction with the burner flames  
appearing yellow and lazy.  
the crossover tube(1) from the burners. Remove the  
burners from the cooking box.  
2) Barbecue does not reach temperature.  
3) Barbecue heats unevenly.  
(1)  
4) One or more of the burners do not ignite.  
ƽ DANGER  
Failure to correct the above mentioned  
symptoms may result in a fire, which can  
cause serious bodily injury or death, and  
cause damage to property.  
8) To reinstall the burners, reverse 3) through 7).  
ƽ CAUTION:The burner openings(1) must be  
positioned properly over the valve orifices(2).  
Check proper assembly before fastening manifold in  
place.  
Replacing Main Burners  
1) Your Weber Gas Barbecue must be OFF and cool.  
2) Turn gas OFF at source.  
3) To remove control panel: take off the burner control  
knobs. Remove the screws holding the control panel in  
place. Lift off the control panel.  
(2)  
4) Unlatch the Spider Stopper™ Guards and remove  
them.  
(1)  
5) Remove the manifold bracket and unscrew the two  
wing nuts(1) that hold the manifold to the cooking box.  
Pull the manifold and valve assembly out of the  
burners and carefully set it down.  
9) Reinstall the Spider Stopper Guards. Slightly rotate  
the Spider Stopper Guards so that the seams are in  
line with the Venturi fins(1). There should be no gaps  
in the seams or in the fit around the burners(2) and  
valves(3).  
(1)  
6) Slide the burner assembly out from under the guide  
screw and washer(1) in the corners of the cooking box.  
(1)  
(1)  
(3)  
(2)  
ƽ CAUTION: If the Spider Stopper Guards do not fit  
tightly, contact the Customer Service Representative  
in your region using the contact information sheet  
provided with your manual.  
ƽ 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.)  
7) Lift and twist the burner assembly slightly, to separate  
2
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