Weber Gas Grill FT 600 User Manual

Serial Number  
Please use this number in registering your warranty  
and any correspondence with the factory.  
FT 600  
LP Gas Barbecue  
Owners’ Manual  
E
F
®
NationalPROPANEGAS Association  
WARNING: Follow all leak check  
procedures carefully in this manual prior  
to barbecue operation. Do this even if  
barbecue was dealer assembled.  
FOR YOUR SAFETY  
1. Do not store or use gasoline or other  
flammable vapors and liquids in the  
vicinity of this or any other appliance.  
2. An LP tank not connected for use  
shall not be stored in the vicinity of  
this or any other appliance.  
NOTICE TO INSTALLER: These  
instructions must be left with the owner  
and the owner should keep them for  
future use.  
FOR YOUR SAFETY  
If you smell gas:  
1. Shut off gas to the appliance.  
2. Extinguish any open flame.  
3. If odor continues, immediately call  
your gas supplier or your fire  
department.  
THIS GAS APPLIANCE IS DESIGNED FOR  
OUTDOOR USE ONLY.  
WARNING: Do not try to light this  
appliance without reading "Lighting"  
instructions section of this manual.  
96619  
4/96  
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WARRANTY  
Weber-Stephen Products Co. (Weber) hereby  
There are no other express warrants except  
as set forth herein and any applicable implied  
warranties of merchantability and fitness are  
limited in duration to the period of coverage of  
this express written Limited Warranty. Some  
states do not allow limitation on how long an  
implied warranty lasts, so this limitation may  
not apply to you.  
warrants to the ORIGINAL PURCHASER of  
this Weber Gas Barbecue that it will be free of  
defects in material and workmanship from the  
date of purchase as follows:  
Aluminum Castings, 10 years,  
Stainless Steel Flavorizer Bars, 5 years,  
Cooking Grill, 3 years,  
Cast Iron Griddle, 1 year,  
All Remaining Parts, 5 years,  
Weber is not liable for any special, indirect or  
consequential damages. Some states do not  
allow the exclusion or limitation of incidental or  
consequential damages, so this limitation or  
exclusion may not apply to you.  
when assembled and operated in accordance  
with the printed instructions accompanying it.  
Weber may require reasonable proof of your  
date of purchase. THEREFORE, YOU  
SHOULD RETAIN YOUR SALES SLIP OR  
INVOICE.  
This Limited Warranty shall be limited to the  
repair or replacement of parts which 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 Weber-  
Stephen Products Co. Customer Service  
Center. 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.  
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.  
This Warranty applies only to products sold at  
retail.  
WEBER-STEPHEN PRODUCTS CO.  
Customer Service Center  
250 South Hicks Road  
Palatine, IL 60067-6241  
(847) 705-8660  
(800) 446-1071  
This Limited Warranty does not cover any  
failures or operating difficulties due to  
accident, abuse, misuse, alteration,  
LP Tank  
The LP tank 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 manufac-  
turer's 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 call Weber-Stephen  
Products Co., Customer Service Center.  
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.  
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.  
3
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PATENTS AND TRADEMARKS  
© 1996 Weber-Stephen Products Co. Weber,  
, Flavorizer and  
Crossover are registered U.S. trademarks; Gas Catcher is a  
trademark of Weber-Stephen Products Co., 200 East Daniels Road,  
Palatine, IL 60067-6266, U.S.A. Weber is also a registered  
trademark (Reg. TM., Marca Registrada, Marque Desposee,  
Schutzmarke) in Canada, Germany, France, Italy, Spain, Japan,  
Switzerland, Austria, Norway, Denmark, Greece, Benelux, South  
Africa, Ireland, United Kingdom, Australia, New Zealand and Korea.  
This product is covered by: U.S. Patent Nos. 4,677,964; 4,727,853;  
4,829,978; 4,860,724 and 4,941,817; Australia Patent No. 598,709  
and E83630. Printed in the U.S.A.  
4
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Contents  
WARNINGS..................................................................2  
Warranty & Patents .................................................. 3-4  
General Instructions .................................................... 6  
Assembly................................................................ 7-29  
Operating Instructions  
Lighting .........................................................30-31  
Cooking.........................................................32-33  
Storage and/or Nonuse..................................... 33  
Cleaning............................................................ 33  
Gas supply tank  
Information................................................... 34-36  
Troubleshooting & Maintenance  
Annual Maintenance.................................... 36-37  
General Maintenance .................................. 38-41  
Troubleshooting ................................................ 42  
Parts Listing ......................................................... 44-45  
c
b
a
d
b
e
a
i
h
g
f
FEATURES:  
f) Fuel scale indicates gas supply.  
a) Convenient work surfaces and racks.  
g) Catch pan catches excess grease.  
h) Separate burners for temperature control.  
i) Locking casters for additional portability.  
b) Crossover Ignition System with Gas Catcher Ignition  
Chamber.  
c) Splash guards reduce grease spatters.  
d) Cooking grill for searing and grilling foods.  
e) Cast Iron Griddle for frying foods.  
5
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General Instructions  
The Weber Gas Barbecue is a portable outdoor cooking  
appliance. With your Weber Gas Barbecue you can grill  
and barbecue with results that are difficult to duplicate  
with indoor kitchen appliances.  
Storage  
The gas must be turned OFF at the LP tank 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  
tank stored 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 you if you move.  
LP tanks must be stored outdoors in a well-  
ventilated area out of the reach of children.  
Disconnected LP tanks must not be stored in a  
building, garage or any other enclosed area.  
Liquid Propane (LP) gas supply is easy to use and  
gives you more cooking control than charcoal fuel.  
When the LP tank is not disconnected from the  
Weber Gas Barbecue, the appliance and LP tank  
must be kept outdoors in a well-ventilated space.  
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 area  
Not for use by children.  
WARNING: Only use this barbecue outdoors in a  
well ventilated area. Do not use in a garage,  
building, breezeway or any other enclosed area.  
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.  
Never use your Weber Gas Barbecue under an  
unprotected combustible roof or overhang.  
Your Weber Gas Barbecue is not intended to be  
installed in or on recreational vehicles and/or boats.  
The pressure regulator and hose supplied with the  
Weber Gas Barbecue must be used. This regulator  
is set for 10.5 inches of water column (pressure).  
Do not use combustible materials within 24 inches  
of the top, bottom, back or sides of the grill.  
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.  
The entire cooking box gets hot when in use. Do  
not leave unattended.  
Keep any electrical supply cord and the fuel supply  
hose away from any heated surface.  
Do not use with charcoal fuel.  
Check that the areas under the control panel and  
the bottom tray are free from debris that might  
obstruct the flow of combustion or ventilation air.  
Keep the cooking area clear of flammable vapors  
and liquids, such as gasoline, alcohol, etc., and  
combustible materials.  
The area around the LP tank must be free and  
clear from debris.  
Never store an extra (spare) LP tank under or near  
the Weber Gas Barbecue.  
6
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Step 1  
Assembly  
Tools needed  
Check package contents  
Cooking box  
(assembly)  
Hammer  
7/16 inch open end or an adjustable wrench  
Pliers  
Wheel frame  
Caster frame  
Block of wood  
Phillips screwdriver  
Regular screwdriver  
Supplies needed  
Bottom connectors (2)  
Back panel  
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 leaks. (See Step "Check for gas leaks.")  
Note - The hardware size of nuts, bolts and screws is  
given. For example "1/4-20 x 2 inch bolt" means a bolt  
1/4 inch in diameter with 20 threads to the inch, 2  
inches long. On a small screw for example, "6-32 x 1/2  
inch screw" means a number 6 screw, with 32 threads  
to the inch, 1/2 inch long.  
Top frame rail #1’s (2)  
Top frame rail #2’s (2)  
While we give much attention to our products,  
unfortunately an occasional error may occur.  
If a part is missing, do not go back to the store.  
Call the Weber Customer Service Center toll free  
1-800-446-1071 to receive immediate assistance. Have  
your owner’s manual and serial number of the  
barbecue available for reference.  
Splash guards (2)  
7
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Right work surface  
Tank panel assembly  
Fuel scale assembly  
Left work surface  
Catch pan holder  
Catch pan  
Bottom tray  
Flavorizer bar / Cooking grill holders (2)  
Aluminum drip pans (2)  
E R  
W
B
E
E
B
W
E
R
Wheels (2)  
Cooking grills (2)  
Accessory rack  
Griddle  
LP tank  
Flavorizer bars (11)  
LP tank filler adapter  
8
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Wheel hubcaps (3)  
(one is a spare)  
(actual size)  
Check contents of hardware packs  
Glides (4)  
Plastic button  
(actual size)  
1/4-20 x 3 1/2 inch bolts (4)  
(actual size)  
Casters (2)  
1/4-20 x 1 3/4 inch bolt  
(actual size)  
Match holder bracket  
1/4-20 x 1/2 inch bolts (6)  
(actual size)  
1/4-20 x 5/8 screw  
(actual size)  
Phillips head 1/4-20 x 1 inch machine screws (4)  
(actual size)  
1/4-20 wing nuts (2)  
(actual size)  
1/4-20 hex nut  
(actual size)  
1/4 inch nylon washers (12)  
(actual size)  
hose clamp  
9
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Step 2  
Step 3  
Assemble wheel frame  
Insert casters  
You will need: wheel frame, two wheels, two wheel  
hubcaps, hammer and a block of wood.  
You will need: caster frame and two casters.  
Push the casters firmly into the inserts in the ends of  
the caster legs. Figure 2.  
Note: Work on a carpeted area (on grass, or on one of  
the boxes) to protect the finish during the frame  
assembly.  
Set one end of wheel frame on the block of wood (or  
other hard, protected surface). Put one wheel on axle,  
WEBER side facing up, and tap on one hubcap.  
Figure 1.  
Repeat with other wheel and hubcap.  
E R  
W
B
E
E
B
W
E
R
Caster frame  
Wheel frame  
Figure 2  
Figure 1  
10  
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Turn frame assembly right side up. The fuel scale decal  
should be toward the front. Figure 4.  
Step 4  
Continue frame assembly  
You will need: Wheel frame, caster frame, two bottom  
connectors, four 1/4-20 x 3 1/2 inch bolts, four nylon  
washers and a 7/16 inch or adjustable wrench.  
Turn caster frame and wheel frame upside down, and  
space apart. Figure 3.  
Note: Fuel scale decal on wheel frame must be on  
the back side.  
Fuel scale  
decal  
Hold one bottom connector up to the wheel frame, slots  
to the outside. Add the nylon washer to the bolt. Put the  
bolt through the frame and screw into frame connector.  
Tighten bolt with a 7/16 inch or adjustable wrench.  
Hold the other end of the frame connector up to the  
caster frame, slots to the outside. Add the nylon washer  
to the bolt. Put the bolt through the frame and screw  
into the bottom connector. Tighten.  
Figure 4  
Repeat with the other bottom connector.  
(a)  
Fuel scale  
decal on  
back side  
slots to the  
outside  
Caster frame  
slots to the  
outside  
Wheel frame  
Figure 3  
11  
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Step 5  
Step 6  
Install match holder bracket  
Assemble front top frame rail  
You will need: one plastic button, match holder bracket  
and frame assembly.  
You will need: one top frame rail #1,  
one top frame rail #2, one 1/4-20 x 1/2 inch bolt, frame  
assembly and 7/16 inch or adjustable wrench.  
Align the match holder with the hole in the frame cross  
piece and insert the plastic button through the match  
holder bracket and frame.Figure 5.  
Put top frame rail #1 to your right and top frame rail #2  
to your left. Figure 6. Insert top frame rail #1 into top  
frame rail #2. Figure 6 (a).  
Uncoil match holder and chain and hang on bracket.  
Insert the bolt. Figure 6 (b). Tighten bolt with a wrench.  
(If you try to insert a bolt and there are no holes, you  
have top frame rail #2 turned the wrong way. Turn top  
frame rail #2 around.)  
View from underneath  
side of frame  
Note: Do not use a washer for this step.  
(a)  
(b)  
2
1
Figure 5  
Figure 6  
12  
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Position the top frame rail assembly with the tabs to the  
inside of the cart. Figure 7 (a).  
Step 7  
Assemble back top frame rail  
Insert the tabs into the front caster frame and front  
wheel frame, the round tubing of the top frame rail  
assembly will rest in the cut out portion of the caster  
frame and wheel frame.  
You will need: one top frame rail #1,  
one top frame rail #2, one 1/4-20 x 1/2 inch bolt, frame  
assembly and 7/16 inch or adjustable wrench.  
Put top frame rail #1 to your left and top frame rail #2 to  
your right. Insert top frame rail #1 into top frame rail #2.  
Figure 8 (a).  
(a)  
Insert the bolt. Figure 8 (b). Tighten bolt with a  
7/16 inch or adjustable wrench. (If you try to insert a  
bolt and there are no holes, you have top frame rail #2  
turned the wrong way. Turn top frame rail #2 around.)  
Note: Do not use a washer for this step.  
Cut out  
(a)  
View from  
the back  
Top frame rail  
assembly  
(b)  
Front  
caster  
frame  
1
Front wheel  
frame  
Fuel scale  
decal on  
front side  
2
Figure 7  
Figure 8  
13  
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Position the top frame rail assembly with the tabs to the  
inside of the cart. Figure 9 (a).  
Step 8  
Bolt front top frame rail assembly  
Insert the tabs onto the back caster frame and back  
wheel frame, the round tubing of the top frame rail  
assembly will rest in the cut out portion of the caster  
frame and wheel frame.  
You will need: two 1/4-20 x 1/2 inch bolts, two nylon  
washers, frame assembly and 7/16 or adjustable  
wrench.  
Slip a washer over the bolt. Insert the bolt from the  
inside of the frame assembly into the caster frame.  
Figure 10 (a).  
(a)  
Align the hole in the tab of the top frame rail assembly  
and start the bolt.  
Cut out  
Note: If there are no threads for the bolt to thread into:  
a) you may not have the holes of the frame, and top  
frame rail tab aligned.  
b) the tabs of the top rail may not be to the inside of the  
cart. Refer to Figure 7.  
Top frame rail  
assembly  
Back caster  
frame  
Repeat procedure for second bolt. Insert the bolt into  
the wheel frame and hand tighten.  
Tighten both bolts with 7/16 or adjustable wrench.  
View from  
the back  
(a)  
Tab  
Back wheel  
frame  
Caster frame  
Figure 9  
Caster frame  
Wheel frame  
Figure 10  
14  
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Align hole of back panel and wheel frame and tab of top  
frame rail assembly. Slip washer over bolt and start  
bolt. Figure 12 (a).  
Step 9  
Bolt back panel and back top frame rail  
assembly  
Note: If there are no threads for the bolt to thread into:  
You will need: back panel, two nylon washers,  
two 1/4-20 x 1/2 inch bolts and frame assembly.  
a) you may not have the holes of the back panel,  
frame, and top frame rail tab aligned.  
Position back panel cut outs to the top and the flanges  
to inside of the frame assembly. Figure 11 (a).  
b) the tabs of the top rail may not be to the inside of the  
cart. Refer to Figure 9.  
Repeat with second bolt aligning back panel and hole in  
caster frame and tab of top frame rail assembly.  
Slip washer and start bolt.  
Flange  
(a)  
Tighten both bolts with 7/16 or adjustable wrench.  
(a)  
Caster frame  
Cut out  
Wheel frame  
Figure 11  
Figure 12  
15  
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Step 10  
Step 11  
Add tank panel  
Add fuel scale  
You will need: tank panel assembly,  
1/4-20 x 1 3/4 inch bolt, 1/4-20 hex nut, two 1/4 inch  
nylon washers, pliers, and a 7/16 inch or adjustable  
wrench.  
You will need: fuel scale assembly, two 1/4-20 wing  
nuts and two nylon washers.  
Slip the bolts on the back of the fuel scale assembly  
through the two small holes in the tank panel. Make  
sure indicator rod of fuel scale is on the left side of the  
wheel frame.  
Insert the tank panel tabs into the slots in the wheel  
frame brace. Slide up until the notch at the bottom of  
the tank panel fits over the cross brace of wheel frame.  
Figure 13 (a).  
Add washers, then wing nuts and tighten. Figure 14.  
Add the washer to the bolt. Put the bolt through panel  
and cross brace. Add washer and hex nut and tighten  
with 7/16 inch or adjustable wrench holding the nut  
with the pliers. Figure 13 (b).  
Slot in frame brace  
(a)  
Tabs on tank panel  
Wheel frame  
E
E
F
F
View from front left  
View from front right  
(b)  
Figure 14  
Cross brace  
of wheel frame  
Figure 13  
16  
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Step 12  
Add cooking box assembly  
The cooking box assembly fits into place between the  
two flanges in the back panel. The entire cooking box  
assembly rests on the top frame rails. Figure 16 (a).  
You will need: frame assembly and cooking box  
assembly.  
Note: This assembly takes two people to lift the  
cooking box assembly into the frame.  
Flanges  
Uncoil the hose.  
(a)  
Set the cooking box into the frame so the control panel  
is under the top frame rail. Figure 15.  
Cooking box  
assembly  
Control  
panel  
Figure 15  
Figure 16  
17  
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Put your fingers under the front edge of the control  
panel and lift up and pull evenly toward you.  
Figure 19 (a).  
Step 13  
Remove the control panel and the front panel  
Take off all 6 burner control knobs.  
Front edge of the  
control panel  
Pull up on the ignition buttons until they stay in the up  
position. Figure 17.  
Burner control knobs  
(a)  
Front Panel  
Control Panel  
Ignition button  
Figure 19  
Figure 17  
Pull the front panel up and out of the cooking box  
assembly. Figure 20.  
The control panel is separate from the front panel. The  
control panel needs to be removed before the front  
panel can be removed. Figure 18.  
Front panel  
Control  
panel  
Front  
panel  
Figure 20  
Figure 18  
18  
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Step 14  
Step 15  
Check burner alignment  
Set LP fuel scale  
You will need: LP tank (empty).  
Your Weber Gas Barbecue burner assembly has been  
factory assembled, pressure and flame tested. As a  
safety precaution we recommend you check the burner  
alignment. Figure 21.  
Note - For accuracy, the fuel scale must be set with an  
empty tank.  
We utilize various LP tank manufacturers. Some of the  
tanks we receive have differing top collar assemblies.  
(The top collar is the metal protective ring around the  
valve.) One series of tanks mounts with the valve  
facing front. The other tanks mount with the valve  
facing away from the fuel scale. These types of tanks  
are illustrated in Figure 22.  
a) Are the mounting clips that hold the manifold and  
burner assembly in place? Figure 21 (a).  
b) Do the valves fit into the ends of the burners?  
Figure 21 (b).  
c) Is the end of each burner inserted into its locating  
slot? Figure 21 (c).  
Loosen the tank lock wing nut. Tighten so the lock is  
held up out of the way. Figure 22 (a). Lift and hook the  
tank onto the fuel scale. With an empty LP tank, adjust  
the fuel scale setting to E with scale setting (top) wing  
nut. Figure 22 (b).  
(b)  
ƽCAUTION: Do not remove adjustment wing nut  
from tank scale.  
(a)  
After adjusting tank scale, push tank down a couple of  
times to check that the tank scale is set on “E”.  
(c)  
Scale setting  
Tank lock  
wing nut  
wing nut  
(a)  
(b)  
E
E
F
Figure 21  
F
Figure 22  
19  
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Step 16  
Step 17  
Fill LP tank  
Check that burners are off  
You will need: one burner control knob.  
Note - The LP tank 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  
manufacturer's 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 call Weber-  
Stephen Products Co., Customer Service Center.  
Valves are shipped in the off position, but you should  
check to be sure. 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. Figure 23.  
Take the LP tank to an RV center (or some other source  
of LP gas) to fill the tank with 20 pounds of liquid  
propane.  
ƽWARNING: We recommend that your LP tank be  
filled at an authorized LP gas dealer by a qualified  
attendant, who fills the tank by weight.  
IMPROPER FILLING IS DANGEROUS.  
Tell your LP dealer that this is a new LP tank. The air  
must be removed from a new LP tank before the initial  
filling. Your LP tank dealer is equipped to do this.  
Figure 23  
ƽCAUTION: If you exchange your LP tank, make  
sure you get a similar tank in return. Your LP tank is  
equipped with a quick-disconnect valve. Other LP  
tanks are not compatible with your barbecue  
connection.  
The LP tank must be installed, transported and stored  
in an upright position. LP tank should not be dropped or  
handled roughly.  
Never store or transport the LP tank where  
temperatures can reach 125° Fahrenheit (too hot to  
hold by hand – for example: do not leave the LP tank in  
a car on a hot day).  
For full instructions on safe handling of LP tanks, see  
Section "Operating Instructions".  
20  
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The hose and regulator are connected in the following  
manner:  
Step 18  
Connect LP tank  
Slide back the collar of the quick disconnect on the tank  
valve. Push the male fitting of the regulator into the  
quick disconnect, and maintain pressure. Slide the collar  
closed. Figure 26 (a). Figure 26 (b) shows the quick  
disconnect engaged and various components of the  
tank and regulator. Regulator vent hole should be at  
3, 6, or 9 o'clock. It should not be pointed up.  
Figure 26 (c).  
You will need: hose clamp and 1/4-20 x5/8 screw,  
regular screwdriver.  
ƽWARNING: Make sure that the LP tank valve is  
closed. Close by turning clockwise.  
Hook the LP tank onto the fuel scale. Loosen the tank  
lock wing nut. Swing the tank lock down. Tighten the  
wing nut. Figure 24.  
(a)  
E
Tank lock  
wing nut  
Collar  
F
Male  
fitting  
Figure 24  
Put the clamp over the hose. Insert the screw through  
the hose clamp and into the threaded hole in the side of  
the wheel frame leg. Tighten. Figure 25.  
(b)  
Hose  
ƽWARNING: Hose must be in front of the wheel  
frame leg.  
Valve handwheel  
close clockwise  
Tank valve  
ƽWARNING: Make sure that the hose cannot come  
in contact with the cooking box assembly.  
Regulator  
Pressure  
relief valve  
Tank  
Regulator  
vent  
Quick disconnect  
engaged  
(c)  
a)  
Turn so regulator vent  
does not collect water  
Figure 26  
Hose  
Hose  
clamp  
Hole in side  
of wheel  
frame leg  
Figure 25  
21  
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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.  
Step 19  
Check for gas leaks  
ƽWARNING: Do not ignite burners while leak  
ƽ DANGER ƽ  
checking.  
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. This will result in a fire or  
Check:  
a) Left valves to manifold connection. Figure 27 (a).  
b) Center valves to manifold connection. Figure 27 (b).  
c) Right valves to manifold connection. Figure 27 (c).  
d) Hose to manifold connection. Figure 27 (d)  
explosion which can cause serious bodily  
injury or death and damage to property.  
ƽWARNING: You should check for gas leaks every  
ƽWARNING: If there is a leak at connection 27 (d)  
turn OFF the gas and retighten the fitting with a  
wrench and recheck for leaks with soap and water  
solution.  
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 you should  
recheck all fittings for leaks before using your Weber  
Gas Barbecue. Shipping and handling may have  
loosened or damaged a gas fitting.  
If a leak persists after retightening the fitting, turn  
OFF the gas. DO NOT OPERATE THE BARBECUE.  
Contact your dealer.  
a) Hose to regulator connection. Figure 28 (a).  
b) Regulator to tank connection. Figure 28 (b).  
You will need: a soap and water solution and a rag or  
brush to apply it.  
To perform leak checks: Open tank valve by turning the  
tank valve handwheel counterclockwise.  
ƽWARNING: If there is a leak at connections 27 (a),  
27 (b), 27 (c) or 28 (a), turn OFF the gas. Do not  
operate the barbecue. Contact your dealer.  
Figure 26.  
b)  
ƽWARNING: If there is a leak at connection 28 (b)  
retighten and recheck for leaks with soap and  
water.  
a)  
When leak checks are complete, turn gas supply OFF  
at the source and rinse connections with water.  
c)  
Manifold  
b)  
a)  
d)  
Figure 28  
Manifold  
Figure 27  
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Step 20  
Step 21  
Install Flavorizer Bar/cooking grill support  
You will need: two Flavorizer Bar/cooking grill supports.  
Install Flavorizer Bars  
You will need: eleven flavorizer bars.  
Slide one Flavorizer Bar/cooking grill support behind the  
bracket in the rear of the cooking box assembly.  
Figure 29 (a).  
Set the Flavorizer bars front to back over the burners in  
the slots of the Flavorizer Bar/cooking grill support.  
Figure 30 (a).  
Slide the second Flavorizer Bar/cooking grill support  
behind the brackets at the front of the cooking box  
assembly. Figure 29.  
Flavorizer Bar/cooking grill  
support  
Slides behind this bracket  
Flavorizer Bar  
Flavorizer Bar/cooking grill  
support  
Slot  
Rear  
Front  
Figure 30  
Figure 29  
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Step 22  
Install splash guards  
You will need: two splash guards  
Splash guards open for use. Figure 32.  
Position splash guard, flanges to the rear, at the back of  
the cooking box assembly. Figure 31 (a). Insert both  
wire ends into the mounting holes in the cooking box.  
Figure 31.  
Note: You will have to bend the splash guards slightly  
to fit into the mounting holes.  
Position the second splash guard, flanges facing you, at  
the front of the cooking box assembly. Insert both wire  
ends into the mounting holes in the cooking box.  
Figure 31.  
(a)  
Flanges at the  
back of the  
splash guards  
Figure 32  
Splash guards  
Mounting holes  
Splash guards closed for storage. Figure 33.  
(b)  
Figure 33  
Figure 31  
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The open “U” of the cooking grill goes down. Set both  
cooking grills in place next to the griddle. Figure 35.  
Step 23  
Install Cooking Grills and Griddle  
You will need: two cooking grills and one griddle.  
Set the griddle on top of the Flavorizer Bar/cooking grill  
support. Figure 34.  
ƽCAUTION: The drain hole of the griddle needs to  
be toward the front.  
Figure 35  
Figure 34  
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Step 24  
Step 25  
Install left work surface and glides  
Install right work surface and glides  
You will need: left work surface, two nylon (plastic)  
glides, two Phillips head 1/4-20 x 1 inch machine  
screws and a Phillips screwdriver.  
You will need: right work surface, two nylon (plastic)  
glides, two Phillips head 1/4-20 x 1 inch machine  
screws and a Phillips screwdriver.  
Set the left work surface over the top of the cooking box  
and the top frame rails. Figure 36. The left work surface  
will cover half of the handles on the left side.  
Set the right work surface over the top of the cooking  
box and the top frame rails. Figure 37. The right work  
surface will cover half of the handles on the right side.  
Position the glide as shown in figure 36 (a). Align the  
front hole in the left work surface and the glide.  
Position the glide as shown in figure 37 (a). Align the  
front hole in the right work surface and the glide.  
Thread screw in and tighten with a Phillips screwdriver.  
Figure 36 (b).  
Thread screw in and tighten with a Phillips screwdriver.  
Figure 37 (b).  
Repeat the procedure with the second glide at the rear  
of the left work surface.  
Repeat the procedure with the second glide at the rear  
of the right work surface.  
ƽWARNING: The load limit for the work surface is  
25 pounds.  
ƽWARNING: The load limit for the work surface is  
25 pounds.  
(a)  
(a)  
(b)  
(b)  
Figure 37  
Figure 36  
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Step 26  
Pull igniter buttons up until they stay in the up position.  
Place the control panel into the grooves on either side  
of the front of the cooking box. Push the control panel  
into place, using even pressure while pushing.  
Figure 39 (a).  
Reinstall front panel, control panel and burner  
control knobs  
You will need: control panel, front panel, and four  
burner control knobs.  
With the Weber logo to the left, slide front panel down  
into place. Figure 38.  
Use your fingers to lift the front edge of the control  
panel slightly and set it into the recess on both sides of  
the cooking box. Figure 39.  
(a)  
Figure 38  
Front Panel  
Control Panel  
Figure 39  
Push on the burner control knobs. Figure 40.  
Figure 40  
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Slide the bottom tray into the mounting slots under the  
bottom of the cooking box with the finger grip of the  
catch pan toward you. Figure 43.  
Step 27  
Install bottom tray  
You will need: Bottom tray, catch pan holder, catch  
pan, and one drip pan.  
ƽCAUTION: Do not line the bottom tray with  
aluminum foil. It can cause grease fires by trapping  
the grease and not allowing grease to flow into the  
catch pan.  
Figure 41  
Note: It may be easier to install the catch pan holder  
by removing the catch pan from the holder.  
Hook the ends of the catch pan holder into the hole in  
the bottom tray. Figure 42.  
Figure 43  
View from front of the Cooking Box  
Mounting  
slots  
Mounting  
slots  
Tabs of  
bottom tray  
Figure 42  
Tabs of  
bottom tray  
Figure 44  
Put the foil drip pan into the catch pan.  
28  
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Step 28  
Add accessory rack  
You will need: accessory rack.  
Set the bottom rack between the two bottom  
connectors. Figure 45.  
Figure 45  
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OPERATING INSTRUCTIONS  
1) Open the sliding work surfaces and splash guards.  
Lighting  
Figure 1.  
EACH HEAT ZONE OPERATES INDEPENDENTLY.  
2) Check that the fuel scale reads more than “E”.  
Note - E = empty; F = full.  
Summary lighting instructions are on the control panel.  
3) Make sure all burner control knobs are OFF. (Push  
each burner control knob down and turn clockwise.)  
ƽWARNING: The burner control knobs must be in  
the OFF position before turning on the LP tank  
valve. If they are not in the OFF position, when you  
turn on the LP tank valve, the excess flow control  
will activate, limiting the flow of gas from the LP  
tank. If this should occur, turn OFF the LP tank valve  
and burner control knobs and start over.  
High Medium  
Low  
Off  
ƽ DANGER ƽ  
Failure to open sliding work surfaces  
while igniting the barbecue, 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 ƽ  
When the excess flow control is  
activated, a small amount of gas is still  
flowing to the burners. After turning OFF  
the tank 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.  
Crossover Ignition System  
Note - The Crossover Ignition System ignites the Left  
burner of each heat zone 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.  
4) Turn the tank on by turning the tank valve  
counterclockwise.  
ƽWARNING: 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. Contact your dealer.  
ƽWARNING: Do not lean over open barbecue. Keep  
your face and body at least one foot away from the  
matchlight hole when lighting the barbecue.  
Crossover Ignition System  
5) Select Heat Zone.  
1
6) Push LEFT burner control knob down and turn to  
START/ HI.  
7) Push the Crossover Ignition Button several times,  
so it clicks each time.  
8) Check that the burner is lit by looking through the  
matchlight hole above the burner control knob.  
ƽWARNING: If the burner does not light, turn the  
LEFT 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.  
4
3
9) After the LEFT burner is lit you can turn on the  
RIGHT burner.  
Note - Always light the LEFT burner first. The RIGHT  
burner ignites from the LEFT burner.  
2
To Extinguish  
Figure 1  
Turn gas supply OFF at the source, then push down  
and turn each burner control knob clockwise to OFF.  
30  
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Manual Lighting  
EACH HEAT ZONE OPERATES INDEPENDENTLY.  
ƽ DANGER ƽ  
When the excess flow control is activated,  
a small amount of gas is still flowing to the  
burners. After turning OFF the tank 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.  
High Medium  
Low  
Off  
ƽ DANGER ƽ  
Failure to open sliding work surfaces  
while igniting the barbecue, 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.  
4) Turn on gas supply.  
5) Select heat zone.  
6) Put a match in the match holder and strike the  
match.  
7) Push LEFT burner control knob down and turn to  
H (high).  
1) Open the sliding work surfaces and splash guards.  
Figure 2.  
ƽWARNING: Do not lean over open barbecue. Keep  
your face and body at least one foot away from the  
matchlight hole when lighting the barbecue.  
2) Check that fuel scale reads more than “E”.  
Note - E = empty; F = full.  
3) Make sure all burner control knobs are turned OFF.  
(Push each burner control knob down and turn  
clockwise.)  
8) Insert match holder and lit match through matchlight  
hole to ignite LEFT burner.  
ƽWARNING: The burner control knobs must be in  
the OFF position before turning on the LP tank  
valve. If they are not in the OFF position, when you  
turn on the LP tank valve, the excess flow control  
will activate, limiting the flow of gas from the LP  
tank. If this should occur, turn OFF the LP tank valve  
and burner control knobs and start over.  
matchlight hole  
in control panel  
Hole in cooking  
box assembly  
Control panel  
Manual Lighting  
Left burner tube  
1
Figure 3  
9) Observe if LEFT burner has ignited by looking  
through matchlight hole.  
ƽWARNING: If LEFT burner fails to ignite turn LEFT  
burner control knob to OFF and wait 5 minutes  
before attempting to ignite again.  
10) After the LEFT burner is lit you can turn on the  
RIGHT burner.  
4
Note: Always light the LEFT burner first. The RIGHT  
burner ignites from the LEFT burner.  
3
To Extinguish  
Turn gas supply OFF at the source, then push down  
and turn each burner control knob clockwise to OFF.  
2
Figure 2  
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Cooking  
Using the Cast Iron Griddle  
The Weber Gas Barbecue should not be moved  
when operating or hot.  
WARNINGS:  
ƽ Use heat-resistant barbecue mitts or gloves  
when handling or cooking on the griddle.  
ƽ Do not wear clothing with loose flowing sleeves  
High Medium  
Low  
Off  
while using the griddle.  
You can adjust the LEFT and RIGHT 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 LEFT and RIGHT burners.  
ƽ Do not remove the griddle until it is cold.  
ƽ Use caution when cooking foods with high fat  
content, such as chops, bacon or sausage.  
ƽ Follow all safety instructions provided with your  
Note: Cooking conditions may require the adjustment  
of the burner controls.  
barbecue.  
ƽ Do not drop cast iron griddle, it will break.  
If burners go out during cooking, turn off all burners  
and wait 5 minutes before relighting.  
ƽ Prior to storing, grease very lightly with solid  
vegetable oil or vegetable cooking spray, then  
wipe dry with a paper towel. Store in a dry place.  
ƽCAUTION: Check the bottom tray for grease build-  
up before each use. Remove excess grease to avoid  
a grease fire in the bottom tray.  
First Time Use  
Using the Cooking Grates  
To preheat, after lighting, turn both burners to high (HH).  
Preheating will take 10 to 15 minutes depending on  
conditions such as air temperature and wind.  
Wash thoroughly with a mild dishwashing liquid to  
remove the wax coating used for protection in shipping.  
Rinse with hot water and dry completely with a soft cloth  
or paper towel. NEVER ALLOW TO DRAIN DRY, OR  
WASH IN A DISHWASHER. You must season the  
griddle before first use to prevent rust and keep foods  
from sticking.  
See your Weber cookbook for detailed cooking  
instructions.  
Drippings and grease - The Flavorizer Bars are  
designed to "smoke" the right amount of drippings for  
flavorful cooking. Excess drippings and grease  
accumulate in the catch pan under the bottom tray.  
Disposable foil liners are available that fit the catch pan.  
Seasoning The Griddle  
Spread a thin coating of solid vegetable oil over entire  
surface of the cast iron griddle with a paper towel. Be  
certain the entire surface, including all corners, has  
been coated thoroughly. (Do not use salted fat such as  
margarine or butter.)  
Season the cast iron griddle in your oven. Put griddle on  
top oven rack. Place aluminum foil on lower oven rack  
to catch any drippings. Bake in a moderate oven for 112  
hours. If you are not planning to use the oven for  
several hours — you can turn oven off after seasoning  
and leave griddle in oven to cool to room temperature.  
Note: If oven is to be used immediately after seasoning  
use heat-resistant barbecue mitts or gloves to remove  
griddle from oven while HOT. Place griddle on a heat-  
resistant surface and allow it to cool to room  
temperature.  
Important Note: To prevent rusting the cast iron  
griddle should be reseasoned frequently. If rust  
occurs, clean with a steel wool scouring pad, rinse  
with hot water and dry. Coat with a solid vegetable  
oil or a vegetable cooking spray and heat in grill or  
oven as indicated above.  
32  
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Maintenance  
Periodic Cleaning  
Always clean the griddle immediately after each use  
with boiling hot water and a brush. Rinse and dry  
thoroughly. If there is a lot of food sticking to the surface  
of the griddle it may be cleaned with a steel wool  
scouring pad. Rinse well with hot water and reseason  
per instructions in grill or oven. Prior to storing, grease  
very lightly with a solid vegetable oil or a vegetable  
cooking spray, then wipe dry with a paper towel. Store in  
a dry place.  
ƽCAUTION: Turn your Weber Gas Barbecue OFF  
and wait for it to cool before cleaning.  
ƽCAUTION: Do not clean your Flavorizer Bars or  
cooking grills in a self-cleaning oven.Replacement  
cooking grills and griddles and Flavorizer Bars are  
available through your retailer.  
Outside surfaces - Use a warm soapy water solution.  
ƽCAUTION: Do not use oven cleaner, abrasive  
cleansers (kitchen cleansers) cleaners that contain  
citrus products or abrasive cleaning pads on  
barbecue or cart surfaces.  
Reseasoning  
After each use the griddle may be reseasoned by  
coating with a solid vegetable oil.  
Bottom tray - Remove excess grease and then wash  
with warm soapy water.  
A vegetable cooking spray may be used as a  
convenient method for quick reseasoning.  
Flavorizer Bars and Cooking Grills - Clean with a  
suitable brass bristle brush. As needed, remove from grill  
and wash with warm soapy water.  
Tips  
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.  
The cast iron griddle will turn black with use. The  
pores of the iron will be sealed, providing a durable  
coating that helps to prevent foods from sticking. The  
griddle will further season with use. Regular applications  
of solid vegetable oil or vegetable cooking spray will  
improve its resistance to rust.  
Inside cooking box - Brush any debris off of burners  
tubes. DO NOT ENLARGE BURNER PORTS  
(OPENINGS). Wash inside of cooking box with warm  
soapy water.  
Rust, a metallic taste or discolored foods are signs of  
improper or inadequate seasoning or may result from  
cooking acidic foods. If this occurs, wash thoroughly and  
reseason.  
Cast Iron Griddle - See “Maintenance” under “Using  
the Cast Iron Griddle”.  
Storage and/or Nonuse  
The gas must be turned off at the LP cylinder when  
Since cast iron holds heat well, you will not need to  
use extremely high cooking temperatures. Best results  
are obtained with medium to medium-high heat. Do not  
overheat.  
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.  
As with all cast iron, the more the use, the easier the  
maintenance.  
Cooking with the Griddle  
LP cylinders must be stored outdoors in a well-  
ventilated area out of reach of children.  
To preheat, after lighting, turn both burners to high (HH).  
Preheating will take 10 to 15 minutes depending on  
conditions such as air temperature and wind.  
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.  
Your Weber Gas Barbecue is an energy efficient  
appliance. It operates at a low B.T.U. rate for economy.  
See your Weber cookbook for detailed cooking  
instructions.  
The Weber Gas Barbecue should be checked for  
gas leaks and any obstructions in the burner tubes  
before using. (See Sections "General and Annual  
Maintenance.")  
Check that the areas under the control panel and  
the bottom tray are free from debris that might  
obstruct the flow of combustion or ventilation air.  
33  
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Connecting the filled LP tank  
Refilling the LP tank  
We recommend that you refill before the scale indicator  
reaches "E".  
ƽWARNING: Make sure that the LP tank valve is  
closed. Close by turning clockwise.  
Note - If you run out of fuel, check the indicator setting  
and/or adjust the fuel scale indicator setting with the  
scale setting wing nut, while the tank is empty so you do  
not run out again.  
ƽ DANGER ƽ  
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. This will result in a fire or explosion  
which can cause serious bodily injury or  
death and damage to property.  
Removal of the LP tank  
1) Close tank valve (turn clockwise). Figure 4 (a).  
2) Slide the collar back on the quick disconnect to  
disengage the fitting. Figure 4 (b).  
3) Loosen tank lock wing nut and turn tank lock up out  
of the way.  
You will need: LP tank, a soap and water solution and a  
rag or brush to apply it.  
4) Lift tank off.  
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  
To refill take LP tank and tank filler adapter to a "Gas  
Propane" dealer.  
ƽWARNING: We recommend that your LP tank be  
filled at an authorized LP gas dealer, by a qualified  
attendant, who fills the tank by weight. IMPROPER  
FILLING IS DANGEROUS.  
a) Lift and hook the tank onto the fuel scale.  
b) Loosen the tank lock wing nut. Swing the tank lock  
down. Tighten the wing nut. Figure 5.  
ƽCAUTION: If you exchange your LP tank, make  
sure you get a similar tank in return. Your LP tank is  
equipped with a quick-disconnect valve. Other LP  
tanks are not compatible with your barbecue  
connection.  
Scale setting wing nut  
Tank lock  
wing nut  
Figure 5  
(a)  
Tank valve  
Collar  
(b)  
Figure 4  
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c) Connect the hose to the tank. Route the hose so it  
does not interfere with the scale indicator rod. Slide  
back the collar of the quick disconnect on the tank  
valve. Figure 6 (a). Push the male fitting of the  
regulator into the quick disconnect, and maintain  
pressure. Slide the collar closed. Figure 6 (b). If it  
does not engage or lock, repeat procedure. Gas will  
not flow unless the quick disconnect is properly  
engaged.  
f) 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 leak does not stop, turn off the gas and contact  
Weber-Stephen Customer Service. Do not use the  
barbecue.  
g) When leak checks are complete, turn gas supply  
OFF and rinse connections with water.  
(a)  
LP Tank  
The LP tank 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 manufacturer's  
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 call Weber-Stephen Products  
Co., Customer Service Center.  
Male fitting  
Regulator  
Collar  
(b)  
Quick disconnect  
engaged  
Figure 6  
d) Mix soap and water.  
Figure 7  
e) Open the tank valve. Figure 7.  
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Liquid Propane (LP) Tank(s)  
Safe handling tips for LP Gas  
The LP tank 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 (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.  
Replacement LP tanks supplied by Weber satisfy  
the requirements. Check to be sure the tank has a  
D.O.T. certification, and has been tested within five  
years. Your LP gas supplier can do this for you.  
Figure 8.  
LP gas has an odor similar to natural gas. You  
should know this odor.  
LP gas is heavier than air. Leaking LP gas may  
collect in low areas that prevent dispersion.  
If you have questions about spare LP tanks, please  
call Weber-Stephen Customer Service.  
To fill, take the LP tank to an RV center, or look up  
gas-propane in the phone book for other sources of  
LP gas, to fill the tank with 20 pounds of liquid  
propane.  
D.O.T. Certification (example)  
ƽWARNING: We recommend that your LP tank be  
filled at an authorized LP gas dealer, by a qualified  
attendant, who fills the tank by weight. IMPROPER  
FILLING IS DANGEROUS.  
DOT 4BA240  
ƽCAUTION: If you exchange your LP tank, make  
sure you get a similar tank in return. Your LP tank is  
equipped with a quick-disconnect valve. Other LP  
tanks are not compatible with your barbecue  
connection.  
2/96  
Air must be removed from a new LP tank before the  
initial filling. Your LP dealer is equipped to do this.  
20 lb LP tank  
Date tested  
The LP tank must be installed, transported and  
stored in an upright position. LP tanks should not be  
dropped or handled roughly.  
Figure 8  
Never store or transport the LP tank where  
temperatures can reach 125° F (too hot to hold by  
hand - for example: do not leave the LP tank in a  
car on a hot day).  
All LP tank supply systems must include a collar to  
protect the tank valve.  
The LP tank must be a 20 lb size (18 1/4 inches  
high, 12 1/4 inches in diameter).  
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.  
The LP tank 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 "empty" LP tanks 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 tank valve before disconnecting.  
Do not use a damaged LP tank. Dented or rusty LP  
tanks or LP tanks with a damaged valve may be  
hazardous and should be replaced with a new one  
immediately.  
The joint where the hose connects to the LP tank  
must be leak tested each time the LP tank is  
reconnected. For example, test each time the LP  
tank is refilled.  
Be sure the regulator is mounted with the small vent  
hole pointed downward so it will not collect water.  
This vent should be free of dirt, grease, bugs etc.  
36  
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ƽWARNING: You should check for gas leaks every  
time you disconnect and reconnect a gas fitting.  
Annual Maintenance  
After a period of nonuse we recommend that you  
perform the following maintenance procedures for your  
safety.  
Note: All factory made connections have been  
thoroughly checked for gas leaks. The burners have  
been flame tested. As a safety precaution you should  
recheck all fittings for leaks before using your Weber  
Gas Barbecue. Shipping and handling may have  
loosened or damaged a gas fitting.  
ƽWARNING: 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 manifold assembly. Contact  
your dealer.  
You will need: a soap and water solution and a rag or  
brush to apply it.  
To perform leak checks: Open cylinder valve by turning  
the cylinder valve handwheel counterclockwise.  
Check all gas fittings for leaks.  
ƽ DANGER ƽ  
b)  
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. This will result in a fire or explosion  
which can cause serious bodily injury or  
death and damage to property.  
a)  
c)  
Inspection and Cleaning of the Weber  
Spider Stopper Guards  
Manifold  
To inspect the Spider Stopper Guards, remove the  
control panel and look to see if they have dust or dirt on  
their outside surfaces. If they are dirty, brush off the  
outside surface of the Spider Stopper Guards with a soft  
bristle brush (an old toothbrush for example). Check that  
there are no gaps in the Spider Stopper Guards’ seams  
or in the fit around the burners or valves. (See Section  
"General Maintenance".)  
d)  
Manifold  
Figure 9  
37  
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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.  
General Maintenance  
Burner Inspection  
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 of the burner tubes. This  
blocks the normal gas flow, and can cause the gas to  
flow back out of the air shutter. Figure 11. This could  
result in a fire in and around the air shutters, under the  
control panel, causing serious damage to your  
barbecue.  
ƽWARNING: Do not ignite burners while leak  
checking.  
Check:  
a) Left valves to manifold connection. Figure 9 (a).  
b) Center valves to manifold connection. Figure 9 (b).  
c) Right valves to manifold connection. Figure 9 (c).  
d) Hose to manifold connection. Figure 9 (d)  
Venturi  
ƽWARNING: If there is a leak at connection 9 (d),  
turn OFF the gas and retighten the fitting with a  
spanner and recheck for leaks with soap and water  
solution.  
Venturi fin  
Air shutter  
If a leak persists after retightening the fitting, turn  
OFF the gas. DO NOT OPERATE THE BARBECUE.  
Contact your dealer.  
Figure 11  
a) Hose to regulator connection. Figure 10 (a).  
b) Regulator to cylinder connection. Figure 10 (b).  
The Weber Spider Stopper Guard 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. Figure 12.  
ƽWARNING: If there is a leak at connections 9 (a),  
9 (b), 9 (c) or 10 (a), turn OFF the gas. Do not  
operate the barbecue. Contact your dealer.  
ƽWARNING: If there is a leak at connection 10 (b),  
retighten and recheck for leaks with soap and water  
solution.  
When leak checks are complete, turn gas supply OFF at  
the source and rinse connections with water.  
Weber Spider  
Stopper Guard  
Figure 12  
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. The smell of gas in conjunction with the burner  
flames appearing yellow and lazy.  
2. Barbecue does not reach temperature.  
3. Barbecue heats unevenly.  
b)  
a)  
4. One or more of the burners do not ignite.  
ƽ DANGER ƽ  
Failure to correct these symptoms  
may result in a fire which can cause  
serious bodily injury or death and cause  
damage to property.  
Figure 10  
38  
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Main Burner Flame Pattern  
Replacing the Burners  
The Weber Gas Barbecue burners have been factory set  
for the correct air and gas mixture. The correct flame  
pattern is shown in Figure 13.  
1. Your Weber Gas Barbecue must be OFF and cool.  
2. Turn OFF gas at source.  
3. Disconnect regulator.  
4. To remove control panel refer to Step “Remove the  
control panel and the front panel”.  
5. Remove splash guards.  
Tips occasionally yellowish  
Burner inside  
cooking box  
6. Remove cooking grill(s) and griddle.  
7. Remove Flavorizer bars.  
Light blue  
8. Remove the manifold by unsnapping the clips at the  
right and left front of the cooking box. Figure 16.  
Dark blue  
Flames  
Figure 13  
If the flames do not appear to be uniform the length of the  
burner tube, follow the burner cleaning procedures.  
Main Burner Cleaning Procedure  
Turn off the gas supply. Remove the manifold.  
(See Section “Replacing the main burners”.)  
Look inside each burner with a flashlight. Figure 14.  
Figure 14  
Clean the inside of the burners with a wire  
(a straightened out coat hanger will work). Figure 15.  
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.  
Figure 16  
9. Disconnect white and black wire from each igniter.  
Figure 17.  
Figure 15  
ƽCAUTION: Do not enlarge the burner ports when  
cleaning.  
White wire  
Black wire  
Figure 17  
39  
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10. Unlatch the Spider Stopper Guards and remove.  
Figure 18.  
12. Slide the burner assembly from each Heat Zone.  
The left and right burners are connected by the  
Crossover tube. Figure 20(a).  
Pull out of here  
Crossover tube  
Figure 18  
11. Pull the manifold out of the burners. Figure 19.  
Figure 20  
Manifold  
Figure 19  
40  
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13. Lift and twist the burner assembly slightly to  
separate the crossover tube from the burners.  
Remove the burners from the cooking box.  
Figure 21.  
15. Reinstall the Spider Stopper Guards. Slightly rotate  
the Spider Stopper Guards so that the seams are in  
line with the Venturi fins. There should be no gaps  
in the seams or in the fit around the burners and  
valves. Figure 23.  
Separate here  
Check fit  
around valve  
Venturi fin  
Crossover tube  
Check fit around burner  
Figure 23  
Figure 21  
14. To reinstall the burners, reverse steps 3 through 13.  
ƽCAUTION: If the Spider Stopper Guards do not fit  
tightly, contact Weber-Stephen Customer Service.  
ƽCAUTION: The burner openings must be  
positioned properly over the valve orifices.  
Figure 22a.  
ƽCAUTION: 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”.  
Check proper assembly before fastening manifold in  
place. Figure 22b.  
(a)  
Valve  
Crossover Ignition System Operations  
If the Crossover Ignition System fails to ignite the Front  
burner, light the Front burner with a match. If the Front  
burner lights with a match, then check the Crossover  
Ignition System.  
Check that both the white and black ignition wires  
Burner  
are attached properly. Figure 24.  
(b)  
Figure 24  
Check that the Crossover Ignition button pushes the  
Figure 22  
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 igniter” for  
correct procedure.  
If the Crossover Ignition System still fails to light, contact  
your dealer.  
41  
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TROUBLESHOOTING  
Problem  
Cure  
Check  
Burners burn with a yellow or orange  
flame, in conjunction with the smell of gas.  
Clean Weber Spider Stopper  
Guards. (See Section "Annual  
Maintenance".)  
Inspect Weber Spider Stopper  
Guards for possible obstructions.  
(Blockage of holes.)  
Burners do not light. -or-  
Burners have a small flickering flame in  
the HIGH position. -or-  
Barbecue temperature only reaches 250˚ to  
300˚ degrees in the HIGH position.  
To reset the excess flow safety  
device turn all burner control knobs  
and the tank valve OFF. Disconnect  
the regulator from the tank. Turn  
burner control knobs  
The excess flow safety device,  
which is part of the barbecue to  
tank connection, may have  
activated.  
to HIGH. Wait at least 1 minute.  
Turn burner control knobs OFF.  
Reconnect the regulator to the tank.  
Turn tank valve on slowly. Refer to  
“Lighting Instructions”.  
Burner does not light, or flame is low in  
HIGH position.  
Refill LP tank.  
Is LP fuel low or empty?  
Straighten fuel hose.  
Is fuel hose bent or kinked?  
If you can light the Front burner with  
a match, then check the Crossover  
Ignition System.  
Does the Front burner light with a  
match?  
Experiencing flare-ups:  
All burners on high for 10 to 15  
minutes for preheating.  
Are you preheating barbecue in the  
prescribed manner?  
Clean thoroughly. (See Section  
"Periodic Cleaning".)  
Are the cooking grates and  
Flavorizer Bars heavily coated with  
burned-on grease?  
Clean bottom tray.  
Is the bottom tray "dirty" and not  
allowing grease to flow into catch  
pan?  
CAUTION: Do not line the bottom tray  
with aluminum foil.  
Burner flame pattern is erratic. Flame is  
low when burner is on HIGH. Flames do  
not run the whole length of the burner  
tube.  
Clean burners. (See Section  
"General Maintenance".)  
Are burners clean?  
Fuel scale shows that there is gas in the  
LP tank, but tank is empty.  
Fuel scale must be adjusted with an  
empty tank.  
Check adjustment of fuel scale.  
Barbecue seems to lose heat when  
Turn off burner control knobs and  
the LP cylinder. Replace with a  
spare LP cylinder and resume  
cooking.  
Is there frost/ice on the outside of  
the LP cylinder?  
cooking in cold weather temperatures  
50˚ F or colder. (The liquid propane in the  
cylinder turns to vapor too slowly to  
supply the burners with gas. This is due to  
the air temperature cooling the LP cylinder  
which slows the vaporization process.)  
ƽWARNING: The spare or  
disconnected LP cylinder must  
be stored outdoors in a well  
ventilated area out of the reach of  
children. The spare or  
disconnected LP cylinder must  
never be stored under or near  
your Weber Gas Barbecue.  
If problems cannot be corrected by using these methods, please contact  
Weber-Stephen Customer Service.  
42  
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1
2
3
41  
42  
4
5
6
7
8
9-13  
14  
15  
43  
44  
16  
17  
45  
46  
18  
47  
19  
20  
21  
48, 39  
49  
22  
50  
51  
52  
53  
54  
23  
24  
39,55  
56  
57  
E B  
E R  
W
25  
58  
59  
W
E
B
R
E
26  
27  
35  
36  
37  
38  
29  
30 31 32 33 34  
3940  
28  
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Parts List  
All items are single quantities unless otherwise  
specified.  
While we give much attention to our products,  
unfortunately an occasional error may occur.  
If a part is missing, do not go back to the store.  
Call the Weber Customer Service Center toll free  
1-800-446-1071 to receive immediate assistance.  
Have your owner’s manual and serial number  
of the barbecue available for reference.  
Parts can be ordered directly from Weber-Stephen  
Products Company by phone or mail.  
Note - Do not return parts to Weber-Stephen Products  
Co. without first contacting the Customer Service  
Center by phone or mail. Returning the part may not be  
necessary.  
Weber-Stephen Products Company  
Customer Service Center  
250 South Hicks Road  
Palatine, IL 60067-6241  
(847) 705-8660  
(800) 446-1071  
1
2
3
4
5
6
7
8
9
Cooking grills (2)  
Griddle  
Flavorizer bars (11)  
Left work surface  
Glides (4)  
Phillips head 1/4-20 x 1 inch machine screws (4)  
Cooking box (assembly)  
Burner control knobs (6)  
Igniter (3)  
31 Wheel hub caps (2)  
32 Wheels (2)  
33 Wheel frame  
34 1/4-20 hex nut  
35 Cylinder glides (2)  
36 Glide axle  
37 Glide hubcaps (2)  
38 Cylinder panel  
39 1/4 inch nylon washers (12)  
40 1/4-20 x 1 3/4 inch bolt  
41 Splash guards (2)  
42 Flavorizer bar / Cooking grill holders (2)  
43 Right work surface  
44 Crossover tubes (3)  
45 Left burner (3)  
10 Igniter lock nut (3)  
11 Igniter wire (black) (3)  
12 Igniter wire (white) (3)  
13 Gas catcher ignition chamber (3)  
14 Manifold mounting clips (2)  
15 Manifold assembly  
16 Igniter buttons (3)  
17 Control panel  
18 Front panel  
19 Match holder bracket  
20 Plastic button  
21 Caster frame  
22 Match holder  
23 1/4-20 x 3 1/2 inch bolt (4)  
24 Caster (2)  
25 Bottom tray  
26 Catch pan holder  
27 Catch pan  
28 Drip pans (2)  
46 Right burner (3)  
47 Top frame rail #1 (2)  
48 1/4-20 x 1/2 inch bolts (6)  
49 Back panel  
50 Top frame rail #2 (2)  
51 Plastic handle (4)  
52 #8-16 x 1 inch screw (8)  
53 Hose Clamp  
54 1/4-20 x 5/8 screw  
55 1/4-20 wing nuts  
56 Fuel scale assembly  
57 Hose / Regulator  
58 LP tank  
59 Filler adapter  
29 Accessory rack  
30 Bottom connectors (2)  
ƽ WARNING:  
Use only Weber factory authorized parts.  
The use of any part that is not factory  
authorized can be dangerous. This will also  
void your warranty.  
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A FINAL WORD  
OF THANKS  
hank you for choosing a Weber Barbecue.  
T
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 to help you with any  
problems with parts or assembly.  
Call our toll free number 1-800-446-1071.  
For quicker service, please have your owner’s manual  
available for reference. We also welcome any comments  
or suggestions you might have regarding our products.  
We wish your family the  
best in outdoor cooking enjoyment.  
Weber-Stephen Products Company  
Customer Service Center  
200 East Daniels Road  
Palatine, Illinois 60067-6266  
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