GENESIS®5500 Series
Perma-Mount
™
Natural Gas Barbecue
Serial Number
Please use this number in registering your warranty
and any correspondence with the factory.
Owner’s Manual
FOR YOUR SAFETY
Do not store or use gasoline or other
flammable vapors and liquids 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.
WARNING: Follow all leak check
procedures carefully in this manual prior
to barbecue operation. Do this even if
barbecue was dealer assembled.
WARNING: Do not try to light this
appliance without reading "Lighting"
instructions section of this manual.
THIS GAS APPLIANCE IS DESIGNED FOR
OUTDOOR USE ONLY.
FOR YOUR SAFETY
If you smell gas:
1. Shut off gas to the appliance.
2. Extinguish any open flame.
3. Open lid.
4. If odor continues, immediately call
your gas supplier or your fire
department.
86033 6/96
®
2
DANGER
Failure to follow the Dangers, Warnings and Cautions contained in this Owner’s
Manual may result in serious bodily injury or death, or in a fire or an explosion causing
damage to property.
WARNINGS
■ Do not store a spare or disconnected LP tank under or near this barbecue.
■ Improper assembly may be dangerous. Please carefully follow the assembly instructions in this manual.
■ After a period of storage, and/or nonuse, the Weber Gas Barbecue should be checked for
gas leaks and burner obstructions before using. See instructions in this manual for correct
procedures.
■ Do not operate the Weber Gas Barbecue if there is a gas leak present.
■ Do not use a flame to check for gas leaks.
■ Combustible materials should never be within 24 inches of the top, bottom, back or sides of your
Weber Gas Barbecue.
■ Do not put a barbecue cover or anything flammable on or in the storage area under the barbecue.
■ Your Weber Gas Barbecue should never be used by children.
■ You should exercise reasonable care when operating your Weber Gas Barbecue. It will be hot during
cooking or cleaning, and should never be left unattended.
■ Should the burners go out during operation, turn all gas valves off. Open the lid and wait five minutes
before attempting to relight, using the lighting instructions.
■ Do not use charcoal or lava rock in your Weber Gas Barbecue.
■ Never lean over open grill or place hands or fingers on the front edge of the cooking box.
■ Should a grease fire occur, turn off all burners and leave lid closed until fire is out.
■ Do not enlarge valve orifices or burner ports when cleaning the valves or burners.
■ The Weber Gas Barbecue should be thoroughly cleaned on a regular basis.
■ LP gas is not natural gas. The conversion or attempted use of natural gas in an LP unit or LP gas in a
natural gas unit is dangerous and will void your warranty.
■ Do not attempt to disconnect any gas fitting while your barbecue is in operation.
■ Use heat-resistant barbecue mitts or gloves when operating barbecue.
LP GAS UNITS ONLY:
■ Use the regulator that is supplied with your Weber Gas Barbecue.
■ Do not attempt to disconnect the gas regulator or any gas fitting while your barbecue is in operation.
■ A dented or rusty LP tank may be hazardous and should be checked by your liquid propane supplier.
Do not use an LP tank with a damaged valve.
■ Although your LP tank may appear to be empty, gas may still be present, and the tank should be
transported and stored accordingly.
■ If you see, smell or hear the hiss of escaping gas from the LP tank:
1. Get away from LP tank.
2. Do not attempt to correct the problem yourself.
3. Call your fire department.
3
Weber-Stephen Products Co. (Weber) hereby
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,
Cooking Grates, 3 years,
Stainless Steel Flavorizer Bars, 5 years,
All Remaining Parts, 5 years,
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.
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.
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
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.
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.
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
(800) 446-1071
WARRANTY
PATENTS AND TRADEMARKS
© 1996 Weber. Weber, , Genesis, Flavorizer and Crossover are
registered U.S. trademarks; Perma-Mount, Gas Catcher,
FlameCheck, Steam-N-Chips, Spider Stopper, and Warm-Up are
U.S. trademarks of Weber-Stephen Products Co., 200 East Daniels
Road, Palatine, IL 60067-6266. U.S.A.
Printed in the U.S.A.
4
5
Contents
WARNINGS ................................................................ 2
Warranty & Patents .................................................. 3-4
General Instructions.................................................... 6
Assembly ............................................................... 7-34
Operating Instructions
Lighting........................................................ 35-37
Cooking ............................................................ 37
After a Period of Nonuse ................................. 38
Cleaning ........................................................... 38
Steam-N-Chips Smoker ................................... 39
Troubleshooting and Maintenance
Annual Maintenance ................................... 40-41
General Maintenance.................................. 41-43
Troubleshooting........................................... 44-45
Parts Listing .............................................................. 47
FEATURES:
a) Convenient tables and racks.
b) Heavy gauge porcelain-on-steel lid seals in heat.
c) Rapid read thermometer for precision cooking.
d) Stainless Steel Flavorizer Bars vaporize just the
right amount of drippings for flavoring.
e) Separate burners for temperature control.
f) Crossover Ignition System with Gas Catcher Ignition
Chamber.
g) Weber Warm-Up Basket for additional cooking or
warming space.
h) FlameCheck Safety System automatically shuts off
gas to the burners if the flame goes out.
i) Steam-N-Chips Smoker lets you add American
smokehouse flavor to any food prepared on this grill.
j) Side burner for making sauces, gravies, etc., while
main grill is in use.
k) Enclosed storage area.
a
g
b
c
d
e
a
f
j
h
k
j
6
General Instructions
Your Weber Gas Barbecue is a stationary 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.
The natural 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.
■ Not for use by children.
■
If there are local codes that apply to 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.
■
This Weber Gas Barbecue is designed for natural
(piped in city) gas only. Do not use Liquid Propane
(LP) bottled gas. The valves and orifices are for
natural 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.
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-B149.1
(Installation Code for Natural Gas Burning Appliances
and Equipment).
Storage
■ The gas must be turned OFF at the natural gas
supply when the Weber Gas Barbecue is not in use.
Operating area
WARNING: Only use this barbecue outdoors in a
well ventilated area. Do not use in a garage,
building, breezeway or any other enclosed area.
■ 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.
■ Do not use combustible materials within 24 inches
of the top, bottom, back or sides of the grill.
■ The entire cooking box gets hot when in use. Do not
leave unattended.
■ Keep any electrical supply cord away from any
heated surface.
■ Keep the cooking area clear of flammable vapors
and liquids, such as gasoline, alcohol, etc., and
combustible materials.
Gas supply testing
■ Disconnect your Weber Gas Barbecue when the
gas supply is being tested at high pressures. This
appliance and its individual shutoff valve must be
disconnected from the gas supply piping system
during any pressure testing of that system at test
pressures in excess of 1/2 psig (3.5 kPa).
■ Turn off your Weber Gas Barbecue when the gas
supply is being tested at low pressures. This
appliance must be isolated from the gas supply
piping system by closing its individual manual
shutoff valve during any pressure testing of the gas
supply piping system at the pressure equal to or
less than 1/2 psig (3.5 kPa).
7
General Specifications for Piping
American National Standards Institute (ANSI)
Recommendations for gas supply installations:
Connections:
■ This barbecue is designed to operate at 7 inches of
water column pressure (.2526 psi).
■ A manual shut-off valve must be installed outdoors,
immediately ahead of any connections or change in
pipe material.
CAUTION: If young children are in the area, a
locking valve should be considered.
■ An additional manual shut-off valve indoors should
be installed in the branch fuel line in an accessible
location near the supply line.
■ The point of tie into the branch line should be
carefully selected to avoid a drip leg or be
downstream of a valve controlling another
appliance.
■ Pipe compound should be used which is resistant to
action of natural gas when connections are made.
■ The outdoor connector must be firmly attached to
rigid, permanent construction.
Gas line piping
■ If the length of line required does not exceed 50
feet, use a 5/8" O.D. tube. One size larger should be
used for lengths greater than 50 feet.
■ Indoor and above ground piping can be steel
or copper.
Steel
New standard weight (Schedule 40) steel pipe with
malleable iron fittings.
Copper
New copper tubing type K or L.
Copper tubing must meet requirements of ASTM B88
latest edition.
Use flared fittings. Metallic ball sleeve compression
fittings must not be used.
Copper tube joints may be soldered or brazed with
material having a melting point in excess of 1,000°F.
Outside underground piping
Outside underground piping may be copper tubing, type
K or L (ASTM B88) or polyethylene plastic tube PE3306
(Minimum wall thickness .062") meeting ASTM 2513,
latest specifications.
Steel pipe is not recommended for underground use
unless it is protected with an approved coating,
insulated from hose piping and cathodically protected.
It is recommended that copper tubing be corrosion
protected with a satisfactory material such as TC
Mastic.
All buried fittings should be corrosion protected with a
satisfactory material such as TC Mastic.
Underground piping must have a minimum of 10" cover.
Plastic tubing
Plastic tubing is suitable only for outside underground
use.
■ The transition from metallic pipe to plastic pipe
should be made outside and at least 10"
underground.
■ When compression or crimp type mechanical joints
are used with plastic pipe, it is advisable to use an
internal rigid stiffener in conjunction with the fitting.
■ The stiffener should be assembled flush with the
end of the tube and extend at least to the outside
edge of the compression fitting.
Testing connections
You will need a soap and water solution and a rag or
brush to apply it.
All connections and joints must be thoroughly tested for
leaks after gas has been turned into the line.
Wet the fitting with a soap and water solution. Any
bubbles that form or grow indicate a leak. If bubbles
occur shut off gas, tighten the fitting, and retest.
WARNING: If a leak persists after tightening the
fitting, turn gas off at the supply. DO NOT OPERATE
YOUR BARBECUE. Contact your dealer.
Notice Before Installation
Contact your local municipality for any building codes regulating outdoor barbecue installations. In absence of
local codes, you must conform to the latest edition of ANSI Z223.1.
WE RECOMMEND THAT THIS INSTALLATION BE DONE BY A PROFESSIONAL.
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
gas leaks. This will result in a fire or
explosion which can cause serious bodily
injury or death, and damage to property.
8
Typical natural gas supply installation to a concrete patio or pad
View from behind
barbecue
Accessible
Locking Shut off
Outside
Inside
Gas Supply
Indoor Shut off
Figure 1
CAUTION: Follow "General Specifications for
Piping" in this manual.
We recommend that this installation be done by a
professional.
CAUTION: Combustible materials should never be
within 24 inches of the top, bottom, back or sides of
the barbecue. Do not locate under overhead
combustible construction.
Typical natural gas supply installation to a wood deck
View from behind
barbecue
Gas Supply
Accessible
Locking Shut off
Indoor Shut off
Figure 2
Outside
Inside
CAUTION: Follow "General Specifications for
Piping" in this manual.
We recommend that this installation be done by a
professional.
CAUTION: Combustible materials should never be
within 24 inches of the top, bottom, back or sides of
the barbecue. Do not locate under overhead
combustible construction.
View from behind
barbecue
Outside
Indoor Shut off
Figure 3
Accessible
Locking Shut off
Inside
Gas Supply
Typical natural gas supply installation over an existing post
WARNING: Turn off the natural gas supply at the
source before working on the post.
Prepare the post so that it will be approximately 2 inches
above the pad or ground. Inspect the gas supply line at
the post for any sign of deterioration or corrosion.
CAUTION: If you are in doubt as to the condition
of an existing natural gas supply line, you should
contact a professional or your local gas utility
before attempting any assembly.
CAUTION: Combustible materials should never be
within 24 inches of the top, bottom, back or sides of
the barbecue. Do not locate under overhead
combustible construction.
9
Recommended concrete pad requirements
We recommend a pad a minimum of 40 inches left to
right, 20 inches front to back and 4 inches deep (1.85
cubic feet). Figure 4.
Note - Cubic feet is determined by multiplying length
times width times depth and dividing by 1728.
Figure 4
If you use a concrete bag mix, use the mix for maximum
strength. An average 80 pound bag of concrete mix will
make approximately 2/3 of a cubic foot of concrete.
Note - Follow the concrete bag mix, manufacturers
recommendations concerning pad preparation, gravel,
sand, etc. Figure 5.
CAUTION: Allow fresh concrete to cure completely
before attempting to anchor the barbecue to the
concrete.
Concrete Pad
Crushed stone,
sand or gravel
Earth
Figure 5
Method 1
A strike anchor, a minimum size of 3/8 inch x 3 1/2 inches
long with a 3/8 inch flat washer and 3/8 inch nut.
Figure 6.
Note - Use a 3/8 inch diameter concrete drill bit for drilling
the hole for the strike anchor.
Strike anchor
3/8 inch nut
3/8 inch flat washer
Mount plate
Drilled hole
Figure 6
Typical installation of the base for an existing concrete patio or a new pad
After assembling the base (see Steps 2 and 3), position
the base assembly on your concrete patio for mounting.
CAUTION: Combustible materials should never be
within 24 inches of the top, bottom, back or sides of
the barbecue. Do not locate under overhead
combustible construction.
Note - With the lid open the depth of the barbecue is 28
inches, front to back. After positioning, level the base.
(See Step "Level the base.")
After leveling, anchor the base to the concrete patio or
pad. For anchoring, we recommend use of one of the
following methods:
WARNING: Whichever method used, the base
must be bolted down (anchored) at ALL four
anchoring points prior to barbecue assembly.
20”
40”
4”
10
Method 3
A 3/8 inch machine screw anchor, using a
3/8-16 x 1 1/2 inch machine screw and a flat washer.
Figure 8.
Note - Use a 3/4 inch diameter concrete drill bit for drilling
the hole for the screw base. The machine screw anchor
requires a setting tool.
3/8-16 x 1 1/2 machine screw
3/8 inch flat washer
Mount plate
3/8 inch screw anchor
Drilled hole
Figure 8
Method 2
A concrete lag bolt, a minimum of 3/8 inch x 2 1/2 inches
long with a 3/8 inch diameter long lag shield and a
3/8 inch flat washer. Figure 7.
Note - Use a 5/8 inch concrete drill bit for drilling the hole
for the lag shield.
Concrete lag bolt
3/8 inch flat washer
Mount plate
Lag shield
Drilled hole
Figure 7
Typical base installation for a wood deck
After assembling the base according to the assembly
instructions, position the base assembly on your deck for
anchoring.
CAUTION: Combustible materials should never be
within 24 inches of the top, bottom, back or sides of
the barbecue. Do not locate under overhead
combustible construction.
Note - With the lid open, the depth of the barbecue is 28
inches, front to back. After positioning, level the base.
(See Step "Level the base.")
After leveling, anchor the base to the deck. We
recommend using a minimum of a 3/8 inch x 1 1/2 inch
lag bolt with a 3/8 inch flat washer. Figure 9.
Note - Use a 3/16 inch drill bit for drilling a pilot hole for a
3/8 inch lag bolt.
WARNING: The base must be bolted down
(anchored) at ALL four anchoring points prior to
barbecue assembly.
3/8 inch x 1 1/2 inch lag bolt
3/8 inch flat washer
Mount plate
Drilled hole
Figure 9
11
Assembly
Tools needed
Screwdrivers, regular and
Phillips
Hammer
Two 7/16 inch, one 5/8, 11/16, and 3/4 inch open end or
two adjustable wrenches
Pliers
Level
Electric drill
Supplies needed
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.
Step 1
Check package contents
Cooking box
(assembly)
Lid
(assembly)
Bottom tray
Front panel
Accessory tray
Accessory tray with notch
Control panel
®®®®®®®
®
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.
12
Left frame
Upright frame
Brace panel
Frame connector with bushings
Frame connector
Two front/back
base panels
Steam-N-Chips Smoker body
Steam-N-Chips Smoker flue
Steam-N-Chips Smoker water pan
Work table
Two swing tables
Left end panel (#1)
Panels and doors are
identified with removable stickers.
Please leave on during assembly.
Three back
panels (#2)
Right end panel (#3)
Left hand glass
door assembly (LH)
Two right hand glass
door assemblies (RH)
Serving tray
Barbecue gas supply line
1
2
3
LH
RH
13
Right hand slide bar assembly
Assembly consists of:
Right hand slide bar
Support rod
Slide
Left hand slide bar assembly
Assembly consists of:
Left hand slide bar
Support rod
Slide
Side burner assembly
Burner grate
Side burner knob
Two side burner locks
Two left/right base panels
Warm-Up Basket
Five long Flavorizer Bars
Seven short Flavorizer Bars
Two cross brace assemblies
Assemblies consist of:
7/16-14 square lock nuts
(actual size)
7/16-14 x 2 1/2 inch hex head bolts
(actual size)
Mount plates
Cross brace
14
Check contents of hardware packs
Three burner control knobs
FlameCheck Button
Three tool holders
Eight tubing plugs
(two are spares)
Manifold bracket
Four 10-24 x 1 3/4 inch machine screws
(actual size)
Four 10-24 hex nuts
(actual size)
Two hinge pins
(hardware size: 1/4 x 1 1/2 inch clevis pin)
(actual size)
Five 1/4-20 x 2 inch bolts
(actual size)
Eleven 1/4-20 x 1/2 inch bolts
(actual size)
1/4-20 wing nut
(actual size)
Right frame
Upright frame
Warming rack
Cooking grate
Narrow cooking grate
Catch pan holder
Catch pan
Two drip pans
Thermometer
15
1/4-20 keps nut
Thirteen 1/4-20 hex nuts
(actual size)
Forty two nylon washers
(actual size)
Nine 1/4-20 x 1 1/2 inch bolts
(actual size)
Two hair pin cotters
(actual size)
Four 1/4 inch fender washers
(actual size)
Gas line bracket
Four plastic buttons
Two swing table end brackets
16
Step 2
Assemble base
You will need: left/right base panels, front/back base
panels, four 1/4-20 x 1/2 inch bolts, eight nylon washers
and four 1/4-20 hex nuts.
Position a left/right base panel with a front/back base
panel (flanges down) with left/right base panel on the
outside. Align the bottom holes. Slip a washer on a 1/4-20
x 1/2 inch bolt, insert the bolt (head on the outside)
through the bottom hole of both panels. Add a washer
and nut and finger tighten. Figure 1. Add the second
front/back base panel using the same procedure.
Then add the second left/right base panel to the
front/back panels, using the same procedure.
Figure 1
Flanges
Step 3
Finish base assembly
You will need: partial base assembly, two cross brace
assemblies, four 1/4-20 x 1 1/2 inch bolts, four nylon
washers, four 1/4 inch fender washers, four 1/4-20 hex
nuts and two 7/16 inch wrenches.
Hold one cross brace assembly inside the partially
assembled base.
Note - The mounting plate should be above the base and
be able to rotate a full 360 degrees.
Slip a nylon washer on a 1/4-20 x 1 1/2 inch bolt. Insert
the bolt through the base and the cross brace assembly.
(Head on the outside.) Figure 2. Add the 1/4 inch fender
washer and 1/4-20 hex nut and tighten using the 7/16
inch wrenches. Use one wrench to hold the head of the
bolt and the other wrench to tighten the nut. Repeat the
procedure to install the second cross brace assembly.
Tighten the lower base bolts using the same tightening
procedure.
Figure 2
Nylon washer
Fender washer
Mount plate
17
Step 4
Level the base
You will need: base assembly, level, 5/8 inch and 3/4 inch
wrenches.
Using the 3/4 inch wrench, loosen the locking nuts
(square nuts). Figure 3.
Locking nut
Mount plate
Figure 3
Turn the base assembly over or right side up. (Flanges
are now up.)
Set the base in position on your deck, concrete pad, or
patio for anchoring. To level, set a level on the top flange
of a front/back base panel. Hold the mounting plate up
and use a 5/8 inch wrench to turn the hex head of the
leveling bolts until level. Figure 4.
Figure 4
Leveling hex
head bolt
FlangesLevel
Repeat procedure on the remaining three sides of the
base until the base is level. Turn the mounting plates to
approximately 20 degrees. Figure 5. Using the 3/4 inch
wrench, tighten the locking nut (square nut).
You are now ready to anchor the base. (See the various
typical mounting methods in the front section of this
manual.)
20°
Figure 5
18
Step 5
Assemble the frame
You will need: left frame, right frame, two nylon
washers, two 1/4-20 x 1/2 inch bolts and a 7/16 inch
wrench.
Note - Work on carpeted area (on grass, or on one of
the boxes) to protect the finish during frame assembly.
Put the frame pieces so the leg tabs are up. Put the right
frame to your right and left frame to your left. Figure 6.
Slip the two frame halves together with the tabs inside
,
until the tabs of the right frame are inside the left frame
and the holes align. Figure 6 (a).
Slip washers over bolts; insert and tighten bolts. (If you
try to insert a bolt and there are no holes, you have the
left frame turned the wrong way. Turn the left frame
around.) Figure 6 (b).
(a)
Left frame
Leg tabs
Frame tabs
Right frame
Figure 6
(b)
Step 6
Continue frame assembly
You will need: frame assembly, two upright frames, front
panel, four 1/4-20 x 1/2 inch bolts, four nylon washers and
a 7/16 inch wrench.
Assemble one upright frame onto the leg tabs of the right
frame, and the second upright frame onto the leg tabs of
the left frame. The tabs must be on the inside
of the
frames when the joints are closed. Add front panel with
the large hole down and to your right. Add front panel
with the hole down and to your right. Add washers and
bolts to the left frame/upright frame joint. Tighten. Add
washers and bolts to the right frame/ upright frame joint.
Only start these bolts.
Only start
this bolt
Dimples to
the inside
Only start
this bolt
Figure 7
(a)
(b)
19
Step 7
Complete frame assembly
You will need: partial frame assembly, one frame
connector with bushings, one frame connector without
bushings, four 1/4-20 x 2 inch bolts, four nylon washers
and a 7/16 inch wrench.
Hold the frame connector with the bushings between the
two upright frames above the front panel. Turn it so the
bushings are facing down. Add a nylon washer to the
bolt, put the bolts through the frame and screw into the
frame connector. Tighten.
The second frame connector has no bushings. Hold it in
place between the two upright frames. Add a nylon
washer to the bolt, put the bolts through the frame and
screw into the frame connector. Tighten. Figure 8.
Figure 8
Holes up
Bushings
down
Step 8
Insert bottom tubing plugs
You will need: frame assembly, four tubing plugs and a
hammer.
Insert the tubing plugs into the ends of the two upright
frames. To fully seat the plugs, you may have to tap them
lightly with a hammer. Figure 9.
Figure 9
Step 9
Check the frame assembly
To avoid having to disassemble your Weber Gas
Barbecue in a later step, check the positioning of both
frame connectors before continuing with the assembly.
Turn the frame assembly over. The bushings in the front
frame connector should correspond with Figure 10.
The back frame connector has two 1/4 inch diameter
holes in the middle. These holes should be facing down.
Figure 10.
Figure 10
Two bushings
at right
Single bushing
at left
20
Step 10
Secure frame assembly to anchored base
You will need: completed frame assembly, four 1/4-20 x 1
1/2 inch bolts, eight nylon washers, four 1/4-20 hex nuts,
four plastic buttons and a 7/16 inch wrench.
CAUTION: The base must be anchored at all four
anchor points prior to mounting the frame to the
base. See base installation instructions.
Set the assembled frame onto the base. Align the holes
of the frame assembly with the holes in the base. Slip a
washer on a 1/4-20 x 1 1/2 inch bolt. Insert the bolt
through the frame and the base assembly, add a washer
and a 1/4-20 hex nut. Figure 11 (a). Install the remaining
bolts. Tighten using a 7/16 inch wrench.
Align the holes in the flanges of the base assembly with
the front and back frame connector holes. Push in the
four plastic buttons. Figure 11 (b).
Figure 11
(a)(b)
Step 11
Install left end panel
You will need: frame assembly and left end panel
(Number 1).
Place the bottom of the left end panel on the upright
frame lower cross piece. Set the end panel upright in
place. Figure 12.
Figure 12
Step 12
Install three back panels
You will need: frame assembly and the three back panels
(Number 2).
Place the bottom of one back panel on the back frame
connector, notches to the top. Set in place to the far right,
butting up against the right upright frame. Figure 13.
Figure 13
21
Repeat the procedure with the other two back panels.
When in place they should be flush with each other.
Figure 14.
Left upright
Figure 14
Right
upright
Step 14
Install side burner locks
You will need: frame assembly, two side burner locks and
a 7/16 inch wrench.
Loosen the right rear 1/4 x 20 bolt. Install the side
burner lock. The “U” shape cut out of the lock slips down
over the bolt. Tighten with a wrench. Figure 16 (a).
Loosen the right front 1/4 x 20 bolt. The side burner lock
fits between the front panel and the frame.
The “U” shape cut out slips up over the bolt.
Tighten with a wrench. Figure 16 (b).
Figure 16
Step 13
Install bottom accessory trays
You will need: two accessory trays.
Set the accessory tray without the “notched” board
between the two frame connectors. Set the accessory
tray with the notched board halfway in place to hold the
back panels in position. Figure 15.
Notched
accessory
tray
Figure 15
(a)
(b)
22
Step 15
Add cooking box
You will need: frame assembly, cooking box assembly,
1/4-20 x 2 inch bolt, nylon washer, 1/4-20 keps nut,
pliers and a 7/16 inch wrench.
Set the cooking box into the frame so the burner tubes
are under the frame brace. Figure 17.
Burner tubes
Frame brace
Figure 17
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:
a) Do the valves fit into the ends of the burners? Figure
19 (a).
b) 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.
Figure 19 (b).
c) Are the wing nuts under the burner assembly hand
tight? Do not tighten with pliers. Figure 19 (c).
If you answered YES to a, b and c, the burners are
correctly aligned. If you answered NO, the burners are
misaligned. Contact Weber-Stephen Customer Service.
Do not use your barbecue.
View from
below
cooking
box
Guide screw
Figure 19
(a)
(b)
(c)
Wing nuts
Slide the cooking box to the left within the frame. Put the
washer on the bolt. Insert the bolt through the cooking
box and frame with the head of the bolt outside the box.
Figure 18. Add the keps nut. Tighten by holding the bolt
with pliers while you tighten the nut with the 7/16 inch
wrench.
Figure 18
23
Step 16
Install side burner
You will need: side burner assembly, 5/8 inch, 11/16
inch and 3/4 inch or two adjustable wrenches.
WARNING: No sealant is required on the side
burner fitting. Do not use pipe dope, tape or any
other type of sealant on the fitting or hose.
Use an 11/16 inch wrench to remove the protective
brass cap from the side burner fitting on the manifold.
Figure 20 (a).
CAUTION: When removing the cap use a 5/8 inch
wrench to "hold" the side burner fitting to keep it
from becoming loose. If the side burner fitting should
loosen, tighten before attaching the side burner hose.
Slide the side burner assembly into the open end of the
right frame. Route the side burner hose so that it parallels
the front of the barbecue. Loop the hose so that it is in
front of the barbecue gas supply line, and reaches the
side burner fitting without strain. Attach hose and tighten
using a 3/4 inch wrench. Figure 20 (b). Install burner
grate. Check to be sure the side burner valve is OFF.
Push the side burner control knob down and turn
clockwise.
Figure 20
Brass cap
(a)
(b)
Step 17
Install manifold bracket
You will need: manifold bracket.
Hook the bracket onto the manifold at the center burner
valve. Figure 21. Place your hand underneath the bracket.
Lift the bracket, manifold and cooking box slightly as a
unit and hook onto the frame brace. Figure 21 (a).
View from below
cooking box
Frame brace
Manifold bracket
Figure 21
(a)
24
Figure 23
Step 19
Check that all burner valves are off
You will need: one burner control knob.
(Valves are shipped in the OFF position, but you 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 show. Figure 23.
Step 18
Connect barbecue gas supply line to the natural gas supply
Note - We recommend that the connection between
the barbecue gas supply line and the natural gas
supply be flare to flare. A 3/8-inch flare fitting has
been included with the barbecue gas supply line of
your Perma-Mount Gas Barbecue. The fitting is
loosely connected for shipping and should be
removed before installation.
You will need: barbecue gas supply line, 3/8 inch flare
fitting, 3/4 inch and 11/16 inch wrenches.
WARNING: This barbecue is NO
T portable. It
must be bolted down at all times when it is
connected to a natural gas supply.
Unscrew the 3/8 inch flare fitting from the barbecue gas
supply line. Screw the pipe fitting end of the 3/8 inch
flare fitting into the natural gas supply pipe. Tighten with
an 11/16 inch wrench. Figure 22 (a).
Attach the flare nut on the barbecue gas supply line to
the flare fitting end of the 3/8 inch flare fitting. Tighten
with a 3/4 inch wrench. Figure 22 (a).
Attach the flare nut at the other end of the barbecue gas
supply line to the manifold fitting. Finger tighten only. Hold
the supply line against the upright frame crosspiece and
tighten the fitting at the manifold using the 3/4 inch wrench.
Figure 22 (b).
Figure 22
(a)
(b)
Natural Gas
Supply Pipe
Pipe fitting end of
3/8-inch Flare Fitting
Flare fitting end of
3/8-inch Flare Fitting
Barbecue gas
supply line
25
Step 21
Purge air from gas lines
You will need: one burner control knob and FlameCheck
button.
It is necessary to bleed the air out of newly installed gas
lines. Turn gas supply ON at the source. Put on the
FlameCheck button and the front burner control knob.
Push the front burner control knob down and turn to HI.
Push FlameCheck button down and hold down to bleed
the air from lines. When you start to smell gas, release
FlameCheck button and turn front burner control knob to
OFF. Figure 25.
DANGER
Be sure there are no sparks or open
flames in the area while purging. This
can cause fire, explosion or serious
bodily injury.
Figure 25
Step 20
Install igniter
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.
Insert the top of the igniter up through the large part of
the key hole in the frame brace. Loosen the igniter lock
nut and slide the igniter into the small part of the keyhole.
Tighten the igniter lock nut. Figure 24.
Note - If the igniter works loose, carefully tighten the
igniter lock nut with an adjustable wrench or pliers.
Figure 24
Igniter lock nut
Key hole in
frame brace
Small part of
keyhole in
frame brace
Frame brace
Frame brace
(a)
(b)
(c)
26
Step 22
Check for gas leaks
WARNING: You should check for gas leaks every
time you disconnect and reconnect a gas fitting.
Note - All factory made connections have 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.
WARNING: Perform these leak checks even if
your barbecue was dealer or store assembled.
You will need: soap and water solution and a rag or
brush to apply it.
Make sure side burner is OFF. Remove valve control
knob and screws. Remove porcelain top.
Put the FlameCheck button on the FlameCheck valve.
To perform leak checks: Turn ON gas supply.
When checking for gas leaks, push the FlameCheck
button down and hold down until leak checking is
complete. This will allow gas to fill the hoses and
manifold. Figure 26.
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. This will result in a fire or explosion
which can cause serious bodily injury or
death and damage to property.
Check:
a) Barbecue gas supply line to FlameCheck valve
connection. Figure 27 (a).
b) Manifold to side burner hose connection.
Figure 27 (b).
c) Barbecue gas supply line to natural gas supply
connection. Figure 27 (c).
WARNING: If there is a leak at connections a, b or
c, retighten the fitting with a wrench and recheck for
leaks with soap and water solution.
If a leak persists after retightening the fitting, turn
OFF the gas. DO NOT OPERATE THE BARBECUE.
Contact Weber-Stephen Customer Service.
d) Valves to manifold connections. Figure 27 (d).
e) Side burner hose to side burner connection.
Figure 27 (e).
WARNING: If there is a leak at connections d or e,
turn OFF the gas. DO NO
T OPERATE THE
BARBECUE. Contact Weber-Stephen Customer
Service.
When leak checks are complete, turn gas supply OFF
and rinse connections with water.
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.
Figure 26
Figure 27
(a)
(e)
(d)
(c)
(b)
27
Step 23
Install brace panel and right end panel
You will need: brace panel, right end panel,
1/4-20 x 1 1/2 inch bolt, 1/4-20 hex nut, 1/4-20 x 1/2 inch
bolt, 1/4-20 wing nut, three nylon washers, gas line
bracket and a 7/16 inch wrench.
Position the right end panel with the flange at the top
facing away from the barbecue, and the bottom flange
toward the barbecue.
Place a nylon washer on the 1/4-20 x 1/2 inch bolt. Insert
the bolt through the top of the right end panel and the
brace panel. Put on nylon washer, then wing nut and
tighten. Figure 28.
Figure 28
Slide the side burner back. Insert the tabs of the brace
panel into the slots in the frame brace. (Make sure that
the side burner hose is to the front of the barbecue.)
Figure 29. Slide up until the notch in the bottom of the
brace panel fits over the cross brace.
Figure 29
Put a nylon washer on a 1/4-20 x 1 1/2 inch bolt, and
insert through the brace and end panel assembly and the
frame brace. Add the gas line bracket and hex nut.
Tighten with the 7/16 inch wrench. Figure 30. The side
burner hose should be at the top front of the right end
panel.
Note - The bracket holds the barbecue gas supply line to
the frame assembly.
Side burner hose
Tabs on
brace panel
Slots in frame brace
Figure 30
Step 24
Set notched accessory tray in place
Move the accessory tray to the right, in place between the
frame connectors with the notched board toward the
barbecue gas supply line. Figure 31.
Figure 31
28
Step 25
Insert Flavorizer Bars and Steam-N-Chips Smoker
You will need: five long Flavorizer Bars, seven short
Flavorizer Bars, Steam-N-Chips Smoker body and flue.
Place the three long Flavorizer Bars in the rear of the
cooking box. Insert the remaining two bars through the
Steam-N-Chips Smoker flue and set into place in the
cooking box. Figure 32.
Figure 32
Place the short Flavorizer Bars in place in the upper
positions in the cooking box. Set the Steam-N-Chips
Smoker body on the flue and across the long Flavorizer
Bars. Figure 33.
Figure 33
Step 26
Install cooking grates
You will need: two cooking grates.
The open "U" of the cooking grates goes down. The
wide cooking grate goes to the right, narrow grate goes
to the left side of the cooking box. Set the cooking
grates onto the ledges in the cooking box. Figure 34.
Figure 34
29
Step 27
Install left hand swing table
You will need: swing table end bracket, two 10-24 hex
nuts, two 10-24 x 1 3/4 inch machine screws, left hand
slide bar assembly, swing table, four nylon washers,
screwdriver and pliers.
Allow the slide bar to hang down. Push the support rod
into the lower support bracket. Figure 35 (a). Swing the
rod up so you can slide the rod all the way inside the
locking tab. Figure 35 (b). The rod should swing freely
inside the locking tab. Figure 35 (c).
Figure 35
(a)
(b)
(c)
Support rod
Slide bar assembly
Slot in frame
(view from below)
Insert one end of the hinge rod into the hole in the
frame. Figure 36 (a).
Insert the other end into the hole in the swing table end
bracket. Figure 36 (b). Hold the end bracket at an angle so
the lower tab is inside the frame tube. Push the bracket into
the frame. Check to see that the lower tab of the bracket is
hooked in the slot in the frame. Figure 36 (c).
To fully seat the bracket, you may have to tap it lightly with a
hammer.
WARNING: If swing table end bracket is in any
way cracked or damaged, do not use swing table.
Call our Customer Service Center to order a new
part.
WARNING: The load limit for the swing table is
30 pounds.
Figure 36
(c)
View from rear
of barbecue
Hinge rod
(b)
(a)
30
Position slide bar assembly on the outside of the caster
frame. Put a nylon washer on each 1 3/4 inch screw,
insert screws through frame and slide bar assembly and
add nylon washers and hex nuts. Tighten nuts using a
screwdriver and pliers. Figure 37.
Figure 37
View from front of barbecue
Notch to the front
Slide bar
Step 28
Install right hand swing table
You will need: swing table end bracket, two 10-24 hex
nuts, two 10-24 x 1 3/4 inch machine screws, right
hand slide bar assembly, swing table, four nylon
washers, screwdriver and pliers.
Allow the slide bar to hang down. Push the support rod
into the lower support bracket. Figure 39 (a). Swing the
rod up so you can slide the rod all the way inside the
locking tab. Figure 39 (b). The rod should swing freely
inside the locking tab. Figure 39 (c).
Figure 39
(a)
(b) (c)
View from rear
Support rod
Slide bar
assembly
To lower table: Pull support rod up to disengage slide
lock, and lower table. To raise table, lift table up and
engage slide in locked position. Figure 38.
View from rear
of barbecue
Support rod
Locked position
Unlocked position
Figure 38
Slide
31
Figure 41
Figure 42
Position slide bar assembly on the outside of the wheel
frame. Put a nylon washer on each 1 3/4 inch screw,
insert screws through frame and slide bar assembly and
add nylon washers and hex nuts. Tighten nuts using a
screwdriver and pliers. Figure 41.
To lower table: Pull support rod up to disengage slide
lock and lower table. To raise table, lift table up and
engage slide in locked position. Figure 42.
Notch to the front
Slide bar
Support rod
Unlocked position
Slide
Support rod
Locked position
View from front of barbecue
Figure 40
View from rear
of barbecue
Hinge rod
Slot in frame
(view from below)
Insert one end of the hinge rod into the hole in the
frame. Figure 40 (a).
Insert the other end into the hole in the swing table end
bracket. Figure 40 (b). Hold the end bracket at an angle so
the lower tab is inside the frame tube. Push the bracket into
the frame. Check to see that the lower tab of the bracket is
hooked in the slot in the frame. Figure 40 (c).
To fully seat the bracket, you may have to tap it lightly with a
hammer.
WARNING: If swing table end bracket is in any
way cracked or damaged, do not use swing table.
Call our Customer Service Center to order a new
part.
WARNING: The load limit for the swing table is
30 pounds.
(b)
(c)
(a)
32
Step 30
Install the lid
You will need: lid, two hinge pins and two hair pin cotters.
Set the lid in place from the rear of the barbecue. Close
and align the hinge at the rear. Insert hinge pins from the
outside through the hinge. Insert hair pin cotters into the
small holes in the hinge pins. Figure 46.
Figure 46
Hair pin cotter
Hinge pin
Step 29
Install the bottom tray
You will need: bottom tray, catch pan holder, catch pan
and one drip pan.
Hook the ends of the catch pan holder into the hole in the
bottom tray. Figure 44. The front of the catch pan
holder must be on the same side as the finger grip of
the bottom tray.
Slide the bottom tray onto the mounting rails under the
cooking box with finger grip toward you. Figure 45.
CAUTION: 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.
Put the foil drip pan into the catch pan.
Slide the catch pan into the catch pan holder with its
finger grip towards you.
Figure 44
Figure 43
Figure 45
Bottom tray
Finger grip on front
edge of bottom tray
Finger grip
Front side of catch
pan holder
33
Step 31
Install the control panel, burner control knobs, FlameCheck button and tool holders
You will need: control panel, three burner control knobs,
FlameCheck button and three tool holders.
Hook the tool holders over the frame rail. Figure 47.
Set the control panel in place over both frame braces.
(Hold the Crossover Ignition button up while setting the
control panel in place.) Place your thumbs over the
control panel push-in buttons, and push them into the
frame brace until they snap into place. Figure 47 (a).
Push on the burner control knobs and FlameCheck
button. Figure 47 (b).
Hole in frame brace
Figure 47
(a)
(b)
Control panel
push-in buttons
Tool holders
Step 32
Secure the side burner
Pull the right hand swing table up. Stand to the right side
of the barbecue. Slightly pull back both side burner
locks. Slide the side burner toward the control panel.
The locks will snap into the slots in the front and back of
the side burner. Figure 48.
Caution: Make sure both locks have snapped
into place.
View from above
View from side
Figure 48
34
(b)
Figure 50
(c)
(d)
(e)
(f)
Step 33
Install glass doors
You will need: one LH glass door assembly and two RH
glass door assemblies.
Start with the LH door assembly. Insert the long hinge pin
at the top of the door into the plastic bushing in the
underside of the left frame. Insert the bottom (short) hinge
pin into the bushing in the frame connector. Repeat the
procedure with the RH door assemblies. The glass doors
latch on the frame connector. Figure 49.
Bushing in frame
connector and
short hinge pin
Figure 49
Bushing in
underside and
long hinge pin
Step 34
Complete accessory installation
You will need: work table, serving tray, Warm-Up Basket,
warming rack, thermometer, two tubing plugs and a
hammer.
Insert one end of the Weber Warm-Up Basket into the
hole in the right end of the lid and the other end into the
slot in the left end of the lid. Figure 50 (a).
Set the work table onto the left side rails. Figure 50 (b).
Place porcelain serving tray on the work table.
Figure 50 (c).
Set the warming rack into the slots at the rear of the
cooking box. Figure 50 (d).
Insert the thermometer into its holder. Figure 50 (e).
Insert tubing plugs into the ends of the frame. To fully seat
the plugs, you may have to tap them lightly with a
hammer. Figure 50 (f).
(a)
35
Lighting
Summary lighting instructions are on the control panel.
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.
WARNING: Check gas supply line before each use
of barbecue for nicks or cracking. If the gas supply
line is found to be unserviceable, do not use
barbecue. Replace using only Weber authorized
replacement gas supply line. Order from WeberStephen Products Co., Customer Service Center or
authorized dealer.
Figure 1
Crossover Ignition System
3) Turn the gas supply valve on.
4) Push Front burner control knob down and turn to
START/HI.
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.
5) Push down the FlameCheck button and hold down.
Note - Gas is supplied to the burner only when the
FlameCheck button is depressed.
6) Push the Crossover Ignition button several times, so
it clicks each time.
Observe if front burner has ignited by looking
through matchlight hole. If the burner is lit, continue
to hold the FlameCheck button down for about 8
seconds. When the button is released the burner will
stay lit.
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.
7) After the FRONT burner is lit you can turn on the
other burners.
Note - The FRONT burner must be on at all times when
operating the other burners. The FlameCheck Safety
System monitors the Front burner. For your safety, the
FlameCheck valve will shut off the gas to the burners if
the front burner should inadvertently go out during
cooking.
To Extinguish
Turn gas supply OFF at the source, then push down
and turn each burner control knob clockwise to OFF.
OPERATING INSTRUCTIONS
DANGER
Failure to open lid 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.
1) Open the lid. Figure 1.
2) Make sure all burner control knobs are turned OFF.
(Push each burner control knob down and turn
clockwise.)
1
2
7
6
3
4
5
36
5) Open the center glass door. Strike a match and put
the flame into the matchlight hole in the front of the
cooking box.
6) Push down and hold the FlameCheck button down.
Note - Gas is supplied to the burner only when the
FlameCheck button is depressed.
Observe if front burner has ignited by looking
through matchlight hole. If the burner is lit, continue
to hold the FlameCheck button down for about 8
seconds. When the button is released the burner
will stay lit.
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.
7) After the FRONT burner is lit you can turn on the
other burners.
Note - The FRONT burner must be on at all times when
operating the other burners. The FlameCheck Safety
System monitors the Front burner. For your safety, the
FlameCheck valve will shut off the gas to the burners if
the front burner should inadvertently go out during
cooking.
To Extinguish
Turn gas supply OFF at the source, then push down
and turn each burner control knob clockwise to OFF.
Manual Lighting
Summary lighting instructions are on the control panel.
1) Open the lid. Figure 2.
2) Make sure all burner control knobs are turned OFF.
(Push each burner control knob down and turn
clockwise.)
3) Turn the gas supply valve on.
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.
4) Push Front burner control knob down and turn to
START/HI.
Figure 2
Manual Lighting
DANGER
Failure to open lid 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.
1
2
7
3
5
4
6
37
Lighting the side burner
The side burner has a separate ignition system from the
main cooking box.
The side burner will only operate when the Front
burner is lit.
1) Open the side burner lid. Figure 3.
2) Push down and turn the side burner control
valve ON.
3) Push the side burner igniter button several times so
it clicks each time.
CAUTION: Side burner flame may be difficult to see
on a bright sunny day.
WARNING: If the side burner does not light:
a) Turn off the side burner control valve.
b) Wait 5 minutes to let the gas clear before you try
again or try to light with a match.
3
2
1
Figure 3
DANGER
Failure to open lid while igniting the
side burner, or not waiting 5 minutes to
allow 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.
Cooking
You can adjust the FRONT, CENTER, 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, CENTER, and BACK
burners. For example, to sear steaks you would use
(HHH) (all burners at high). Then to complete cooking you
would use (MOM) (FRONT at medium, CENTER off, and
BACK at medium). See your Weber cookbook for detailed
cooking instructions.
If burners go out during cooking, open lid, turn off all
burners and wait 5 minutes before relighting.
Note: The temperatures 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 may require the adjustment of the
burner controls to attain the correct cooking
temperatures.
CAUTION: Replace thermometer in lid when not in
use. Do not leave thermometer in food while cooking
Preheating
Your Weber Gas Barbecue is an energy efficient
appliance. It operates at a low B.T.U. rate for economy. To
preheat, after lighting, close lid and turn all burners to
high (HHH). Preheating to between 500° to 550° F (260°
and 290° C) will take 10 to 15 minutes depending on
conditions such as air temperature and wind.
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.
CAUTION: Check the bottom tray for grease buildup before each use. Remove excess grease to avoid
a grease fire in the bottom tray.
38
After a Period of Nonuse
■ 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.
■ The Spider Stopper Guards should also be checked
for any obstructions. (See Section "Annual
Maintenance.")
Periodic Cleaning
CAUTION: Turn your Weber Gas Barbecue OFF
and wait for it to cool before cleaning.
CAUTION: Do not clean your Flavorizer Bars or
cooking grates in a self-cleaning oven. Replacement
cooking grates and Flavorizer Bars are available
through your retailer or the Weber-Stephen Customer
Service Center.
Outside surfaces - Use a warm soapy water solution.
CAUTION: Do not use oven cleaner, abrasive
cleansers (kitchen cleansers) cleaners that contain
citrus products or abrasive cleaning pads on
barbecue or cart surfaces.
Bottom tray - Remove excess grease and then wash
with warm soapy water.
Flavorizer Bars and Cooking Grates- Clean with a
suitable brass bristle brush. As needed, remove from grill
and wash with warm soapy water.
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.
Thermometer - Wipe with warm soapy water, clean with
plastic scrub ball. Do not put in dishwasher or submerge
in water.
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.
Inside Lid - While lid is warm, wipe inside with paper
towel to prevent flaking due to grease build-up.
39
Using the Steam-N-Chips Smoker
The Steam-N-Chips Smoker cooks with both Weber
FireSpice Wood Chips and Chunks. For best results with
faster cooking foods like steaks, burgers and chops, etc.,
we recommend using the FireSpice Chips because they
ignite and create smoke faster. For longer cooking foods
such as roasts, chicken and turkeys, etc., we recommend
using FireSpice Chunks because they ignite slowly and
provide smoke for a longer period of time. As you gain
experience in using your Steam-N-Chips Smoker, we
encourage you to experiment with different combinations
of FireSpice Chips and Chunks to find the smoke flavor
that best suits your taste.
To use the Steam-N-Chips Smoker
As a starting point, place a handful of FireSpice Chips or
a few FireSpice Chunks in the bottom of the smoker.
Figure 4. Since the chunks vary in size, place as many as
you can in the smoker, allowing room for the water pan.
As you gain experience in smoking, increase or decrease
the amount of wood to suit your taste. Fill water pan,
place it in the smoker and close the smoker lid.
Light the barbecue and preheat with all burners on HIGH,
lid down, for 10 minutes or until thermometer registers
500°F - 550°F. Adjust the burners for cooking; MOM or
LOL will be your best settings for long duration smoking.
Smoke will start in approximately 10 minutes and last as
long as 45 minutes. If you require more smoke flavor, refill
the smoker with FireSpice Chips and /or Chunks and refill
the water pan with water. The Steam-N-Chip Smoker may
be used to enhance any of the meat, poultry and fish
recipes in the gas barbecue cookbook. Cook with the lid
down according to the times indicated in charts
or recipes.
Note - After refilling smoker, smoke will take about 10 to
15 minutes to start again.
Cutaway view
Cleaning the Steam-N-Chips Smoker
Before each use, empty the Steam-N-Chips Smoker of
ash to allow proper air flow. Accomplish this by tapping
the sides of the smoker and stirring the ashes so that they
sift through the bottom and fall into the bottom tray of your
barbecue. Remove bottom tray and empty.
Note - Smoking will leave a "smoke" residue on the
surface of the smoker. This residue cannot be removed
and will not affect the function of the smoker. To a lesser
degree a "smoke" residue will accumulate on the inside
of your Weber Gas Barbecue. This residue need not be
removed and will not adversely affect the function of your
barbecue.
DANGER
Do not use any flammable fluid in the
Steam-N-Chips Smoker to ignite the wood.
This will cause serious bodily injury.
Place wood in here
Steam-N-Chips Flue
Figure 4
Water Pan
Steam-N-Chips Body
40
Annual Maintenance
After a period of nonuse, we recommend that you
perform the following maintenance procedures,
f
or your safety.
WARNING: Check gas supply line before each use
of barbecue for nicks or cracking. If the gas supply
line is found to be unserviceable, do not use
barbecue. Replace using only Weber authorized
replacement gas supply line. Order from WeberStephen Products Co., Customer Service Center or
authorized dealer.
CAUTION: If the barbecue gas supply line is
damaged in any way or leaking, do not use
the barbecue.
■ Inspect the burners for correct flame pattern. Clean
if necessary, following the procedures outlined in the
"General Maintenance" section of this manual.
■ Check all gas fittings for leaks.
WARNING: You should check for gas leaks every
time you disconnect and reconnect a gas fitting.
You will need: soap and water solution and a rag or
brush to apply it.
Make sure main burners are in the OFF position.
Make sure side burner is OFF. Remove valve control
knob and screws. Remove enamel top. Figure 5.
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. This will result in a fire
or explosion which can cause serious
bodily injury or death and damage to
property.
Figure 5
Put the FlameCheck button on the FlameCheck valve.
To perform leak checks: Turn the gas supply on.
WARNING: Do
not ignite burners while
leak checking.
When checking for gas leaks push the FlameCheck
button down and hold down until leak checking is
complete. This will allow gas to fill the hoses and
manifold. Figure 6.
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:
a) Barbecue gas supply line to FlameCheck valve
connection. Figure 7 (a).
b) Manifold to side burner hose connection.
Figure 7 (b).
c) Barbecue gas supply line to natural gas supply
connection. Figure 7(c).
WARNING: If there is a leak at connections (a) or
(c), retighten the fitting with a wrench and recheck
for leaks with soap and water solution.
If a leak persists after retightening the fitting, turn
OFF the gas. DO NO
T OPERATE THE BARBECUE.
Contact Weber-Stephen Customer Service.
Figure 6
41
Inspection and Cleaning of the Weber Spider Stopper Guards
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 do, 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".)
Check:
d) Valves to manifold connections. Figure 7 (d).
e) Side burner hose to side burner connection.
Figure 7 (e).
WARNING: If there is a leak at connections
(b), (d) or (e), turn OFF the gas. DO NO
T OPERATE
THE BARBECUE. Contact Weber-Stephen
Customer Service.
When leak checks are complete, turn gas supply OFF
and rinse connections with water.
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 of the burner tubes. This
blocks the normal gas flow, and can cause the gas to
flow back out of the air shutter. Figure 8. This could
result in a fire in and around the air shutters, under the
control panel, causing serious damage to your
barbecue.
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 9.
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.
4. One or more of the burners do not ignite.
Figure 8
Figure 9
Venturi
Air shutter
Venturi fin
Weber Spider
Stopper Guard
DANGER
Failure to correct these symptoms
may result in a fire which can cause
serious bodily injury or death and cause
damage to property.
Figure 7
(a)
(e)
(d)
(c)
(b)
42
e) Unlatch the Spider Stopper Guards and remove.
Figure 13.
f) Use an adjustable wrench to remove the
thermocouple from the FlameCheck valve.
g) Remove the manifold bracket and unscrew the two
thumb screws that hold the manifold to the cooking
box. Pull the manifold and valve assembly out of the
burners and carefully set it down. Figure 14.
h) Slide the burner assembly out from under the guide
screw and washer in the corners of the cooking box.
Figure 15.
Figure 13
View from below
and behind
cooking box
Thumb screws
Figure 14
Guide screw
Figure 15
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 in Figure 10.
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 11.
Clean the inside of the burners with a wire
(a straightened out coat hanger will work). Figure 12.
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.
CAUTION: Do not enlarge the burner ports when
cleaning.
Replacing Main Burners
a) Your Weber Gas Barbecue must be OFF and cool.
b) Turn gas OFF at source.
c) Remove control panel: take off the burner control
knobs. Put your fingers under the edge of the
control panel at the control panel push-in buttons
and pull toward you. Lift off the control panel.
d) Use a 3/4 inch wrench to unscrew the flare nut on
the barbecue gas supply line from the manifold
fitting.
Figure 11
Figure 12
) Lift and twist the burner assembly slightly, to
separate the crossover tube from the burners.
Figure 16. Remove the burners from the
cooking box.
Crossover tube
Figure 16
Figure 10
Burner inside
cooking box Tips occasionally yellowish
Light blue
Flames
Dark blue
43
ij) To reinstall burners, reverse steps c) through i).
Venturi fin
Check fit around burner
Figure 18
Check fit around
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
are attached properly. Figure 19.
■ 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 igniter” for
correct procedure.
If the Crossover Ignition System still fails to light, contact
Weber-Stephen Customer Service.
FlameCheck Safety System
The correct positioning of the thermocouple probe is
shown in Figure 20. The tip of the probe is positioned in
the flame. The probe senses the heat from the Front
burner, and activates the FlameCheck valve. The valve
allows the gas to flow into the Front burner. If the Front
burner should go out for any reason, the thermocouple
probe will cool off, thereby closing the FlameCheck
valve, which stops the gas flow to the burners.
If the FlameCheck Safety System should fail to operate,
contact Weber-Stephen Customer Service.
Center line
Thermocouple nuts
Figure 20
1/8 inch
Ignition holes
Wall of
cooking box
Figure 19
White wire
Black wire
CAUTION: If the Spider Stopper Guards do not fit
tightly, contact Weber-Stephen Customer Service.
CAUTION: 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".)
k) 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 18.
CAUTION: The burner openings must be
positioned properly over the valve orifices.
Figure 17a.
Check proper assembly before fastening manifold in
place. Figure 17b.
Figure 17
Valve
Burner
(a)
(b)
44
Problem
Burners burn with a yellow or orange flame, in
conjunction with the smell of gas.
Burner does not light, or flame is low
in HIGH position.
Experiencing flare-ups:
CAUTION: Do not line the bottom tray
with aluminum foil.
Burner flame pattern is erratic. Flame is low
when burner is on HIGH. Flames do not run
the whole length of the burner tube.
Inside of lid appears to be “peeling.”
(Resembles paint peeling.)
Check
Inspect Weber Spider Stopper
Guards for possible obstructions.
(Blockage of holes.)
Is natural gas supply on?
Does the Front burner light with a
match?
Are you holding the FlameCheck
button down long enough?
Were the natural gas lines purged?
(air removed)
Are you preheating barbecue in the
prescribed manner?
Are the cooking grates and
Flavorizer Bars heavily coated with
burned-on grease?
Is the bottom tray "dirty" and not
allowing grease to flow into catch
pan?
Are burners clean?
The lid is porcelain-on-steel, not
paint. It cannot “peel.” What you are
seeing is baked on grease that has
turned to carbon and is flaking off.
THIS IS NOT A DEFECT.
Cure
Clean Weber Spider Stopper
Guards. (See Section "Annual
Maintenance".)
Turn on natural gas supply.
If you can light the Front burner
with a match, then check the
Crossover Ignition System.
Hold the FlameCheck button
down for a full eight seconds.
Purge the natural gas lines.
See Step "Purge air from gas
lines."
All burners on high for 10 to 15
minutes for preheating.
Clean thoroughly. (See Section
"Periodic Cleaning".)
Clean bottom tray.
Clean burners. (See Section
"General Maintenance".)
Clean thoroughly. (See Section
"Periodic Cleaning".)
TROUBLESHOOTING
If the problem cannot be corrected using these methods, please contact Weber-Stephen Customer Service.
45
Side Burner Maintenance
WARNING: All gas controls and supply valves
should be in the OFF position.
Check igniter: Remove side burner cover. To remove
side burner cover, remove control knob and screws that
hold cover to bottom. Figure 21. Make sure wire is
connected between igniter and electrode. Check that
igniter lock nut is tight. Figure 22.
Note - If the igniter works loose, carefully tighten the
igniter lock nut with an adjustable wrench or pliers.
Adjust igniter electrode. Gap should be 1/8 to 3/16 inch
from tip of electrode to burner. Figure 23. Spark should
be a white/blue color, not yellow.
Figure 21
Igniter
1/8 to 3/16 inch gap
Figure 22
Figure 23
Problem
Side burner does not light.
Flame is low in HIGH position.
Flame is very yellow in conjunction with
the smell of gas,
OR
Burner makes popping noise in conjunction
with the smell of gas.
Push button ignition does not work.
Check
Is gas supply off? Is the Front
burner on?
Is fuel hose bent or kinked?
Inspect the Weber Spider Stopper
Guard for possible obstructions.
(Blockage of holes.)
Does burner light with a match?
Cure
Turn supply on. Light front
burner.
Straighten hose.
Clean Weber Spider Stopper
Guard. (See Section "Annual
Maintenance.")
If match lights burner, check
igniter (see below).
Side Burner Troubleshooting
WARNING: Before attempting any troubleshooting
steps, all gas controls and supply valves should be
in the OFF position.
Venturi/Burner
Igniter wire
Electrode
46
®®®®®®®
®
1
2
3
7
8
9
10
11
12
13
14
15
16
19-20
22-24
15
34
26
27
31
32
33
34
23
43 44 47
49
20
23
24
18
71-72
50
69
68
70
65
63
64
62
61
60
59
57
56
55
54
53
2
2
2
3
LH
RH
RH
21
18
25
29
30
48
58
67
39
73
73
1
66
75
4-6
1920 3946 5145
36
37
38
39
40
41
42
35
76
52
17
17
28
47
1 Lid (assembly)
2 Weber Warm-Up Basket
3 Warming rack
4 Steam-N-Chips Smoker body
5 Steam-N-Chips Smoker flue
6 Steam-N-Chips Smoker water pan
7 Stainless Steel Short Flavorizer Bars (7)
8 Stainless Steel Long Flavorizer Bars (5)
9 Narrow cooking grate
10 Wide cooking grate
11 Serving tray
12 Work table (Grey)
13 Back panels (3)
14 Tubing plugs (8)
15 1/4-20 x 2 inch bolts (5)
16 Left frame
17 Swing table end brackets (2)
18 Swing tables (2)
19 1/4-20 x 1/2 inch bolts (11)
20 1/4 inch nylon washers (42)
21 Left end panel
22 Left hand slide bar assembly
23 10-24 x 1 3/4 inch machine screws (4)
24 10-24 hex nuts (4)
25 Bottom tray
26 Catch pan holder
27 Catch pan
28 Drip pans (2)
29 Left hand glass door assembly
30 Right hand glass door assemblies (2)
31 Frame connector with bushings
32 Accessory tray (Grey)
33 Accessory tray (Grey) with notch
34 Front/ back base panels (2)
35 Left/ right base panels (2)
36 Cross brace assemblies (2)
37 7/16 - 14 square lock nuts (4)
38 7/16 - 14 x 2 1/2 inch hex head bolts (4)
39 1/4-20 x 1 1/2 inch bolts (9)
40 1/4 inch fender washers (4)
41 Cross braces (2)
42 Mount plates (4)
43 Front panel
44 Frame connector with holes (no bushings)
45 Plastic buttons (4)
46 1/4-20 hex nuts (13)
47 Brace panel
48 Right end panel
49 Right hand slide bar assembly
50 Barbecue gas supply line
51 Gas line bracket
52 3/8 inch flare fitting
53 Hair pin cotters (2)
54 Hinge pins (2) (Hardware size: 1/4 x 1 1/2 inch
clevis pin)
55 Thermometer
56 1/4-20 keps nut
57 Cooking box
58 Burner control knobs (3)
59 FlameCheck button
60 Control panel
61 Crossover tube
62 Front or Back burner
63 Center burner
64 1/4-20 stainless steel wing nuts (2)
65 Manifold assembly
66 Spider Stopper Guards (3)
67 Side burner assembly
68 Thermocouple/capillary
69 Tool holders (3)
70 Right frame
71 Igniter
72 Igniter lock nut
73 Side burner locks (2)
74 Manifold bracket
75 1/4-20 wing nut
76 Upright frames (2)
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.
Parts List
All items are single quantities unless otherwise
specified.
Parts can be ordered directly from Weber-Stephen
Products Co. 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.
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.
Weber-Stephen Products Company
Customer Service Center
250 South Hicks Road
Palatine, IL 60067-6241
(800) 446-1071
A FINAL WORD
OF
THANKS
hank you for choosing a Weber Barbecue.
Our family here at Weber has worked hard
to produce the highest quality products
for your satisfaction.
While we give much attention to our products, an
occasional error may occur. Our knowledgeable
Customer Service staff is prepared 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
T
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