Weber 55159 User Manual

®®

55159 10/18/01

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.

DANGER

If you smell gas:

1. Shut off gas to the appliance.

2. Extinguish any open flames.

3. Open lid.

4. If odor continues, keep away from the
appliance and immediately call your
gas supplier or your fire department.

Leaking gas may cause a fire or
explosion which can cause serious
bodily injury or death, or damage to
property.

Owners Guide

Natural Gas

Y

OU MUST READ THIS OWNERS GUIDE

BEFORE OPERATING YOUR GAS GRILL

WARNING

Do not store or use gasoline or other
flammable liquids or vapors within 25
feet (8m) of this appliance.

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. Accessible parts of the barbecue

may be very hot. Keep young children away while it is in use.

 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, or moved while in operation.

 Should the burners go out while in 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.

 Liquid Propane gas is not natural gas. The conversion or attempted use of natural gas in an

liquid propane unit or liquid propane 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.

 Combustion byproducts produced when using this product contain chemicals known to the

state of California to cause cancer, birth defects, or other reproductive harm.

3

Weber-Stephen Products Co. (Weber) hereby
warrants to the ORIGINAL PURCHASER of this
Weber Gas Grill that it will be free of defects in
material and workmanship from the date of purchase
as follows:

Aluminum Castings, lifetime, 1 year paint

Porcelain Hood Section, 25 years

Burners, 10 years

Igniter, 3 years

Cooking Grates, 3 years no rust through

Flavorizer Bars, 1 year no rust through

Thermoplastic/

Thermoset Parts, 10 years excluding fading

All Remaining Parts, 5 years,

when assembled and operated in accordance with the
printed instructions accompanying it.

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 that prove defective under
normal use and service and which on examination
shall indicate, to Weber's satisfaction, they are
defective. Before returning any parts, contact the
Customer Service representative in your region using
the contact infromation sheet provided with your
manual. If Weber confirms the defect and approves
the claim, Weber will elect to replace such parts
without charge. If you are required to return defective
parts, transportation charges must be prepaid. Weber
will return parts to the purchaser, freight or postage
prepaid.

This Limited Warranty does not cover any failures or
operating difficulties due to accident, abuse, misuse,
alteration, misapplication, vandalism, improper
installation or improper maintenance or service, or
failure to perform normal and routine maintenance,
including but not limited to damage caused by insects
within the burner tubes, as set 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.

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 regions do not allow
the exclusion or limitation of incidental or
consequential damages, so this limitation or exclusion
may not apply to you.

Weber does not authorize any person or company to
assume for it any other obligation or liability in
connection with the sale, installation, use, removal,
return, or replacement of its equipment; and no such
representations are binding on Weber.

This Warranty applies only to products sold at retail.

WEBER-STEPHEN PRODUCTS CO.
Customer Service Center
1890 Roselle Road, Suite 308
Schaumburg, IL 60195
USA

WARRANTY

4

CONTENTS

Danger & Warnings . . . . . . . . . . . . . . . . . . . . .2

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

General Instructions . . . . . . . . . . . . . . . . . . . .5

Exploded View . . . . . . . . . . . . . . . . . . . . . . . .6

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

General Specifications for Piping . . . . . . . . .11

Assembly Instructions . . . . . . . . . . . . . . . . . .14

Operating . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Manual Lighting . . . . . . . . . . . . . . . . . . . . . . .29

Cooking . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

After a Period of Nonuse . . . . . . . . . . . . . . . .30

Periodic Cleaning . . . . . . . . . . . . . . . . . . . . .30

Annual Maintenance . . . . . . . . . . . . . . . . . . .31

General Maintenance . . . . . . . . . . . . . . . . . .32

Replacing Main Burners . . . . . . . . . . . . . . . .32

Crossover Ignition System Operations . . . . .34

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . .35

55

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 accecptable, 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 Standards 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.

WARNING: Never use your Weber Gas Barbecue
under an unprotected combustible roof or
overhang.

WARNING: Your Weber Gas Barbecue is not
intended to be installed in or on recreational
vehicles and/or boats.

WARNING: Do not use combustible materials
within 24 inches of the top, bottom, back or sides
of the grill.

WARNING: The entire cooking box gets hot
when in use. Do not leave unattended.

WARNING: Keep any electrical supply cord away
from any heated surface.

WARNING: 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).

6

Genesis Silver-B Permamount NG 051701

1

2

3

4

6

7

8

9

10

11

12

14

13

15
16

17

18, 19

20

21

22

23

42

43

44

20

41

30

40

39

37

38

36

35

34

33

32

31

30

29

28

27

26

25

24

5

45

7

1 Hinge pin
2 Left endcap
3 Shroud
4 Handle
5 Warm-Up basket
6 Warming rack
7 Cooking grate
8 Flavorizer bar

9 Cooking box
10 1/4-20 keps nut
11 Slide out bottom tray
12 Catch pan holder
13 1/4-20 x 2 inch bolt
14 Left trim piece
15 Work surface
16 Left frame
17 Condiment basket
18 1/4-20 x 1/2 inch bolt
19 1/4 inch nylon washer
20 Side panel
21 Side frame
22 Accessory rack
23 Base panel

24 Hair pin cotter
25 Thermometer
26 Right endcap
27 Burner control knob
28 Control panel
29 Igniter button
30 Control panel hardware
31 Crossover tube
32 Front and back burners
33 Center burner
34 Manifold hardware
35 Manifold
36 Manifold support bracket
37 Disposable drip pan
38 Catch pan
39 Igniter
40 Right frame
41 Control panel trim piece
42 Right trim piece
43 Gas supply line
44 Flare fitting
45 Plastic button

8

© 2001 Weber-Stephen Products Co., Weber, the silhouette, and the kettle configuration are registered
trademarks of Weber-Stephen Products Co., 200 East Daniels Road, Palatine, IL, 60067-6266, U.S.A. This
product is covered by one or more United States patents and patents in other nations globally. Printed in the
U.S.A.

®

9

Screwdriver

Phillips screwdriver

Hammer

7/16 open-end wrench or adjustable wrench

Pliers

Block of wood

Tape Measure

Pencil

Electric Drill

Lid - 1

Cooking Box - 1

Cooking grates - 2

Control panel - 1

Left frame - 1

Right frame - 1

Side frame - 2

Left trim piece - 1

Right trim piece - 1

Work surface - 1

Gas supply line
(with the flare fitting
loosely attached
for shipping purposes)

®

®®®®

Warming rack - 1

Warm-up basket - 1

Accessory rack - 1

Flavorizer bars - 5

Side panel - 2

Base panel - 1

Wrap-around trim piece - 1

Bottom tray - 1

Catch pan holder - 1

Catch pan - 1

Disposable drip pans - 2

Thermometer - 1

10

Condiment basket - 1

Manifold support bracket - 1

Burner control knobs - 3

Hinge pins (1/4-20 x 1 1/2 inch clevis pin) - 2

2 inch bolts (1/4-20 x 2 inch bolts) - 1

1/2 inch bolts (1/4-20 x 1/2 inch bolts) - 8

Keps nut (1/4-20 keps nut) - 1

1/4 inch nylon washers - 15

Cotter pin - 2

Control panel hardware
(phillips screws/washers) - 2

Plastic button - 8

1111

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.

■ 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.

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.

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 Weber­Stephen Customer Service.

1212

Typical natural gas supply installation to a
concrete patio or pad

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

Figure 2

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.

Figure 3

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.

View from behind barbecue

Outside

Inside

Gas supply

Indoor shut off

Accessible
locking shut off

Outside

Inside

Gas supply

Indoor shut off

Accessible
locking shut off

Outside

Inside

Gas supply

Indoor shut off

Accessible
locking shut off

1313

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.

20”

4”

40”

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.

Figure 5

CAUTION: Allow fresh concrete to cure
completely before attempting to anchor the
barbecue to the concrete.

Crushed stone,
sand or gravel

Earth

Concrete pad

14

Step 2

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 1.

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 1 (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 1 (b).

Step 3

Continue frame assembly

You will need: frame assembly, two side frames,
four 1/4-20 x 1/2 inch bolts, four nylon washers
and a 7/16 inch wrench.

Assemble one side frame onto the leg tabs of the
right frame, and the second side frame onto the leg
tabs of the left frame. Make sure the anchoring base
plates are facing in toward each other. The tabs must
be on the inside

of the frames when the joints are

closed.

Add washers, then bolts. Do not full

y tighten these

bolts. You will tighten them once the base is

anchored. Figure 2 (a).

Turn frame assembly right side up.

Figure 1

Figure 2

(a)

(a)

(b)

Do not fully tighten

these bolts

Anchoring base

plates are facing in

15

(1)

(2)

Step 4

Add Wrap-around Frame Panel

You will need: wrap around frame panel and a
wrench.

Place wrap-around frame panel in place:

1) The cut-out tabs should fit between the washer

and the frame, as shown.

2) The square cut-out holes fit around the white

plugs in the frame as shown.

Tighten Bolts with wrench.

Turn the frame over and continue with assembly.

Figure 2.1

Figure 2.2

Fully tighten the 1/4-20 bolts in the frame assembly,
that you only started in Step “Continue Frame
Assembly” Figure 2.2.

16

Figure 3

Figure 5

Figure 4

25

5/8

1

2

3

4

Step 5

Measure and drill holes

You will need: Completed frame assembly, base
panel, tape measure, and pencil.

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.

Set the completed frame assembly in position on your
deck, concrete pad, or patio for anchoring. Measure the
distance from the outside of the base plate to the
outside of the other base plate. It should be 26 5/8”
across. Figure 3.

Note: If the measurement is not 26 5/8” across
adjust the legs as necessary so that the
measurement is 26 5/8”.

Place the base panel in between the legs to insure fit.
Figure 4. Once the fit is established, remove the base
panel and mark the holes.

CAUTION: A minimum of 2 bolts are required on
each side.

You are now ready to anchor the base.

Step 6

Typical installation of the base for an existing
concrete patio, new pad or wood deck

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.

For anchoring, we recommend use of one of the
following methods:

WARNING:Whichever method used, the base
must be bolted down (anchored) at a minimum of
four anchoring points (two per side) prior to
barbecue assembly. One anchor in each corner of
the base plate. Figure 5.

17

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

Concrete lag bolt

3/8 inch flat washer

Mount plate

Lag shield

Drilled hole

Figure 7

Strike anchor

3/8 inch nut

3/8 inch flat washer

Mount plate

Drilled hole

Figure 6

Method 3 - Concrete

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.

Typical installation of the base for an existing
concrete patio, new pad or wood deck
(continued)

Method 1 - Concrete

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.

Method 2 - Concrete

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.

18

Figure 10

3/8 inch x 1 1/2 inch lag bolt

3/8 inch flat washer

Mount plate

Drilled hole

Figure 9

1

2

3

4

Typical installation of the base for an existing
concrete patio, new pad or wood deck
(continued)

Method 4 - 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.

CAUTION: For a deck installation, it is
recommended to anchor one screw into a joist.

Note - With the lid open, the depth of the barbecue
is 28 inches, front to back.

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: Whichever method used, the base
must be bolted down (anchored) at a minimum of
four anchoring points (two per side) prior to
barbecue assembly. One anchor in each corner of
the base plate. Figure 10.

19

Guide screw

(a)

(b)

Wing nuts

View from
behind
cooking
box

Figure 13

Figure 11

Burner tubes

Frame brace

Slide the cooking box to the left within the frame. Put
nylon washer on bolt. Insert the bolt through the frame
and cooking box with the head of the bolt outside the
frame. Figure 12. Add the keps nut. Tighten by holding
the bolt with pliers while you tighten the nut with the
7/16 inch wrench.

Figure 12

Step 7

Add cooking box

You will need: frame assembly, cooking box assembly,
spacer bracket, 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 in the frame so the burner tubes
are under the frame brace. Figure 11.

Note: Be careful when sliding the burner tubes
through the side frame.

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) 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 13 (a).

b) Are the wing nuts under the burner assembly hand

tight? Do not tighten with pliers. Figure 13 (b).

If you answered YES to a and b, the burners are
correctly aligned. If you answered NO, the burners are
misaligned. Contact Weber-Stephen Customer
Service. Do not use barbecue.

Step 8

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 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. Apply pipe sealant to the threads
of the pipe fitting. 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 14 (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 14 (a).

Attach the flare nut at the other end of the barbecue
gas supply line to the manifold fitting. Tighten with a 3/4
inch wrench. Figure 14 (b).

20

Figure 14

(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

Apply pipe
sealant here

Figure 15

View from below
cooking box

Frame brace

Manifold bracket

Figure 16

(a)

Step 9

Check all 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 step.
Figure 15.

Step 10

Install manifold bracket

You will need: manifold bracket.

Hook the bracket onto the manifold at the center burner
valve. Figure 16. Place your hand underneath the
bracket. Lift the bracket, manifold and cooking
box slightly as a unit and hook onto the frame brace.
Figure 16 (a).

21

Figure 17

Igniter lock nut

Keyhole in
frame brace

Small part of keyhole
in frame brace

Frame brace

Frame brace

(a)

(b)

(c)

Figure 18

Step 11

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 keyhole in the frame brace. Figure 17 (b). Loosen
the igniter lock nut and slide the igniter into the small
part of the keyhole. Figure 17 (c). Tighten the igniter
lock nut. Figure 17.

Note - If the igniter works loose, carefully tighten the
igniter lock nut with an adjustable wrench or pliers.

Step 12

Purge air from gas lines

You will need: one burner control knob.

 DANGER

Be sure there are no sparks or open
flames in the area while purging. This
can cause fire, explosion or serious
bodily injury.

It is necessary to bleed the air out of newly installed
gas lines. Turn gas supply ON at the source. Put on the
front burner control knob. Push the front burner control
knob down and turn to HI. When you start
to smell gas, turn front burner control knob to OFF.
Figure 18.

22

Figure 20

Figure 19

(a)

Gas supply shut
off at the house

(c)

(b)

Step 13

Check for gas leaks

 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.

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.

To perform leak checks: Turn ON gas supply at the
source. Figure 19.

WARNING: Do

not ignite burners while leak

checking.

Check for leaks by wetting the connections with the
soap and water solution and watching for bubbles. If
bubbles form or if a bubble grows there is a leak.

Note - Since some leak test solutions, including soap
and water, may be slightly corrosive, all connections
should be rinsed with water after checking for leaks.

Check:

a) Gas supply line to manifold connection.

Figure 20 (a).

WARNING: If there is a leak at connection a,
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.

b) Valves to manifold connections. Figure 20 (b).

c) Barbecue gas supply line to natural gas supply

connection. Figure 20 (c).

WARNING: If there is a leak at connections b or
c, turn OFF the gas. DO NO

T OPERA

TE THE

BARBECUE.

Contact Weber-Stephen Customer

Service.

When leak checks are complete, turn gas supply OFF
and rinse connections with water.

23

Figure 21

Figure 22

(a)

Base panel

Left side
panel

top

bottom

Right side
panel

Step 14

Add base panel

You will need: Base panel.

Put the right side in and down, tilt and set the left side
in place. Figure 21.

Step 15

Install side panels

You will need: two side panels, and eight plastic
buttons.

From the inside of the frame assembly, set the left
side panel in place between the side frame legs.

Notice that there are two sets of holes in each side
panel. Align the holes in the side panel to match the
holes in the left side frame legs. Push in the four
plastic buttons. Figure 22 (a).

Repeat with the right side panel.

24

Figure 26

Figure 25

Figure 27

Bottom tray

Finger grip on front
edge of bottom tray

Finger grip

Front side of catch
pan holder

Figure 23

Figure 24

Step 16

Install Flavorizer Bars and Cooking Grates

You will need: five long Flavorizer Bars and two
cooking grates.

Set the long Flavorizer Bars side to side in position.
Figure 23.

The open "U" of the cooking grates goes down. Set
the cooking grates onto the ledges in the cooking box.
Figure 24.

Step 17

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 26. 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 27.

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.

25

Hair pin cotter

Hinge pin

Figure 28

Figure 29

Tool holders

Control panel
push-in buttons

(a)

(b)

Step 18

Install Lid

You will need: lid, two hinge pins and two hair pin
cotters.

Set the lid in place. Align the hinges at the rear of the
barbecue. Insert hinge pins from the outside. Insert hair
pin cotters into the small holes in the hinge pins. Figure

28.

Step 19

Add tool holders, control panel and burner
control knobs

You will need: three tool holders, control panel, two
Phillips screws/washers, a Phillips screwdriver, and
three burner control knobs.

Hook the tool holders over the frame rail and snap
down into place. Figure 29.

Set the control panel in place over both frame braces.
(Hold the Crossover Ignition button up while setting the
control panel in place.) Line up the holes in the control
panel with the holes in the inserts in the frame brace.
Insert screws and tighten with a Phillips screwdriver
until snug. Do not overtighten. Figure 29 (a).

Push on the burner control knobs. Figure 29 (b).

Crossover

Ignition Button

Insert in

frame brace

26

Slot in frame
(view from
below)

Figure 30

Wire end

(a)

Step 20

Install the condiment basket

You will need: condiment basket, left end trim piece,
two 1/4-20 x 1/2 inch bolts, and two nylon washers.

Insert one wire end of the condiment basket into the
hole in the side frame. Figure 30 (a).

Push the trim piece into the frame. Check to see that
the lower tab of the bracket is hooked in the slot in
the frame. Figure 31.

Add a washer to the bolt and insert it through the hole
in the frame and the hole in the trim piece. Tighten
with a wrench. Figure 32.

Figure 31

Figure 32

Start the left end trim piece into the frame as shown.
Figure 30 (b). Do not push the trim piece all the
way and do not add bolts yet. While holding the
condiment basket in position, insert the other wire end
of the condiment basket into the left end trim piece.

WARNING: If the left end trim piece is in any
way cracked or damaged, do

not use the
condiment basket. Call our Customer Service
Center to order a new part.

(view from below)

(b)

27

Figure 34

Figure 33

(b)

(a)

Right side

frame

Left side

frame slots

Left hooks

Step 21

Install the accessory rack

You will need: accessory rack.

Rest the left end of the accessory rack on the base
panel. Figure 33 (a).

Insert the right hooks into the right side frame slots.
Figure 33 (b).

Raise the left end up and slide left hooks into the left
side frame slots. Figure 33.

Step 22

Complete accessory installation

You will need: Warm-Up Basket, warming rack, work
surface, thermometer, right trim piece with tool holder,
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 34 (a).

Set the warming rack into the slots at the rear of the
cooking box. Figure 34 (b).

Set the work surface onto the left side rails. Figure
34 (c). Make sure that the tabs on the side of the
table are to the right, next to the cooking box.

Insert the thermometer into its holder. Figure 34 (d).

Push the right trim piece into the frame as shown
34 (e), making sure that the tabs on the underside
of the trim piece are snapped into the slots in the
frame 34 (f).

(a)

(b)

(d)

(c)

(e)(f)

2828

Figure 1

Crossover Ignition System

OPERATING INSTRUCTIONS

Lighting

Summary lighting instructions are on the control panel.

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.)

3) Turn 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.

5) Push the Crossover Ignition Button several times,
so it clicks each time.

6) Check that the burner is lit by looking through the
matchlight hole on the front of the cooking box.

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 - Always light the FRONT burner first. The other
burners ignite from the FRONT burner.

To Extinguish

Turn gas supply OFF at the source, then push
down and turn each burner control knob
clockwise to OFF.

 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.

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 damaged in any way, do
not use the barbecue. Replace using only Weber
authorized replacement gas supply line. Order
from Weber-Stephen Products Co., Customer
Service Center.

1

2

7

6

5

4

29

Figure 2

Manual Lighting

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 - Always light the FRONT burner first. The other
burners ignite from the FRONT burner.

To Extinguish

Turn gas supply OFF at the source, then push
down and turn each burner control knob
clockwise to OFF.

 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 2.

2) Make sure all burner control knobs are turned OFF.
(Push each burner control knob down and turn
clockwise.)

3) Turn gas supply valve on.

4) Strike a match and put the flame into the matchlight
hole in the front of the cooking box.

Manual Lighting

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 Front burner control knob down and turn to
START / HI.

6) Check that the burner is lit by looking through the
matchlight hole on the front of the cooking box.

1

2

7

4,6

5

30

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.

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.

If burners go out during cooking, open lid, turn off
all burners and wait 5 minutes before relighting.

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° and 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
build-up before each use. Remove excess grease
to avoid a grease fire in the bottom tray.

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 Weber­Stephen 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.

Work tables and accessory trays - Use any
household cleaners on these surfaces except those that
contain acid, mineral spirits or Xylene. Rinse well after
cleaning.

Plastic work surfaces are not to be used as cutting
boards.

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.")

■ Keep the appliance area clear and free from

combustible materials, gasoline and other
flammable vapors and liquids.

31

(a)

(c)

(b)

Figure 3

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 damaged in any way, do
not use the barbecue. Replace using only Weber
authorized replacement gas supply line. Order
from Weber-Stephen Products Co., Customer
Service Center.

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.

 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.

WARNING: You should check for gas leaks
every time you disconnect and reconnect a gas
fitting.

You will need: a soap and water solution and a rag or
brush to apply it.

To perform leak checks: Make sure all burners are in
the OFF position. Turn on gas supply.

Refer to the steps “Add side panels” and “Add base
panel” to remove the panels to expose the gas supply
line for leak checking.

WARNING: Do not ignite burners while leak
checking.

Check for leaks by wetting the connections with the
soap and water solution and watching for bubbles. If
bubbles form or if a bubble grows there is a leak.

Note - Since some leak test solutions, including soap
and water, may be slightly corrosive, all connections
should be rinsed with water after checking for leaks.

Check:

a) Gas supply line to manifold connection. Figure 3 (a).

WARNING: If there is a leak at connection (a),
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.

b) Valves to manifold connections. Figure 3 (b).

c) Barbecue gas supply line to natural gas supply

connection. Figure 3 (c).

WARNING: If there is a leak at connections (b)
or (c), turn OFF the gas. DO NO

T OPERATE THE

BARBECUE.

Contact Weber-Stephen Customer

Service.

When leak checks are complete, see steps “Add side
panels” and “Add base panel” to reinstall. Turn gas
supply OFF at the source and rinse connections
with water.

Inspection and cleaning of the Spider/Insect
screens

To inspect the spider/insect screens, remove the
control panel. If there is dust or dirt on the screens,
remove the burners for cleaning the screens. Refer to
Maintenance, Replacing Main Burners. Brush the
spider/inspect screens, lightly, with a soft bristle brush
(i.e. an old toothbrush).

Caution: Do not clean the spider/insect screens
with hard or sharp tools. Do not dislodge the
spider/insect screens or enlarge the screen
openings.

Lightly tap the burner to get debris and dirt out of the
burner tube. Once the spider/insect screens and
burners are clean replace the burners.

If the spider/insect screen becomes damaged or
cannot be cleaned, call Weber-Stephen Products
Customer Service for replacement parts.

32

General Maintenance

Weber Spider/Insect Screen

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.
This could result in a fire in and around the air
shutters, under the control panel, causing serious
damage to your barbecue.

The burner tube air shutter is fitted with a stainless steel
screen(1) to prevent spiders and other insects access
to the burner tubes through the air shutter openings.

We recommend that you inspect the Spider/Insect
Screens at least once a year. (See section “Annual
Maintenance”.) Also inspect and clean the
Spider/Insect Screens 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.

 DANGER

Failure to correct the above mentioned
symptoms may result in a fire, which
may cause serious bodily injury or
death, and cause damage to property.

Main Burner Flame Pattern

The Weber Gas Barbecue burners have been factory
set for the correct air and gas mixture. The correct
flame pattern is shown.

1) Burner Tube

2) Tips occasionally flicker yellow

3) Light Blue

4) Dark Blue

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.

Look inside each burner with a flashlight.

Clean the inside of the burners with a wire (a
straightened out coat hanger will work). Check and
clean the air shutter opening at the ends of the
burners. Check and clean the valve orifices at the
base of the valves. Use a brass bristle brush to clean
outside of burners. This is to make sure all the burner
ports are fully open.

CAUTION: Do not enlarge the burner ports when
cleaning.

Replacing Main Burners

1) Your Weber Gas Barbecue must be OFF and cool.

2) Turn gas OFF at source.

3) Remove control panel: take off the burner control
knobs. Remove the screws holding the control
panel in place. Lift off the control panel.

(1)

(1)

(2)

(3)
(4)

(1)

33

(1)

(1)

4) Disconnect gas supply line.

5) Unhook the manifold bracket and unscrew the two
wing nuts(1) that hold the manifold to the cooking
box. Pull the manifold and valve assembly out of
the burners and carefully set it down.

6) Slide the burner assembly out from under the
guide screw and washer(1) in the corners of the
cooking box.

7) Lift and twist the burner assembly slightly, to
separate the crossover tube(1) from the burners.
Remove the burners from the cooking box.

7) To reinstall the burners, reverse steps 3) through 7).

CAUTION: The burner openings(1) must be
positioned properly over the valve orifices(2).

Check proper assembly before fastening manifold in
place.

WARNING: After reinstalling the gas lines, they
should be leak checked with a soap and water
solution before using the barbecue. (See
Step:”Checking for Gas Leaks.”

(1)

(2)

(1)

34

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(1) and black(2) ignition

wires are attached properly.

■ 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 the Customer Service Representative in your
region using the contact information sheet provided
with your manual.

(1) (2)

35

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 Spider/Insect Screens for
possible obstructions. (Blockage of
holes.)

Is natural gas supply on ?

Does the Front burner light with a
match?

Were 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 Spider/Insect
Screens. (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.

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 problems cannot be corrected by using these methods, please contact Weber-Stephen Customer
Service.