Weber 98615 User Manual

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Serial Number

Please use this number in registering your warranty and any correspondence with the factory.

GENESIS®2000 Series

LP Gas Barbecue

Owner’s Manual

National

Association

PROPANE

GAS

98615 10/97

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.

NOTICE TO INSTALLER: These instructions must be left with the owner and the owner should keep them for future use.

FOR YOUR SAFETY If you smell gas:

1. Shut off gas to the appliance.

2. Extinguish any open flame.

3. Open lid.

4. If odor continues, immediately call your gas supplier or your fire department.

FOR YOUR SAFETY

1. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

2. An LP tank not connected for use shall not be stored in the vicinity of this or any other appliance.

W ARNING: Follow all leak check procedures carefully in this manual prior to barbecue operation. Do this even if barbecue was dealer assembled.

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 danger ous. Please carefully follo w the assembly instructions in this manual.  After a period of storage, and/or nonuse, the Weber Gas Barbecue should be chec ked for gas leaks

and burner obstructions before using. See instructions in this man ual 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 inc hes 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 v alves off . Open the lid and wait five minutes

before attempting to relight, using the lighting instructions.

 Do not use charcoal or lav a 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 thor oughl y cleaned on a regular basis.  LP gas is not natural gas. The conver sion 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 W eber 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 c hec ked 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 y our self .

3. Call your fire department.

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 and Flavorizer Bars, 3 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 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 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

LP Tank

The LP tank manufacturer is responsible for the materials, workmanship and performance of the tank. If the tank has a defect, malfunctions, or you have a question regarding the tank, call the tank manufacturer's customer service center. The phone number is on the warning decal which is permanently attached to the tank. If the tank manufacturer has not resolved the issue to your satisfaction, then call Weber-Stephen Products Co., Customer Service Center.

WARRANTY

© 1997 Weber. Weber, , Genesis, Flavorizer and Crossover are registered U.S. trademarks; Perma-Mount, Gas Catcher, FlameCheck, Steam-N-Chips, Spider Stopper, and Warm-Up are U.S. trademarks of Weber-Stephen Products Co., 200 East Daniels Road, Palatine, IL 60067-6266. U.S.A. Genesis Gas Barbecues are covered under the following patent nos.: U.S.A. #4,677,964; 4,727,853; #4,777,927; #4,829,978; #4,860,724; #4,941,817; #4,966,125; #5,070,776; #D293,067; #D316,355; Canada: Rd 1987 Reg. #58,034; #1,279,540; #1,283,586; #1,300,994; #1,300,995. Printed in the U.S.A.

PATENTS AND TRADEMARKS

WARNINGS................................................................ 2

Warranty & Patents.................................................. 3-4

General Instructions.................................................... 6

Assembly............................................................... 7-21

Operating Instructions

Lighting ........................................................22-23

Cooking............................................................ 24

Storage and/or Nonuse.................................... 24

Cleaning........................................................... 24

LP Tank Information.................................... 25-27

Troubleshooting & Maintenance

Annual Maintenance ........................................ 28

General Maintenance.................................. 29-31

Troubleshooting ............................................... 32

Parts Listing.............................................................. 35

FEATURES:

a) Convenient tables and racks. b) Heavy gauge porcelain-on-steel lid seals in heat. c) Rapid read thermometer for precision cooking

measures grill temperature, and can be removed and inserted into the food.

d) Heavy gauge steel Flavorizer Bars distribute heat

within the grill. Flavorizer Bars heat just the right amount of drippings for flavoring, letting excess fat drip past to help prevent flare-ups. Uncontrolled flareups are eliminated (versus lava rock systems on other grills). The heavy gauge steel Flavorizer Bars are easy to clean.

e) Weber Warm-Up Basket for additional cooking or

warming space. f) Separate burners for temperature control. g) Crossover Ignition System with Gas Catcher Ignition

Chamber. h) Fuel scale indicates LP gas supply. i) Catch pan catches excess grease. j) Locking casters for additional portability.

IMPORTANT NEW FEATURES:

Your Weber Gas Barbecue is equipped with a new and improved LP tank connection, that has additional safety features. They are:

1. The connection of the barbecue to the LP tank can be made without the use of tools.

2. The new connection will not permit the flow of gas until a positive gas connection is made.

3. If an accidental fire occurs at the LP tank connection, the flow of gas is stopped by a temperature activated shutoff.

4. If the LP supply hose becomes damaged, cut, punctured, or accidentally fire damaged, the barbecue connection is equipped with an excess flow control that will limit the flow of gas if leakage or a fire occurs.

General Instructions

Your Weber Gas Barbecue is a portable outdoor cooking appliance. With the Weber Gas Barbecue you can grill, barbecue, roast and bake with results that are difficult to duplicate with indoor kitchen appliances. The closed lid and Flavorizer Bars produce that "outdoor" flavor in the food.

The Weber Gas Barbecue is portable so you can easily change its location in your yard or on your patio. Portability means you can take your Weber Gas Barbecue with you if you move.

Liquid Propane (LP) gas supply is easy to use and gives you more cooking control than charcoal fuel.

■ These instructions will give you the minimum requirements for assembling your Weber Gas

Barbecue. Please read the instructions carefully before using your Weber Gas Barbecue. Improper assembly can be dangerous.

■ Not for use by children.

■ If there are local codes that apply to portable gas grills,

you will have to conform to them. If there are no local codes, you must conform to the latest edition of the National Fuel Gas Code: ANSI Z 223.1.

■ The pressure regulator supplied with the Weber Gas Barbecue must be used. This regulator is set

for 10.5 inches of water column (pressure).

■ This Weber Gas Barbecue is designed for use with liquid propane (LP) gas only. Do not use with natural

(piped in city) gas. The valves, orifices, hose and regulator are for LP gas only.

■ Do not use with charcoal fuel.

■ Check that the area under the control panel and the

bottom tray are free from debris that might obstruct the flow of combustion or ventilation air.

■ The area around the LP tank must be free and clear from debris.

For Installation in Canada

These instructions, while generally acceptable, do not necessarily comply with the Canadian Installation codes, particularly with piping above and below ground. In Canada the installation of this appliance must comply with local codes and/or Standard CAN/CGA-B149.2 (Installation Code for Propane Burning Appliances and Equipment).

Storage

■ The gas must be turned OFF at the LP tank when the Weber Gas Barbecue is not in use.

■ When the Weber Gas Barbecue is stored indoors, the gas supply must be disconnected and the LP tank

stored outdoors in a well-ventilated space.

■ LP tanks must be stored outdoors in a well-ventilated area out of the reach of children. Disconnected LP

tanks must not be stored in a building, garage or any other enclosed area.

■ When the LP tank is not disconnected from the Weber Gas Barbecue, the appliance and LP tank must be

kept outdoors in a well-ventilated space.

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 and the fuel supply hose away from any heated surface.

■ Keep the cooking area clear of flammable vapors and liquids, such as gasoline, alcohol, etc., and

combustible materials.

■ Never store an extra (spare) LP tank under or near the Weber Gas Barbecue.

Step 1

Check package contents

Cooking box (assembly)

Lid (assembly)

LP tank

LP tank filler adapter

Bottom tray

Two work tables

Two accessory trays

Swing table

Assembly

Tools needed

Screwdriver

Phillips screwdriver

Hammer

7/16 inch or an adjustable wrench

Pliers

Block of wood

Supplies needed

Your LP tank is shipped empty for safety. After setting the LP fuel scale you will need to fill it. (See Step "Fill LP tank.")

You will need a soap and water solution to check for gas 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.

®®®®®®®

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.

Control panel

Front panel

Left frame

Wheel frame

Two frame connectors

Tank panel assembly

Five long Flavorizer Bars

Eight short Flavorizer Bars

Two wheels

Two aluminum drip pans

Catch pan

Axle

Right frame

Caster frame

Two casters

Two cooking grates

Warming rack

Warm-Up Basket

Thermometer

Left hand slide bar assembly

Assembly consists of:

Left hand slide bar

Support rod

Slide

Two 10-24 x 1 3/4 machine screws

(actual size)

Two 10-24 hex nuts

(actual size)

Eighteen 1/4 inch nylon washers

(actual size)

1/4-20 keps nut

1/4-20 x 1 1/4 inch bolt

(actual size)

1/4-20 hex nut

(actual size)

Two hair pin cotters

Swing table end bracket

Fuel scale assembly

Catch pan holder

Manifold bracket

Check contents of hardware packs

Three burner control knobs

Three tool holders

Five tubing plugs (two are spares)

Two wheel hubcaps

(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)

Six 1/4-20 x 1/2 inch bolts

(actual size)

Two 1/4-20 wing nuts

(actual size)

Two Phillips screws/washers

Step 2

Assemble wheels

You will need: axle, two wheel hubcaps, two wheels, wheel frame, hammer and a block of wood.

Place one end of the axle on the block of wood (or other protected surface). Tap on one hubcap.

Put one wheel on the axle, WEBER side toward the hubcap. Slide the axle through the frame. Add the other wheel, WEBER side out. Tap on the hubcap. Figure 1.

Figure 1

Step 3

Assemble 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 2.

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 2 (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 2 (b).

Left frame

Leg tabs

Frame tabs

Figure 2

(a)

(b)

Right frame

Step 4

Continue frame assembly

You will need: frame assembly, wheel frame assembly, front panel, caster frame, four 1/4-20 x 1/2 inch bolts, four nylon washers and a 7/16 inch wrench.

Place the caster frame onto the tabs of the left frame with the dimple to the inside. Figure 3. Place the wheel frame onto the tabs of the right frame with the dimple to the inside. The fuel scale decal should face away as shown. Figure 3.

The leg tabs must be on the inside of the frames. Add front panel with large hole down and to your right.

Add the washers to the bolts, insert in the holes as shown and tighten with the wrench. Figure 3.

Note - Fuel scale decal on wheel frame must be on the same side as the front panel.

Dimples to the inside

Fuel scale decal

Figure 3

Step 5

Complete frame assembly

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

Hold one frame connector between the caster and wheel frame. Add nylon washers to the bolts. Put the bolt through the frame and screw into frame connector. Tighten.

Repeat procedure with the other frame connector. Figure 4.

Figure 4

Step 6

Insert casters

You will need: frame assembly and two casters. Push the casters firmly into the inserts in the ends of the

caster legs. Figure 5.

Figure 5

Burner tubes

Figure 6

Frame brace

Step 7

Add cooking box

You will need: frame assembly, cooking box assembly, 1/4-20 x 2 inch bolt, 1/4 inch nylon washer, 1/4-20 keps nut, pliers and a 7/16 inch wrench.

Turn frame assembly right side up. Uncoil the hose. Set the cooking box into the frame so the burner tubes are

under the frame brace. Figure 6.

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 8 (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 8 (b).

c) Are the wing nuts under the burner assembly hand

tight? Do not tighten with pliers. Figure 8 (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.

Guide screw

Figure 8

(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 7. Add keps nut. Tighten by holding the bolt with pliers while you tighten the nut with the 7/16 inch wrench.

Figure 7

Step 9

Install tank panel assembly

You will need: tank panel assembly, 1 1/4 inch bolt, 1/4-20 hex nut, 1/4 inch nylon washer and a 7/16 inch wrench.

Insert the tank panel tabs into the slots in the frame brace. Slide up until the notch at the bottom of the tank panel fits over the cross brace. Figure 10 (a).

Add the washer to the bolt. Put the bolt through panel and frame brace, add hex nut and tighten with the 7/16 inch wrench. Figure 10 (b).

Figure 10

(a)

(b)

Tabs on tank panel

Slot in frame brace

Frame brace

Cross brace

Step 8

Install manifold bracket

You will need: manifold bracket Hook the bracket onto the manifold at the center burner

valve. Figure 9. Place your hand underneath the bracket. Lift the bracket, manifold and cooking box slightly as a unit and hook onto the frame brace.

Figure 9

Frame brace

Manifold bracket

Step 11

Install igniter

Note - The igniter wires are already attached to the Gas Catcher Ignition Chamber and the igniter. This w as 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 12 (b). Loosen the igniter lock nut and slide the igniter into the small part of the keyhole. Figure 12 (c). Tighten the igniter lock nut. Figure 12.

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

Figure 12

Igniter lock nut

Keyhole in frame brace

Step 10

Add fuel scale

You will need: fuel scale, two 1/4-20 wing nuts and two nylon washers.

Slip the bolts on the back of the fuel scale assembly through the two small holes in the tank panel. Make sure indicator rod of fuel scale is on the left side of the wheel frame.

Add washers, then wing nuts and tighten. Figure 11.

Figure 11

View from front left View from front right

Small part of keyhole in frame brace

Frame brace

(a)

(b)

(c)

Step 12

Set LP fuel scale

You will need: LP tank (empty).

Note - For accuracy, the fuel scale must be set with an empty tank.

We utilize various LP tank manufacturers. Some of the tanks we receive have differing top collar assemblies. (The top collar is the metal protective ring around the valve.) One series of tanks mounts with the valve facing the front. The other tanks mount with the valve facing away from the fuel scale. These types of tanks are illustrated in Figure 13.

Loosen the tank lock wing nut. Tighten so the lock is held up out of the way. Figure 13 (a). Lift and hook the tank onto the fuel scale. With an empty LP tank, adjust the fuel scale setting to E by turning the scale setting (top) wing nut. Figure 13 (b).

CAUTION: Do not remove adjustment wing nut from tank scale.

After adjusting tank scale, push tank down a couple of times to check that the tank scale is set on “E”.

FEF

Figure 13

Tank lock wing nut

(a) (b)

Scale setting wing nut

Step 13

Fill LP tank

Note - The LP tank manufacturer is responsible for the materials, workmanship and performance of the tank. If the tank has a defect, malfunctions, or you have a question regarding the tank, call the tank manufacturer's customer service center. The phone number is on the warning decal which is permanently attached to the tank. If the tank manufacturer has not resolved the issue to your satisfaction, then call Weber-Stephen Products Co., Customer Service Center.

To fill, take the LP tank and filler adapter to an RV center or look up gas-propane in the phone book for other sources of LP gas.

WARNING: We recommend that your LP tank be filled at an authorized LP gas dealer by a qualified attendant, who fills the tank by weight.

IMPROPER FILLING IS DANGEROUS.

Tell your LP dealer that this is a new LP tank. The air must be removed from a new LP tank before the initial filling. Your LP tank dealer is equipped to do this.

WARNING: If you exchange your LP tank, make sure you get a similar tank in return. Your LP tank is equipped with a quick-disconnect valve and an OPD (Overfilling Prevention Device). Other LP tanks are not compatible with your barbecue connection.

The LP tank must be installed, transported and stored in an upright position. LP tank should not be dropped or handled roughly.

Never store or transport the LP tank where temperatures can reach 125° Fahrenheit (too hot to hold by hand – for example: do not leave the LP tank in a car on a hot day).

For full instructions on safe handling of LP tanks, see section "Operating Instructions".

Route the hose so it will not interfere with the scale indicator rod.

The hose and regulator are connected in the following manner:

Slide back the collar of the quick disconnect on the tank valve. Push the male fitting of the regulator into the quick disconnect, and maintain pressure. Slide the collar closed. Figure 16 (a). Figure 16 (b) shows the quick disconnect engaged and various components of the tank and regulator. Regulator vent hole should be at 3, 6, or 9 o'clock. It should not be pointed up. Figure 16 (c).

Figure 16

Turn so regulator vent does not collect water

Hose

Tank lock wing nut

Quick disconnect engaged

Valve handwheel close clockwise

Tank valve

Collar

Male fitting

Pressure relief valve

Tank

Regulator

Regulator vent

(a)

(b)

(c)

Step 15

Connect LP tank

WARNING: Make sure that the LP tank valve is closed. Close by turning clockwise.

Hook the LP tank onto the fuel scale. Loosen the tank lock wing nut. Swing the tank lock down. Tighten the wing nut. Figure 15.

Step 14

Check that the 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 step. Figure 14.

Figure 15

Figure 14

Step 16

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.

Check: a) Hose to manifold connection. Figure 18 (a). b) Regulator to tank connection. Figure 18 (b).

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.

c) Valves to manifold connections. Figure 18 (c). d) Hose to regulator connection. Figure 18 (d).

WARNING: If there is a leak at connections (b), (c) or (d), turn OFF the gas. DO NOT OPERATE THE BARBECUE. Contact Weber-Stephen Customer Service.

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

FEF

Figure 17

Figure 18

(a)

(b)

(c)

(d)

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.

WARNING: Do not ignite burners while leak checking.

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 Genesis 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: a soap and water solution and a rag or brush to apply it.

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

To perform leak checks: open tank valve by turning the tank valve handwheel counterclockwise. Figure 17.

Step 17

Install Flavorizer Bars and Cooking Grates

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

Set the long Flavorizer Bars side to side in the lower position, then set the short Flavorizer Bars front to back in the upper position in the cooking box. Figure 19.

Figure 19

The open "U" of the cooking grates goes down. Set the cooking grates onto the ledges in the cooking box. Figure 20.

Figure 20

Step 18

Install the bottom tray

You will need: bottom tray, catch pan holder, catch pan and one drip pan.

Figure 22

Figure 21

Figure 23

Bottom tray

Finger grip on front edge of bottom tray

Finger grip

Front side of catch pan holder

Hook the ends of the catch pan holder into the hole in the bottom tray . Figure 22. 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 23.

CAUTION: Do not line bottom tra y with alumin um 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.

Step 19

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 24.

Figure 24

Hair pin cotter

Hinge pin

Step 20

Install 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. Figure 25. 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 the screws and tighten with a Phillips screwdriver until snug. Do not overtighten. Figure 25 (a).

Push on the burner control knobs. Figure 25 (b).

Figure 25

Insert in frame brace

Tool holders

(a)

(b)

Control panel

Phillips screws/

washers

Crossover

Ignition

Button

Slot in frame (view from below)

Insert one end of the hinge rod into the hole in the frame. Figure 27 (a).

Insert the other end into the hole in the swing table end bracket. Figure 27 (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 27 (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 27

(c)

View from rear

of barbecue

Hinge rod

(b)

(a)

Step 21

Install swing table

You will need: swing table end bracket, two 10-24 hex nuts, two 10-24 x 1 3/4 inch machine screws, 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 26 (a). Swing the rod up so you can slide the rod all the way inside the locking tab. Figure 26 (b). The rod should swing freely inside the locking tab. Figure 26 (c).

Figure 26

(a)

(b)

(c)

Support rod

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 28.

Figure 28

View from front of barbecue

Notch to the front

Slide bar

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 29.

View from rear of barbecue

Support rod

Locked position

Unlocked position

Figure 29

Slide

Step 22

Complete accessory installation

You will need: two work tables, two accessory trays, WarmUp Basket, warming rack, thermometer, three 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 30 (a).

Set the work tables onto the left and right side rails. Figure 30 (b).

Set the accessory trays between the two frame connectors. Figure 30 (c).

Set the warming rack into the slots at the rear of the cooking box. Figure 30 (d).

Insert the thermometer into its holder. Figure 30 (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 30 (f).

Figure 30

(a)

(d)

(e)

(f)

(b)

(c)

(b)

CAUTION: To keep the barbecue stationary, the tabs on the locking casters should be in the down position.

Lighting

Summary lighting instructions are on the control panel.

Figure 1

Crossover Ignition System

WARNING: The burner control knobs must be in the OFF position before turning on the LP tank valve. If they are not in the OFF position, when you turn on the LP tank valve, the excess flow control will activate, limiting the flow of gas from the LP tank. If this should occur, turn OFF the LP tank valve and burner control knobs and start over.

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 flameup which can cause serious bodily injury or death.

 DANGER

When the excess flow control is activated, a small amount of gas is still flowing to the burners. After turning OFF the tank and burner control knobs, wait at least 5 minutes for the gas to clear before attempting to light the barbecue. Failure to do so may result in an explosive flameup 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 clic ks .

WARNING: Check hose before each use of barbecue for nicks, cracking, abrasions or cuts. If the hose is found to be damaged in any way, do not use the barbecue. Replace using only Weber authorized replacement manifold assembly. Order from WeberStephen Products Co., Customer Service Center or authorized dealer.

4) Turn the tank on by turning the tank valve counterclockwise.

5) Push Front burner control knob down and turn to ST ART/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.

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

7) 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.

8) 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 c lockwise to OFF.

1) Open the lid. Figure 1.

2) Check that the fuel scale reads more than “E”.

Note - E = empty; F = full.

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

4) Turn the tank on by turning the tank valve counterclockwise.

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

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.

6) Push Front burner control knob down and turn to ST ART/HI.

7) 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 a gain or try to light with a match.

8) After the FRONT burner is lit you can turn on the other burners.

Note - Always light the FR ONT b urner 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 c lockwise to OFF.

Manual Lighting

Figure 2

Manual Lighting

1) Open the lid. Figure 2.

2) Check that fuel scale reads more than “E”.

Note - E = empty; F = full.

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

 DANGER

Cooking

WARNING: Do not move the Weber Gas Barbecue when operating or hot.

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 Genesis 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.

WARNING: Check the bottom tray for grease buildup before each use. Remove excess grease to avoid a grease fire in the bottom tray.

Storage and/or Nonuse

■ The gas must be turned off at the LP tank when the Weber Gas Barbecue is not in use.

■ When the Weber Gas Barbecue is stored indoors, the gas supply must be DISCONNECTED and the LP

tank stored outdoors in a well-ventilated space.

■ LP tanks must be stored outdoors in a well- ventilated area out of reach of children. Disconnected LP tanks

must not be stored in a building, garage or any other enclosed area.

Storage and/or Nonuse continued

■ When the LP tank is not disconnected from the Weber Gas Barbecue, the appliance and LP tank must be

kept outdoors in a well-ventilated space.

■ 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

WARNING: Turn your Weber Gas Barbecue OFF and wait for it to cool before cleaning.

CAUTION: Do not c lean your Flavorizer Bars or cooking grates in a self-cleaning oven. Replacement cooking grates and Flavorizer Bars are a v ailab le through your retailer or the Weber-Stephen Customer Service Center.

Outside surfaces - Use a warm soapy water solution. CAUTION: Do not use o ven 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.

Scale setting wing nut

Tank lock wing nut

Tank valve

Collar

(a)

(b)

Figure 3

Refilling the LP tank

We recommend that you refill before the scale indicator reaches "E".

Note - If you run out of fuel, check the indicator setting and/or adjust the fuel scale indicator setting with the scale setting wing nut, while the tank is empty so you do not run out again.

Removal of the LP tank

1) Close tank valve (turn clockwise). Figure 3 (a).

2) Slide the collar back on the quick disconnect to disengage the fitting. Figure 3 (b).

3) Loosen tank lock wing nut and turn tank lock up out of the way.

4) Lift tank off.

To refill take LP tank and tank filler adapter to a "Gas Propane" dealer.

WARNING: We recommend that your LP tank be filled at an authorized LP gas dealer, by a qualified attendant, who fills the tank by weight. IMPROPER FILLING IS DANGEROUS.

Connecting the filled LP tank

WARNING: Make sure that the LP tank valve is closed. Close by turning clockwise.

Figure 4

 DANGER

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

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

a) Lift and hook the tank onto the fuel scale. b) Loosen the tank lock wing nut. Swing the tank lock

down. Tighten the wing nut. Figure 4.

c) Connect the hose to the tank. Route the hose so it

does not interfere with the scale indicator rod. Slide back the collar of the quick disconnect on the tank valve. Figure 5 (a). Push the male fitting of the regulator into the quick disconnect, and maintain pressure. Slide the collar closed. Figure 5 (b). If it does not engage or lock, repeat procedure. Gas will not flow unless the quick disconnect is properly engaged.

f) Check for leaks by wetting the fitting with the soap

and water solution and watching for bubbles. If bubbles form or if a bubble grows there is a leak.

If leak does not stop, turn off the gas and contact Weber-Stephen Customer Service. Do not use the barbecue.

g) When leak checks are complete, turn gas supply OFF

and rinse connections with water.

LP Tank

Figure 6

Male fitting

Regulator

Collar

Figure 5

(a)

(b)

d) Mix soap and water. e) Open the tank valve. Figure 6.

Safe handling tips for LP Gas

■ Liquid Propane (LP) gas is a petroleum product as are gasoline and natural gas. LP gas is a gas at regular

temperatures and pressures. Under moderate pressure, inside a tank, LP gas is a liquid. As the pressure is released the liquid readily vaporizes and becomes gas.

■ LP gas has an odor similar to natural gas. You should know this odor.

■ LP gas is heavier than air. Leaking LP gas may collect in low areas that prevent dispersion.

■ To fill, take the LP tank to an RV center, or look up gaspropane in the phone book for other sources of LP gas.

WARNING: We recommend that your LP tank be filled at an authorized LP gas dealer, by a qualified attendant, who fills the tank by weight. IMPROPER FILLING IS DANGEROUS.

■ Air must be removed from a new LP tank before the initial filling. Your LP dealer is equipped to do this.

■ The LP tank must be installed, transported and stored in an upright position. LP tanks should not be dropped

or handled roughly.

■ Never store or transport the LP tank where temperatures can reach 125° F (too hot to hold by

hand - for example: do not leave the LP tank in a car on a hot day).

Note - A refill will last about 20 hours of cooking time at normal use. The fuel scale will indicate the propane supply so you can refill before running out. You do not have to run out before you refill.

■ Treat "empty" LP tanks with the same care as when full. Even when the LP tank is empty of liquid there

still may be gas pressure in the tank. Always close

the tank valve before disconnecting.

■ Do not use a damaged LP tank. Dented or rusty LP tanks or LP tanks with a damaged valve may be

hazardous and should be replaced with a new one immediately. See "LP tank requirements".

■ The joint where the hose connects to the LP tank must be leak tested each time the LP tank is reconnected.

For example, test each time the LP tank is refilled.

■ Be sure the regulator is mounted with the small vent hole pointed downward so it will not collect water. This

vent should be free of dirt, grease, bugs etc.

Liquid Propane (LP) Tank(s)

■ The LP tank and connections supplied with your Weber Gas Barbecue have been designed and tested to meet

government, American Gas Association and Underwriters Laboratories requirements.

■ Replacement LP tanks supplied by Weber satisfy the requirements. Check to be sure the tank has a D.O.T.

certification, and has been tested within five years. Your LP gas supplier can do this for you. Figure 7.

If you have questions about spare LP tanks, please call Weber-Stephen Customer Service.

DOT 4BA240

1/97

Date Tested

20 lb LP tank

D.O.T. Certification (example)

■ All LP tank supply systems must include a collar to protect the tank valve.

■ The LP tank must be a 20 lb size (18 1/4 inches high, 12 1/4 inches in diameter).

■ The LP tank must be constructed and marked in accordance with the specifications for LP gas cylinders of

the U.S. Department of Transportation (D.O.T.).

Figure 7

Check: a) Hose to manifold connections. Figure 8 (a). b) Regulator to tank connection. Figure 8 (b).

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.

c) Valves to manifold connection. Figure 8 (c). d) Hose to regulator connection. Figure 8 (d).

WARNING: If there is a leak at connections (b), (c) or (d), turn OFF the gas. DO NOT OPERATE THE BARBECUE. Contact Weber-Stephen Customer Service.

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

Annual Maintenance

After a period of nonuse we recommend that you perform the following maintenance procedures for your safety.

■ 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

Figure 8

(a) (b)

(c)

(d)

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".)

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.

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

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.

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

Figure 9

Figure 10

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.

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 1 1.

Figure 11

Burner inside cooking box

Flames

Tips occasionally yellowish

Light blue

Dark blue

Figure 12

Figure 13

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 10.

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.

If the flames do not appear to be uniform the length of the burner tube, follow the burner cleaning procedures.

Main Burner Cleaning Procedure(See Section

“Replacing the main burners”.) Look inside each burner with a flashlight. Figure 12.

Clean the inside of the burners with a wire (a straightened out coat hanger will work). Figure 13. 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. Remove the screws holding the control panel in place. Lift off the control panel.

g) Lift and twist the burner assembly slightly, to separate

the crossover tube from the burners. Figure 17. Remove the burners from the cooking box.

Crossover tube

Figure 17

Figure 14

View from behind cooking box

Wing nuts

Figure 15

Guide screw

Figure 16

Figure 18

Valve

Burner

(a)

(b)

e) Remove the manifold bracket and unscrew the two

wing nuts that hold the manifold to the cooking box. Pull the manifold and valve assembly out of the burners and carefully set it down. Figure 15.

f) Slide the burner assembly out from under the guide

screw and washer in the corners of the cooking box. Figure 16.

h) To reinstall burners, reverse steps c) through g).

CA UTION: The burner openings must be positioned properly over the v alve orifices. Figure 18a.

Check proper assembly before fastening manifold in place. Figure 18b.

d) Unlatch the Spider Stopper Guards and remove.

Figure 14.

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 20.

Figure 20

White wire

Black wire

Venturi fin

Check fit around burner

Figure 19

Check fit around valve

i) 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 19.

CAUTION: If the Spider Stopper Guards do not fit tightly, contact Weber-Stephen Customer Service.

WARNING: After reinstalling the gas lines, they should be leak checked with a soap and water solution bef ore using the barbecue. (See Step "Check for gas leaks".)

■ 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.

Problem

Burners burn with a yellow or orange flame, in conjunction with the smell of gas.

Burners do not light. -orBurners have a small flickering flame in the HIGH position. -orBarbecue temperature only reaches 250˚ to 300˚ degrees in the HIGH position.

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.)

Fuel scale shows that there is gas in the LP tank, but tank is empty.

Check

Inspect Weber Spider Stopper Guards for possible obstructions. (Blockage of holes.)

The excess flow safety device, which is part of the barbecue to tank connection, may have activated.

Is LP fuel low or empty? Is fuel hose bent or kinked? Does the Front burner light with a

match?

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.

Check adjustment of fuel scale.

Cure

Clean Weber Spider Stopper Guards. (See Section "Annual Maintenance".)

To reset the excess flow safety device turn all burner control knobs and the tank valve OFF. Disconnect the regulator from the tank. Turn burner control knobs to HIGH. Wait at least 1 minute. Turn burner control knobs OFF. Reconnect the regulator to the tank. Turn tank valve on slowly. Refer to “Lighting Instructions”.

Refill LP tank. Straighten fuel hose. If you can light the Front burner

with a match, then check the Crossover Ignition System.

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".)

Fuel scale must be adjusted with an empty tank.

TROUBLESHOOTING

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

®®®®®®®

4 5

8 9

10-11

13 14

15, 11

26 27 28 29 30 31 32

62-63

11 33

11 38

17-18, 11

66 57

1 Lid (assembly) 2 Lid handle 3 Warm-Up Basket 4 Warming rack 5 Short Flavorizer Bars (8) 6 Long Flavorizer Bars (5) 7 Cooking grates (2) 8 Work tables (2)

9 Tubing plugs (5) 10 1/4-20 x 2 inch bolts (5) 11 1/4 inch nylon washers (18) 12 Swing table end bracket 13 Left frame 14 Swing table 15 1/4-20 x 1/2 inch bolts (6) 16 Slide bar assembly 17 10-24 x 1 3/4 inch machine screws (2) 18 10-24 hex nuts (2) 19 Caster frame 20 Casters (2) 21 Bottom tray mounting rails (2) 22 Bottom tray 23 Catch pan holder 24 Catch pan 25 Drip pans (2) 26 Frame connectors (2) 27 Accessory trays (2) 28 Wheel hub caps (2) 29 Wheels (2) 30 Axle 31 Front panel 32 Wheel frame 33 1/4-20 hex nut 34 Tank glides (2) 35 Glide axle 36 Glide hubcaps (2) 37 Tank panel 38 1/4-20 x 1 1/4 inch bolt

Parts List

All items are single quantities unless otherwise specified. Parts can be ordered directly from Weber-Stephen

Products Company by phone or mail.

Note - Do not return parts to Weber-Stephen Products Co. without first contacting the Customer Service Center by mail or phone. Returning the part may not be necessary.

Weber-Stephen Products Company Customer Service Center 250 South Hicks Road Palatine, IL 60067-6241 (800) 446-1071

39 Hair pin cotters (2) 40 Hinge pins (2) 41 Thermometer 42 1/4-20 keps nut 43 Cooking box 44 Burner control knobs (3) 45 Control panel 46 Igniter button 47 Phillips screws/washers (2) 48 Crossover tube 49 Front or Back burner 50 Center burner 51 1/4-20 stainless steel wing nuts (2) 52 Spider Stopper Guards (3) 53 Manifold assembly 54 Manifold bracket 55 Tool holders (3) 56 Right frame 57 Igniter 58 Igniter lock nut 59 Igniter wire (black) 60 Igniter wire (white) 61 Gas catcher ignition chamber 62 Fuel scale 63 1/4-20 wing nuts (2) 64 LP tank 65 Filler adapter 66 Control panel inserts (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.

A FINAL WORD

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

Weber 98615 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

DANGER

WARNINGS

LP Tank

WARRANTY

PATENTS AND TRADEMARKS

Contents

General Instructions

For Installation in Canada

Storage

Operating area

Check package contents

Assembly

Tools needed

Supplies needed

Assemble wheels

Assemble frame

Continue frame assembly

Complete frame assembly

Insert casters

Add cooking box

Install tank panel assembly

Install manifold bracket

Install igniter

Add fuel scale

Set LP fuel scale

Fill LP tank

Connect LP tank

Check that the burner valves are off

Check for gas leaks

Install Flavorizer Bars and Cooking Grates

Install the lid

Install tool holders, control panel and burner control knobs

Install swing table

Complete accessory installation

Lighting

Crossover Ignition System

OPERATING INSTRUCTIONS

To Extinguish

To Extinguish

Manual Lighting

Cooking

Storage and/or Nonuse

Periodic Cleaning

Refilling the LP tank

Removal of the LP tank

Connecting the filled LP tank

LP Tank

Safe handling tips for LP Gas

Liquid Propane (LP) Tank(s)

Annual Maintenance

Inspection and Cleaning of the Weber Spider Stopper Guards

General Maintenance

Weber Spider Stopper Guards

Main Burner Flame Pattern

Main Burner Cleaning Procedure(See Section

Replacing Main Burners

Crossover Ignition System Operations

TROUBLESHOOTING