Weber 3500 Gas Grill User Manual
Contents
1. Air shutter Venturi fin Figure 6 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 7 Weber Spider Stopper Guard Figure 7 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 Barbecue does not reach temperature Barbecue heats unevenly One or more of the burners do not ignite DANGER Failure to correct these symptoms may result in a fire which can cause serious bodily injury or death and cause damage to property 33 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 8 Tips occasionally yellowish Burner inside cooking box Light blue Flames Dark blue Figure 8 If the flames do not appear to be uniform the length of the burner tube follow the burner cleaning procedures Main Burner Cleaning Procedure Turn off the gas supply Remove the manifold See Section Replacing the main burners Look inside each2. 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 A 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 A WARNING Perform these leak checks even if your barbecue was dealer or store assembled You will need soap and water solution and a rag or brush to apply it Make sure side burner is OFF Remove valve control knob and screws Remove porcelain top Figure 23 Figure 23 To perform leak checks Turn ON gas supply at the source Figure 24 Gas supply shut off at the house fo M Oy Figure 24 A 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 le
3. Figure 12 the Spider Stopper Guards so that the seams are in g Slide the burner assembly out from under the guide line with the Venturi fins There should be no gaps in screw and washer in the corners of the cooking box the seams or in the fit around the burners and valves Figure 13 Figure 16 Check fit around valve US au Check fit around burner Venturi fin h Lift and twist the burner assembly slightly to separate the crossover tube from the burners Figure 14 Remove the burners from the cooking box Crossover tube Figure 16 A CAUTION If the Spider Stopper Guards do not fit tightly contact Weber Stephen Customer Service k Reconnect gas supply line See Check for gas leaks Figure 14 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 M Check that both the white and black ignition wires are attached properly Figure 17 Figure 17 M Check that the Crossover Ignition button pushes the igniter button down and returns to the up position H 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 See Section Manual Lighting and contact Weber Stephen Customer Service 35 TROU
4. weier o GENESIS 3500 Natural Gas Barbecue Owner s Manual YN NN N AN DESIGN ERIC CYAN WANS Pcie CERTIFIED WARNING Do not try to light this appliance without reading Lighting instructions section of this manual WARNING Follow all leak check procedures carefully in this manual prior to barbecue operation Do this even if barbecue was dealer assembled 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 Extinguish any open flame FOR YOUR SAFETY Do not store or use gasoline or other 2 3 Open lid 4 If odor continues immediately call your gas supplier or your fire department flammable vapors and liquids in the vicinity of this or any other appliance 98636 10 97 ADANGER 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 A A A AWARNINGS 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 obstr
5. 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 Annual Maintenance After a period of nonuse we recommend that you perform the following maintenance procedures for your safety AWARNING 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 A Caution If the barbecue gas supply line is damaged in any way or leaking do not use the barbecue E Inspect the burners for correct flame pattern Clean if necessary following the procedures outlined in the General Maintenance section of this manual M Check all gas fittings for leaks DANGER Do not use an open flame to check for gas leaks Be sure there are n
6. The outdoor connector must be firmly attached to rigid permanent construction Gas line piping M 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 E 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 H The transition from metallic pipe to plastic pipe should be made out
7. aC Quick disconnect engaged f Side burner hose Manifold side view Figure 19 Slide the side burner assembly into the open end of the right frame Route the side burner hose so that it parallels the front of the barbecue Loop the hose so that it reaches the side burner connection Attach hose Figure 20 Install burner grate Check to be sure the side burner valve is OFF Push side burner control knob down and turn clockwise Figure 20 Figure 20 Step 13 Install manifold bracket You will need manifold bracket Hook the bracket onto the manifold at the center burner valve Figure 21 Place your hand underneath the bracket Lift the bracket manifold and cooking box slightly as a unit and hook onto the frame brace Figure 21 a Frame brace Manifold bracket View from below cooking box 21 Step 14 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 22 Figure 22 Step 15 Check for gas leaks
8. burner with a flashlight Figure 9 AT OF Figure 9 Clean the inside of the burners with a wire a straightened out coat hanger will work Figure 10 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 F Figure 10 A CAUTION Do not enlarge the burner ports when cleaning Replacing Main Burners a Your Weber Gas Barbecue must be OFF and cool b c Turn gas OFF at source Remove control panel take off the burner control knobs Remove the screws holding the control panel in place Lift off the control panel d Unlatch the Spider Stopper Guards and remove i To reinstall the burners reverse steps c through g Figure 11 A CAUTION The burner openings must be positioned properly over the valve orifices Figure 15 a Check proper assembly before fastening manifold in place Figure 15 b Burner opening a Figure 11 e Disconnect gas supply line and side burner Valve orifice f 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 12 View from behind cooking box Figure 15 Wing nuts j Reinstall the Spider Stopper Guards Slightly rotate
9. cooking box in the frame so the burner tubes are under the frame brace Figure 13 Note Be careful when sliding the burner tubes through the side frame Figure 13 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 14 Add the keps nut Tighten by holding the bolt with pliers while you tighten the nut with the 7 16 inch wrench Figure 14 18 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 15 a b Are the wing nuts under the burner assembly hand tight Do not tighten with pliers Figure 15 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 Guide screw View from behind cooking box Figure 15 Step 9 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
10. cut out of the lock slips down over the bolt Tighten with a wrench Figure 3 a Loosen the right front 1 4 x 20 bolt The side burner lock fits between the front panel and the frame The U shape cut out slips up over the bolt Tighten with a wrench Figure 3 b Step 5 Measure and drill holes You will need Completed frame assembly base panel tape measure and pencil ACAUTION 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 37 1 4 across Figure 4 Note If the measurement is not 37 1 4 across adjust the legs as necessary so that the measurement is 37 1 4 Figure 4 Place the base panel in between the legs to insure fit Figure 5 Once the fit is established remove the base panel and mark the holes ACAUTION A minimum of 2 bolts are required on each side You are now ready to anchor the base Figure 5 Step 6 Typical installation of the base for an existing concrete patio new pad or wood deck continued Method 1 A CAUTION Combustible materials should never be plied 7 onerete within
11. owner s manual and serial number of the barbecue available for reference Weber Stephen Products Company Customer Service Center 250 South Hicks Road Palatine IL 60067 6241 800 446 1071 Hair pin cotters 2 Hinge pins 2 Thermometer 1 4 20 keps nut Cooking box Burner control knobs 3 Control panel Igniter button Phillips screws washers 2 Crossover tube Front and back burners 2 Center burner 1 4 20 stainless steel wing nuts 2 Spider Stopper Guards 3 Manifold assembly Manifold bracket Right frame Igniter Igniter lock nut Gas catcher ignition chamber Igniter wire black Igniter wire white Side burner assembly Burner grate Side burner knob Gas supply line Flare fitting Control panel inserts 2 A 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 OF THANKS Tanz 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 owners manual available for reference We also welcome any comments or suggestions you might have regard
12. should be 1 8 to 3 16 inch from tip of electrode to burner Figure 20 Spark should be a white blue color not yellow Figure 18 37 igniter see below Venturi Burner Igniter Figure 19 Figure 20 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 phone or mail Returning the part may not be necessary Lid assembly Lid handle Warm Up Basket Warming rack Short Flavorizer bars 8 Long Flavorizer bars 5 Cooking grates 2 Work table Tubing plugs 3 1 4 20 x 2 inch bolt End bracket Left frame Front panel Condiment basket 1 4 20 x 1 2 inch bolts 6 1 4 inch nylon washers 7 Side panel 2 Side frame 2 Bottom tray Catch pan holder Catch pan Drip pans 2 Accessory rack Base panel Tool holders 3 Plastic buttons 8 Side burner locks 2 OONDOABRWND 39 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
13. 24 inches of the top bottom back or sides of A strike anchor a minimum size of 3 8 inch x 3 1 2 inches the barbecue Do not locate under overhead long with a 3 8 inch flat washer and 3 8 inch nut Figure 7 combustible construction Typical installation of the base for an existing concrete patio new pad or wood deck Note Use a 3 8 inch diameter concrete drill bit for drilling Note With the lid open the depth of the barbecue is the hole for the strike anchor 28 inches front to back Strike anchor For anchoring we recommend use of one of the following AAWARNING Whichever method used the base must a 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 6 i ES lt _ Figure 6 15 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 8 Note Use a 5 8 inch concrete drill bit for drilling the hole for the lag shield Concrete lag bolt Figure 8 16 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 9 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 x Mount plate 3 8 inch screw
14. AUTION Combustible materials should never be within 24 inches of the top bottom back or sides of the barbecue Do not locate under overhead combustible construction Typical natural gas supply installation to a wood deck View from behind igure A CAUTION Follow General Specifications for Piping in this manual We recommend that this installation be done by a professional ACAUTION 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 over an existing post View from behind barbecue at Accessible Locking Shut off Indoor Shut off Figure 3 A 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 A 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 ACAUTION 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 Recommended concrete pad requirements We recommend a pad a minimum of 40 inches left to right 20 inches front to
15. BLESHOOTING 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 A CAUTION Do not line the bottom tray with aluminum foil Burner flame pattern is erratic Flame is low when burner is on HIGH Flames do not run the whole length of the burner tube Inside of lid appears to be peeling Resembles paint peeling Check Inspect Weber Spider Stopper Guards for possible obstructions Blockage of holes Is natural gas supply on Does the Front burner light with a match 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 Weber Spider Stopper Guards See Section Annual Maintenance Turn on natural gas supply If you can light the Front burner with a match then check the Crossover Ignition System 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 Sect
16. E BARBECUE Side burner hose to side burner connection Figure 5 c Valves to manifold connections Figure 5 d Contact your dealer e Barbecue gas supply line to natural gas supply connection Figure 5 e A WARNING If there is a leak at connection e turn OFF the gas DO NOT OPERATE THE BARBECUE Contact your installer 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 Figure 5 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 are dirty brush off the outside surface of the Spider Stopper Guards with a soft bristle brush an old toothbrush for example Check that there are no gaps in the Spider Stopper Guards seams or in the fit around the burners or valves See Section General Maintenance 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 6 This could result in a fire in and around the air shutters under the control panel causing serious damage to your barbecue Venturi
17. S E o e Bottom tray Control panel eo Work table Gas supply line with the flare fitting loosely attached for shipping purposes Left frame Right frame Side frame 2 Accessory rack Warm Up Basket Five long Flavorizer Bars Eight short Flavorizer Bars Sea Side panel 2 o nn 11 Front Panel Cooking grate 2 a gt Catch pan holder Catch Pan Drip pans 2 Thermometer Condiment basket Side burner assembly Burner grate ED Side burner knob Side burner locks 2 Note The locks are taped to the inside of the side burner lid T o Check contents of hardware packs Three burner control knobs Ten plastic buttons End bracket Three tool holders Three tubing plugs Two Phillips screws washers Manifold bracket LQ Two hinge pins hardware size 1 4 x 1 1 2 inch clevis pin actual size One 1 4 20 x 2 inch bolts actual size i C Six 1 4 20 x 1 2 inch bolts a actual size One 1 4 20 keps nut Seven nylon washers actual size Two hair pin cotters actual size NY SS 12 Step 4 Install side burner locks Note The locks are taped to the inside of the side burner lid You will need frame assembly two side burner locks and a 7 16 inch wrench Turn frame assembly right side up Loosen the right rear 1 4 x 20 bolt Install the side burner lock The U shape
18. ab of the bracket is hooked in the slot in the frame Figure 36 c To fully seat the bracket you may have to tap it lightly with a hammer AWARNING If the end bracket is in any way cracked or damaged do not use the condiment basket Call our Customer Service Center to order a new part Wire end Slot in frame view from below Figure 36 Step 24 Step 25 Install the accessory rack Complete accessory installation You will need accessory rack You will need Warm Up Basket warming rack work table Rest the left end of the accessory rack on the base three tubing plugs thermometer and a hammer panel Figure 37 a 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 38 a Set the warming rack into the slots at the rear of the cooking box Figure 38 b Insert the right hooks into the right side frame slots Figure 37 b Raise the left end up and slide left hooks into the left side frame slots Figure 37 Set the work table onto the left side rails Figure 38 c Insert the thermometer into its holder Figure 38 d Insert the tubing plugs into the ends of the frame To fully seat the plugs you may have to tap them lightly with a hammer Figure 38 e Left side frame slots Left hooks 27 OPERATING INSTRUCTIONS Lighting Summary lighting instru
19. aks Check a Gas supply line to manifold connection Figure 25 a b Manifold to side burner hose connection Figure 25 b A WARNING If there is a leak at connection a or b 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 your dealer c Side burner hose to side burner connection Figure 25 c d Valves to manifold connections Figure 25 d AWARNING If there is a leak at connections c or d turn OFF the gas DO NOT OPERATE THE BARBECUE Contact your dealer e Barbecue gas supply line to natural gas supply connection Figure 25 e AWARNING If there is a leak at connection e turn OFF the gas DO NOT OPERATE THE BARBECUE Contact your installer When leak checks are complete turn gas supply OFF and rinse connections with water f Reinstall the side burner cover Figure 23 Figure 25 Right side panel Figure 27 2 Sec oO jo a o N N o Lu 2 D LL Base panel Step 18 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 28 The open U of t
20. anchor Drilled hole Figure 9 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 ACAUTION 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 A 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 10 Note Use a 3 16 inch drill bit for drilling a pilot hole for a 3 8 inch lag bolt 3 Figure 10 AAWARNING 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 11 Figure 11 17 Step 7 Tighten all frame bolts Fully tighten the 1 4 20 bolts in the frame assembly that you only started in Step Continue Frame Assembly Figure 12 Figure 12 Step 8 Add cooking box You will need cooking box assembly 1 4 20 x 2 inch bolt nylon washer 1 4 20 keps nut pliers and a 7 16 inch wrench Set the
21. and turn each burner control knob clockwise to OFF Figure 2 29 Lighting the side burner The side burner has a separate ignition system from the main cooking box DANGER Failure to open lid while igniting the side burner or not waiting 5 minutes to allow gas to clear if the side burner does not light may result in an explosive flame up which can cause serious bodily injury or death Lighting only the side burner Figure 3 1 Open the side burner lid 2 Check that the side burner valve is OFF push down and turn clockwise and all main burner control valves are OFF push down and turn clockwise 3 Turn gas supply valve on 4 Push down and turn the side burner control valve to HI 5 Push the side burner igniter button several times so it clicks each time A CAUTION Side burner flame may be difficult to see on a bright sunny day A WARNING If the side burner does not light a Turn OFF the side burner control valve b Wait 5 minutes to let the gas clear before you try again or try to light with a match 30 Lighting the side burner if the main burners are lit Figure 4 1 Open the side burner lid 2 Push down and turn the side burner control to HI 3 Press the side burner igniter button several times so it clicks each time A CAUTION Side burner flame may be difficult to see on a bright sunny day A WARNING If the side burner does not light a Turn OFF the side burner con
22. back and 4 inches deep 1 85 cubic feet Figure 4 Note Cubic feet is determined by multiplying length times wiath times depth and dividing by 1728 a ODO OD o So o o o o o 00 0 2 2 0 2 go o 2 9 o c 9D IS 2 o Se a OLE WEE TNA rte ARTE TA CR LE OU PE A a Figure 5 A CAUTION Allow fresh concrete to cure completely before attempting to anchor the barbecue to the concrete Assembly Tools needed or Regular screwdriver Phillips screwdriver enmar 7 16 inch or an adjustable wrench D pe Pliers KR lt Tape Measure Tok Pencil OO Co Electric drill Supplies needed You will need a soap and water solution to check for gas leaks See Step Check for gas leaks Note The hardware size of nuts bolts and screws is given For example 1 4 20 x 2 inch bolt means a bolt 1 4 inch in diameter with 20 threads to the inch 2 inches long On a small screw for example 6 32 x 1 2 inch screw means a number 6 screw with 32 threads to the inch 1 2 inch long 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 Step 1 Check package contents Cooking box assembly Lid assembly ES
23. ctions are on the control panel 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 A 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 Crossover Ignition System Figure 1 28 Open the lid Figure 1 Make sure all burner control knobs are turned OFF Push each burner control knob down and turn clockwise 3 A 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 Turn gas supply valve on Push Front burner control knob down and turn to START HI Push the Crossover Ignition Button several times so it clicks each time Check that the burner is lit by looking through the matchlight hole on the front of the cooking box A WARNING If the b
24. 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 PATENTS AND TRADEMARKS 1997 Weber Weber 2 Genesis Flavorizer and Crossover are registered U S trademarks Perma Mount Gas Catcher FlameCheck Steam N Chips Spider Stopper and Warm Up are U S trademarks of Weber Stephen Products Co 200 East Daniels Road Palatine IL 60067 6266 U S A Printed in the U S A Contents WARNINGS ennenen 2 Warranty amp Patents enana a 2 3 General Instructions 6 ASSEMPIY 5 5 ne tn ne 10 27 Operating Instructions Light E E E EEE 28 30 COUKINOE se aaisa vente Ne 31 After a Period of Nonuse s es 31 CIS AMINO i apiason eaan 31 Troubleshooting amp Maintenance Annual Maintenance General Maintenance Troubleshooting Paris EIS TING ists re A AN S FEATURES Convenient side table condiment basket wire accessory rack and warming rack Heavy gauge porcelain on steel lid seals in heat Ra
25. ective 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
26. er control knobs Hook the tool holders over the frame rail and snap down into place Figure 34 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 34 a Push on the burner control knobs Figure 34 b Insert in frame brace Crossover a Ignition Control panel Phillips screws washers Tool holders Figure 34 Step 22 Secure side burner Stand to the right side of the barbecue Slightly pull back both side burner locks Slide the side burner toward the control panel The locks will snap into the slots in the front and back of the side burner Figure 35 A CAUTION Make sure both locks have snapped into place a View from top View from side Figure 35 Step 23 Install the condiment basket You will need condiment basket and end bracket Insert one wire end of the condiment basket into the hole in the side frame Figure 36 a Insert the opposite wire end of the condiment basket into the hole in the end bracket Hold the end bracket at an angle so the lower tab is inside the frame tube Push the bracket into the frame Figure 36 b Check to see that the lower t
27. form to the latest edition of the National Fuel Gas Code ANSI Z 223 1 M 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 E Do not use with charcoal fuel M 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 Storage E The gas must be turned OFF at the natural gas supply when the Weber Gas Barbecue is not in use Operating area A WARNING Only use this barbecue outdoors in a well ventilated area Do not use in a garage building breezeway or any other enclosed area M Never use your Weber Gas Barbecue under an unprotected combustible roof or overhang E Your Weber Gas Barbecue is not intended to be installed in or on recreational vehicles and or boats HM Do not use combustible materials within 24 inches of the top bottom back or sides of the grill MH The entire cooking box gets hot when in use Do not leave unattended H Keep any electrical supply cord away from any heated surface H Keep the cooking area clear of flammable vapors and liquids such as gasoline alcohol etc and combustible materials Gas supply testing M 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 sup
28. gloves when operating barbecue LP GAS UNITS ONLY Use the regulator that is supplied with your Weber Gas Barbecue Do not attempt to disconnect the gas regulator or any gas fitting while your barbecue is in operation A dented or rusty LP tank may be hazardous and should be checked by your liquid propane supplier Do not use an LP tank with a damaged valve Although your LP tank may appear to be empty gas may still be present and the tank should be transported and stored accordingly A If you see smell or hear the hiss of escaping gas from the LP tank 1 Get away from LP tank 2 Do not attempt to correct the problem yourself gt BE ER BE EEE 3 Call your fire department WARRANTY 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 def
29. he cooking grates goes down Set the cooking grates onto the ledges in the cooking box Figure 29 amp Ss Figure 29 D Step 19 Install the bottom tray You will need bottom tray catch pan holder catch pan and one drip pan G gt Ka Finger grip on front Front side of catch edge of bottom tray pan holder Figure 30 Hook the ends of the catch pan holder into the hole in the bottom tray Figure 31 The front of the catch pan holder must be on the same side as the finger grip of the bottom tray Finger grip Figure 31 Slide the bottom tray onto the mounting rails under the cooking box with finger grip toward you Figure 32 ACAUTION 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 Figure 32 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 20 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 33 Hair pin cotter Hinge pin Figure 33 Step 21 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 burn
30. he flare nut at the other end of the barbecue gas supply line to the manifold fitting Tighten with a 3 4 inch wrench Figure 17 b Apply pipe sealant here a Figure 17 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 19 Step 11 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 18 Figure 18 20 Step 12 Install side burner You will need side burner assembly burner grate and manifold bracket AWARNING Make sure gas supply is OFF Slide the side burner assembly into the open end of the right frame Route the side burner hose around the tank panel so it will not interfere with scale indicator rod The side burner hose is connected in the following manner Slide back the collar of the quick disconnect on the manifold Push the male fitting of the side burner hose into the quick disconnect and maintain pressure Slide the collar closed Figure 19a Figure 19b shows the quick disconnect engaged nstall burner grate Check to be sure the side burner valve is OFF Push side burner control knob down and turn clockwise Figure 19 a Male fitting of side burner LL
31. ing 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
32. ion Periodic Cleaning Clean bottom tray Clean burners See Section General Maintenance Clean thoroughly See Section Periodic Cleaning If problems cannot be corrected by using these methods please contact Weber Stephen Customer Service 36 Side Burner Troubleshooting AWARNING Before attempting any troubleshooting steps all gas controls and supply valves should be in the OFF position Problem Check Cure Side burner does not light Is gas supply off Turn supply on Flame is low in HIGH position Is fuel hose bent or kinked Straighten hose Flame is very yellow in conjunction with Inspect the Weber Spider Stopper Clean Weber Spider Stopper the smell of gas Guard for possible obstructions Guard See Section Annual Blockage of holes Maintenance OR Burner makes popping noise in conjunction with the smell of gas Push button ignition does not work Does burner light with a match If match lights burner check Side Burner Maintenance AWARNING All gas controls and supply valves should be in the OFF position Check igniter Remove side burner cover To remove side burner cover remove control knob and screws that hold cover to bottom Figure 18 Make sure wire is connected between igniter and electrode Check that igniter lock nut is tight Figure 19 Note If the igniter works loose carefully tighten the igniter lock nut with an adjustable wrench or pliers Adjust igniter electrode Gap
33. o sparks or open flames in the area while you check for leaks This will result in a fire or explosion which can cause serious bodily injury or death and damage to property A 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 A 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 b A WARNING If there is a leak at connection a or b retighten the fitting with a wrench and recheck for leaks with soap and water solution Gas supply line to manifold connection Figure 5 a Manifold to side burner hose connection Figure 5 b 32 If a leak persists after retightening the fitting turn OFF the gas DO NOT OPERATE THE BARBECUE Contact your dealer c d AWARNING If there is a leak at connections c or d turn OFF the gas DO NOT OPERATE TH
34. of the keyhole in the frame brace Figure 16 b Loosen the igniter lock nut and slide the igniter into the small part of the keyhole Figure 16 c Tighten the igniter lock nut Figure 16 Note If the igniter works loose carefully tighten the igniter lock nut with an adjustable wrench or pliers frame brace AT Igniter lock nut Frame brace Small part of keyhole in frame brace Step 10 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 AWARNING This barbecue is NOT 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 17 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 17 a Attach t
35. pid read thermometer for precision cooking measures grill temperature and can be removed and inserted into the food 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 Weber Warm Up Basket for additional cooking or warming space Separate burners for temperature control Crossover Ignition System with Gas Catcher Ignition Chamber Catch pan catches excess grease Side burner for making sauces gravies etc while main grill is in use Sleek and sturdy base is an attractive addition to your patio or deck 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 M 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 M Not for use by children Mf there are local codes that apply to gas grills you will have to conform to them If there are no local codes you must con
36. ply piping system during any pressure testing of that system at test pressures in excess of 1 2 psig 3 5 kPa M 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 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 General Specifications for Piping American National Standards Institute ANSI Recommendations for gas supply installations Connections mM This barbecue is designed to operate at 7 inches of water column pressure 2526 psi E A manual shut off valve must be installed outdoors immediately ahead of any connections or change in pipe material E An additional manual shut off valve indoors should be installed in the branch fuel line in an accessible location near the supply line E 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 E Pipe compound should be used which is resistant to action of natural gas when connections are made E
37. r 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 A CAUTION Check the bottom tray for grease build up before each use Remove excess grease to avoid a grease fire in the bottom tray 31 After a Period of Nonuse E amp E 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 A CAUTION Turn your Weber Gas Barbecue OFF and wait for it to cool before cleaning A CAUTION Do not clean your Flavorizer Bars or cooking grates in a self cleaning oven Replacement cooking grates and Flavorizer Bars are available through your retailer or the Weber Stephen Customer Service Center Outside surfaces Use a warm soapy water solution ACAUTION 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
38. side and at least 10 underground E 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 M 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 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 AWARNING If a leak persists after tightening the fitting turn gas off at the supply DO NOT OPERATE YOUR BARBECUE Contact Weber Stephen Customer Service Typical natural gas supply installation to a concrete patio or pad View from behind barbecue Outside Accessible Locking Shut off Indoor Shut off Inside Gas Supply Figure 1 A CAUTION Follow General Specifications for Piping in this manual We recommend that this installation be done by a professional AC
39. trol valve b Wait 5 minutes to let the gas clear before you try again or try to light with a match 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 A CAUTION Replace thermometer in lid when not in use Do not leave thermometer in food while cooking lf 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 Flavorize
40. uctions before using See instructions in this manual for correct procedures Do not operate the Weber Gas Barbecue if there is a gas leak present Do not use a flame to check for gas leaks Combustible materials should never be within 24 inches of the top bottom back or sides of your Weber Gas Barbecue Do not put a barbecue cover or anything flammable on or in the storage area under the barbecue Your Weber Gas Barbecue should never be used by children You should exercise reasonable care when operating your Weber Gas Barbecue It will be hot during cooking or cleaning and should never be left unattended Should the burners go out during operation turn all gas valves off Open the lid and wait five minutes before attempting to relight using the lighting instructions Do not use charcoal or lava rock in your Weber Gas Barbecue Never lean over open grill or place hands or fingers on the front edge of the cooking box Should a grease fire occur turn off all burners and leave lid closed until fire is out Do not enlarge valve orifices or burner ports when cleaning the valves or burners The Weber Gas Barbecue should be thoroughly cleaned on a regular basis LP gas is not natural gas The conversion or attempted use of natural gas in an LP unit or LP gas ina 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
41. urner 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 Manual Lighting A 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 A WARNING If the burner does not light turn the Front burner control knob to OFF and wait 5 minutes to let 1 Open the lid Figure 2 the gas clear before you try again or try to light with a match 2 Make sure all burner control knobs are turned OFF p Push each burner control knob down and turn 7 After the FRONT burner is lit you can turn on the other clockwise burners 3 Turn gas supply valve on Note Always light the FRONT burner first The other l burners ignite from the FRONT burner 4 Strike a match and put the flame into the matchlight hole in the front of the cooking box anual Lighting To Exti ngu ish Turn gas supply OFF at the source then push down
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