Weber Gas Grill SKYLINETM 520 User Manual

Serial Number  
Please use this number in registering your warranty and  
any correspondence with the factory.  
SKYLINE 520  
LP Gas Barbecue  
Owner’s Manual  
R
E
W
B
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®
NationalPROPANEGAS Association  
WARNING: Follow all leak check procedures  
carefully in this manual prior to barbecue  
operation. Do this even if barbecue was  
dealer assembled.  
FOR YOUR SAFETY  
1. Do not store or use gasoline or other  
flammable vapors and liquids in the  
vicinity of this or any other appliance.  
2. An LP tank not connected for use shall  
not be stored in the vicinity of this or  
any other appliance.  
NOTICE TO INSTALLER: These instructions  
must be left with the owner and the owner  
should keep them for future use.  
FOR YOUR SAFETY  
If you smell gas:  
THIS GAS APPLIANCE IS DESIGNED FOR  
OUTDOOR USE ONLY.  
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.  
WARNING: Do not try to light this appliance  
without reading "Lighting" instructions  
section of this manual.  
98692  
12/97  
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WARRANTY  
Weber-Stephen Products Co. (Weber) hereby  
There are no other express warrants except as  
set forth herein and any applicable implied  
warranties of merchantability and fitness are  
limited in duration to the period of coverage of  
this express written Limited Warranty. Some  
states do not allow limitation on how long an  
implied warranty lasts, so this limitation may not  
apply to you.  
warrants to the ORIGINAL PURCHASER of this  
Weber Gas Barbecue that it will be free of  
defects in material and workmanship from the  
date of purchase as follows:  
Aluminum Castings, 10 years,  
Recycled Work Surfaces, 10 years  
Cooking Grates and Flavorizer Bars, 3 years,  
All Remaining Parts, 5 years,  
Weber is not liable for any special, indirect or  
consequential damages. Some states do not  
allow the exclusion or limitation of incidental or  
consequential damages, so this limitation or  
exclusion may not apply to you.  
when assembled and operated in accordance  
with the printed instructions accompanying it.  
Weber may require reasonable proof of your  
date of purchase. THEREFORE, YOU SHOULD  
RETAIN YOUR SALES SLIP OR INVOICE.  
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 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 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  
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.  
The LP tank manufacturer is responsible for the  
materials, workmanship and performance of the tank. If  
the tank has a defect, malfunctions, or you have a  
question regarding the tank, call the tank manufac-  
turer's customer service center. The phone number is  
on the warning decal which is permanently attached to  
the tank. If the tank manufacturer has not resolved the  
issue to your satisfaction, then call Weber-Stephen  
Products Co., Customer Service Center.  
Deterioration or damage due to severe weather  
conditions such as hail, hurricanes, earthquakes  
or tornadoes, discoloration due to exposure to  
chemicals either directly or in the atmosphere, is  
not covered by this Limited Warranty.  
3
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PATENTS AND TRADEMARKS  
© 1997 Weber. Weber, , Flavorizer and Crossover are registered  
U.S. trademarks; Spirit, Gas Catcher, FlameCheck, and Spider  
Stopper are U.S. trademarks of Weber-Stephen Products Co., 200  
East Daniels Road, Palatine, IL 60067-6266. U.S.A. Spirit is  
covered under the following patent nos.: U.S.A. #4,677,964;  
4,727,853; #4,829,978; #4,941,817; and #4,966,125; Canada:  
#1,279,540; #1,300,994; and #1,300,995. Printed in the U.S.A.  
4
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Contents  
Troubleshooting & Maintenance  
WARNINGS................................................................ 2  
Warranty & Patents.................................................. 3-4  
General Instructions.................................................... 6  
Assembly ............................................................... 7-20  
Annual Maintenance......................................... 27  
General Maintenance.................................. 28-30  
Troubleshooting................................................ 31  
Parts Listing .............................................................. 33  
Operating Instructions  
Lighting........................................................ 21-22  
Cooking ............................................................ 23  
Storage and/or Nonuse .................................... 23  
Cleaning .......................................................... 23  
LP Tank Information .................................... 24-26  
b
c
a
d
e
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a
g
FEATURES:  
IMPORTANT NEW FEATURES:  
a) Convenient tables and racks.  
b) Heavy gauge porcelain-on-steel lid seals in heat.  
Your Weber Gas Barbecue is equipped with a new and  
improved LP tank connection, that has additional  
safety features. They are:  
c) Rapid read thermometer for precision cooking  
measures grill temperature, and can be removed and  
inserted into the food.  
1. The connection of the barbecue to the LP tank can be  
made without the use of tools.  
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.  
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.  
e) Separate burners for temperature control.  
f) Crossover Ignition System with Gas Catcher Ignition  
Chamber.  
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.  
g) Fuel scale indicates LP gas supply.  
h) Catch pan catches excess grease.  
5
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General Instructions  
Storage  
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 gas must be turned OFF at the LP tank when the  
Weber Gas Barbecue is not in use.  
When the Weber Gas Barbecue is stored indoors, the  
gas supply must be disconnected and the LP tank  
stored outdoors in a well-ventilated space.  
The Weber Gas Barbecue is portable so you can easily  
change its location in your yard or on your patio. Portability  
means you can take your Weber Gas Barbecue with you if  
you move.  
LP tanks must be stored outdoors in a well-ventilated  
area out of the reach of children. Disconnected LP  
tanks must not be stored in a building, garage or any  
other enclosed area.  
Liquid Propane (LP) gas supply is easy to use and gives  
you more cooking control than charcoal fuel.  
When the LP tank is not disconnected from the Weber  
Gas Barbecue, the appliance and LP tank must be  
kept outdoors in a well-ventilated space.  
These instructions will give you the minimum  
requirements for assembling your Weber Gas  
Barbecue. Please read the instructions carefully  
before using your Weber Gas Barbecue. Improper  
assembly can be dangerous.  
Operating area  
Not for use by children.  
ƽWARNING: Only use this barbecue outdoors in a  
well ventilated area. Do not use in a garage, building,  
breezeway or any other enclosed area.  
If there are local codes that apply to portable gas grills,  
you will have to conform to them. If there are no local  
codes, you must conform to the latest edition of the  
National Fuel Gas Code: ANSI Z 223.1.  
Never use your Weber Gas Barbecue under an  
unprotected combustible roof or overhang.  
The pressure regulator supplied with the Weber  
Gas Barbecue must be used. This regulator is set  
for 10.5 inches of water column (pressure).  
Your Weber Gas Barbecue is not intended to be  
installed in or on recreational vehicles and/or boats.  
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 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.  
Do not use with charcoal fuel.  
Keep any electrical supply cord and the fuel supply  
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.  
hose away from any heated surface.  
Keep the cooking area clear of flammable vapors  
and liquids, such as gasoline, alcohol, etc., and  
combustible materials.  
The area around the LP tank must be free and clear  
from debris.  
Never store an extra (spare) LP tank under or near  
the Weber Gas Barbecue.  
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).  
6
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Step 1  
Assembly  
Tools needed  
Check package contents  
Hammer  
Cooking box  
(assembly)  
7/16 open-end or an adjustable wrench  
Pliers  
Lid  
Block of wood  
(assembly)  
Phillips screwdriver  
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.")  
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.  
Bottom tray  
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.  
Two cooking grates  
LP tank filler adapter  
Control panel  
7
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Left frame  
Tank panel assembly  
Front panel  
Right frame  
Wheel frame  
Leg frame  
Catch pan holder  
Catch pan  
Frame connector  
Work table  
Two drip pans  
Manifold bracket  
Thermometer  
Accessory rack  
Warming rack  
E R  
W
B
E
E
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Two wheels  
Fuel scale assembly  
Five Flavorizer Bars  
Spacer bracket  
8
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Check contents of hardware packs  
Two plastic buttons  
(actual size)  
Two burner control knobs  
Two 1/4-20 wing nuts  
(actual size)  
Two tool holders  
Eleven 1/4 inch nylon washers  
Two hair pin cotters  
Eight tubing plugs  
(two are spares)  
Two hinge pins  
(hardware size: 1/4 x 1 1/2 inch clevis pin)  
(actual size)  
Two wheel hubcaps  
1/4-20 x 2 inch bolt  
(actual size)  
1/4-20 keps nut  
Two 1/4-20 x 1 3/4 inch bolts  
(actual size)  
Two phillips screws/washers  
Six 1/4-20 x 1/2 inch bolts  
(actual size)  
9
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Step 2  
Step 3  
Assemble wheel frame  
Assemble top frame  
You will need: wheel frame, two wheels, two wheel hubcaps,  
hammer and a block of wood.  
You will need: left frame, right frame, two 1/4-20 x 1/2 inch  
bolts, two nylon washers and a 7/16 inch wrench.  
Set one end of wheel frame on the block of wood (or other  
hard, protected surface). Put one wheel on axle, WEBER  
side facing up, and tap on one hubcap.Figure 1.  
Note - Work on carpeted area (on grass or one of the  
boxes) to protect the finish during frame assembly.  
Lay the leg pieces as shown so the leg tabs point up.  
Figure 2.  
Repeat with other wheel and hubcap.  
Slip the two frame pieces together with the tabs inside.  
Figure 2 (a). Slip washers on bolts, insert bolts as shown  
and tighten. Figure 2 (b). (If you try to insert a bolt and  
there are no holes, you have the left frame turned the  
E R  
W
B
E
E
B
W
E
R
wrong way. Turn the left frame around.)  
Frame tabs  
(a)  
Figure 1  
Leg tabs  
Right frame  
Left frame  
(b)  
Figure 2  
10  
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Step 4  
Step 6  
Continue frame assembly  
Add front panel  
You will need: leg frame, wheel frame, four 1/4-20 x 1/2 inch  
bolts, four nylon washers and a 7/16 inch wrench.  
You will need: front panel and two plastic buttons.  
Turn frame assembly right side up.  
Place the leg 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.  
Align the panel with the holes in the frame and insert the  
plastic buttons through the front panel and frame. Figure 5.  
Plastic buttons  
The leg tabs must be on the inside of the frames.  
Add the washers to the bolts, insert in the holes as shown  
and tighten with the wrench. Figure 3.  
Dimples to  
the inside  
Fuel scale  
decal  
View from rear  
of barbecue  
Figure 3  
Step 5  
Figure 5  
Install tubing plugs  
You will need: two tubing plugs and a hammer.  
Insert tubing plugs into the ends of the leg frame.Figure 4.  
To fully seat the plugs, you may have to tap them lightly  
with a hammer.  
Figure 4  
11  
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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:  
Step 7  
Add cooking box  
You will need: frame assembly, cooking box assembly, work  
table spacer, 1/4-20 keps nut, 1/4-20 x 2 inch bolt, pliers  
and a 7/16 inch wrench.  
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).  
Uncoil the hose.  
Set the cooking box in the frame so the burner tubes are  
under the frame brace. Figure 6.  
Burner tubes  
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 barbecue.  
Frame brace  
Guide screw  
(b)  
Figure 6  
(a)  
Slide the cooking box to the left within the frame. Put the  
washer on the bolt. Take the spacer bracket and hold it up  
to the frame making sure both tabs fit underneath the  
frame cross piece. Figure 7 (a). Insert the bolt through the  
center hole in the spacer bracket, frame and cooking box  
with the head of the bolt outside the spacer bracket.  
Figure 7 (b). Add keps nut. Figure 7. Tighten by holding  
the bolt with pliers while you tighten the nut with a wrench.  
View from  
(c)  
behind  
cooking  
box  
Frame  
cross piece  
Wing Nuts  
Figure 8  
(a)  
Spacer bracket  
(b)  
Keps nut  
Tab  
Bolt  
Nylon washer  
Figure 7  
12  
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Step 8  
Step 9  
Install manifold bracket  
You will need: manifold bracket  
Install tank panel assembly and frame connector  
You will need: tank panel assembly, frame connector, two  
1/4-20 x 1 3/4 inch bolts, two nylon washers and a 7/16 inch  
wrench.  
Hook the bracket onto the manifold at approximately the  
center of the length of the manifold. Place your hand  
underneath the bracket. Lift the manifold, bracket and  
cooking box slightly and hook the tab of the bracket onto  
the frame brace. Figure 9.  
Insert the tank panel tabs into the slots in the frame brace.  
Figure 10.  
Frame brace  
Slots in frame brace  
Frame brace  
Manifold bracket  
Tank panel tabs  
Figure 9  
Figure 10  
Slide tank panel up until notch at bottom of panel fits over  
the cross brace. Insert one bolt with washer through the  
hole in the bottom of the tank panel, through the wheel  
frame and into the end of the frame connector. Insert the  
other bolt with washer through the leg frame and into the  
other end of the frame connector. Hold the frame connector  
square and tighten the bolts. Figure 11.  
Frame  
connector  
Cross brace  
Figure 11  
13  
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Step 10  
Step 11  
Add fuel scale assembly  
Install igniter  
You will need: fuel scale assembly, two 1/4-20 wing nuts  
and two nylon washers.  
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.  
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.  
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 13 (b).Loosen the igniter  
lock nut and slide the igniter into the small part of the  
keyhole. Figure 13 (c). Tighten the igniter lock nut. Figure 13.  
Add washers then wing nuts and tighten. Figure 12.  
Note - If the igniter works loose, carefully tighten the igniter  
lock nut with an adjustable wrench or pliers.  
(a)  
Frame brace  
E
E
(b)  
F
F
View from front left  
View from front right  
Figure 12  
Keyhole in  
frame brace  
Igniter lock nut  
Figure 13  
(c)  
Frame brace  
Small part of keyhole  
in frame brace  
14  
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Step 12  
Step 13  
Set LP fuel scale  
You will need: LP tank (empty).  
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.  
Note - For accuracy, the fuel scale must be set with an  
empty tank.  
We utilize various LP tank manufacturers. Some of the  
tanks we receive have differing top collar assemblies.  
(The top collar is the metal protective ring around the  
valve.) One series of tanks mounts with the valve facing  
front. The other tanks mount with the valve facing away  
from the fuel scale. These types of tanks are illustrated in  
Figure 14.  
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.  
Loosen the tank lock wing nut. Tighten so the lock is held  
up out of the way. Figure 14 (a). Lift and hook the tank onto  
the fuel scale. With an empty LP tank, adjust the fuel scale  
setting to E with scale setting (top) wing nut. Figure 14 (b).  
ƽWARNING: We recommend that your LP tank be  
filled at an authorized LP gas dealer by a qualified  
attendant, who fills the tank by weight.  
ƽCAUTION: Do not remove adjustment wing nut from  
tank scale.  
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.  
After adjusting tank scale, push tank down a couple of  
times to check that the tank scale is set on “E”.  
ƽWARNING: 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.  
Scale setting  
Tank lock  
wing nut  
wing nut  
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).  
(a)  
(b)  
For full instructions on safe handling of LP tanks, see  
Section "Safe handling tips for LP gas".  
E
E
F
F
Figure 14  
15  
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Route the hose so it will not interfere with the scale  
indicator rod.  
Step 14  
Check that all burner valves are off  
The hose and regulator are connected in the following  
manner:  
You will need: one burner control knob.  
Valves are shipped in the OFF position, but you should  
check to be sure. Put the knob on each valve. Check by  
pushing down and turning clockwise. If they do not turn  
they are off, proceed to the next step. Figure 15.  
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 17 (a). Figure 17 (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 17 (c).  
(a)  
Collar  
Figure 15  
Male  
fitting  
Step 15  
Connect LP tank  
ƽWARNING: Make sure that the LP tank valve is  
closed. Close by turning clockwise.  
(b)  
Hose  
Hook the LP tank onto the fuel scale. Loosen the tank lock  
wing nut. Swing the tank lock down. Tighten the wing nut.  
Figure 16.  
Valve handwheel  
close clockwise  
Tank valve  
Regulator  
Pressure  
relief valve  
E
Tank lock  
wing nut  
Tank  
F
Regulator  
vent  
Quick disconnect  
engaged  
Figure 16  
(c)  
Turn so regulator vent  
does not collect water  
Figure 17  
16  
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Check:  
Step 16  
a) Hose to manifold connection. Figure 19 (a).  
b) Regulator to tank connection. Figure 19 (b).  
Check for gas leaks  
ƽ DANGER  
ƽWARNING: If there is a leak at connection (a)  
retighten the fitting with a wrench and recheck for  
leaks with soap and water solution.  
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.  
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 19 (c).  
d) The hose to regulator connection. Figure 19 (d).  
ƽWARNING: You should check for gas leaks every  
time you disconnect and reconnect a gas fitting.  
ƽWARNING: 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.  
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.  
When leak checks are complete, turn gas supply OFF  
and rinse connections with water.  
ƽWARNING: Perform these leak checks even if your  
barbecue was dealer or store assembled.  
(a)  
You will need: a soap and water solution and a rag or  
brush to apply it.  
To perform leak checks: open tank valve by turning the  
tank valve handwheel counterclockwise. Figure 18.  
(b)  
(c)  
Figure 19  
Figure 18  
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.  
(d)  
ƽWARNING: Do not ignite burners when leak checking.  
17  
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Step 17  
Step 18  
Install Flavorizer Bars and Cooking Grates  
You will need: five Flavorizer Bars and two cooking grates.  
Install the bottom tray  
You will need: bottom tray, catch pan holder, catch pan and  
one drip pan.  
Set the Flavorizer Bars side to side in the cooking box.  
Figure 20.  
Finger grip on front  
edge of bottom tray  
Front side of catch  
pan holder  
Figure 22  
Hook the ends of the catch pan holder into the hole in the  
bottom tray. Figure 23. The front of the catch pan holder  
must be on the same side as the finger grip of the  
bottom tray.  
Figure 20  
Set the cooking grates onto the ledges in the cooking box  
with the rounded side up. Figure 21.  
Finger grip  
Figure 23  
Slide the bottom tray onto the mounting rails under the  
cooking box with finger grip toward you. Figure 24.  
ƽCAUTION: 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 21  
Bottom tray  
Figure 24  
Put the foil drip pan into the catch pan.  
Slide the catch pan into the catch pan holder with its finger  
grip towards you.  
18  
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Step 19  
Step 20  
Install Lid  
Add tool holders, control panel and burner  
control knobs  
You will need: lid, two hinge pins and two hair pin cotters.  
You will need: two tool holders, control panel, two Phillips  
screws/washers, a Phillips screwdriver, and two burner  
control knobs.  
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 25.  
Hook the tool holders over the frame rail. Figure 26.  
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 26 (a).  
Hair pin cotter  
Hinge pin  
Push on the burner control knobs. Figure 26 (b).  
Insert in  
frame brace  
(a)  
Crossover  
Ignition  
Button  
Figure 25  
Control panel  
Phillips screws/  
washers  
(b)  
Tool holders  
Figure 26  
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Step 21  
Complete accessory installation  
You will need: work table, accessory rack, warming rack,  
four tubing plugs and thermometer.  
Set the accessory rack across the bottom braces in front  
of the frame connector. Figure 27 (a).  
Open the lid and set the warming rack into the slots at the  
rear of the cooking box. Figure 27 (b).  
Set the work table onto the left side rails. Figure 27 (c).  
Insert the thermometer into its holder. Figure 27 (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 27 (e).  
(d)  
(c)  
(b)  
(a)  
(e)  
Figure 27  
20  
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OPERATING INSTRUCTIONS  
ƽWARNING: The burner control knobs must be in the  
Lighting  
Summary lighting instructions are on the control panel.  
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.  
ƽ
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.  
ƽ
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 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.  
ƽWARNING: Check hose before each use of barbecue  
for nicks, cracking, abrasions or cuts. If the hose is  
found to be damaged in any way, do not use the  
barbecue. Replace using only Weber authorized  
replacement manifold assembly. Order from Weber-  
Stephen Products Co., Customer Service Center or  
authorized dealer.  
4) Turn the tank on by turning the tank valve  
counterclockwise.  
ƽWARNING: Do not lean over open barbecue. Keep  
your face and body at least one foot away from the  
matchlight hole when lighting the barbecue.  
Crossover Ignition System  
5) Push Front burner control knob down and turn to  
START/ HI.  
1
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.  
3
ƽWARNING: 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
6
4
7
2
8) After the FRONT burner is lit you can turn on the other  
burner.  
5
Note - Always light the FRONT burner first. The other  
burner ignites from the FRONT burner.  
Figure 1  
1) Open the lid. Figure 1.  
2) Check that the fuel scale reads more than “E”.  
Note - E = empty; F = full.  
To Extinguish  
Turn gas supply OFF at the source, then push down  
and turn each burner control knob clockwise to OFF.  
3) Make sure all burner control knobs are turned OFF.  
(Push control knob down and turn clockwise.)  
21  
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4) Turn the tank on by turning the tank valve  
counterclockwise.  
Manual Lighting  
5) Strike a match and put the flame into the matchlight  
hole in the front of the cooking box.  
ƽ
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.  
ƽWARNING: Do not lean over open barbecue. Keep  
your face and body at least one foot away from the  
matchlight hole when lighting the barbecue.  
6) Push Front burner control knob down and turn to  
START/ HI.  
7) Check that the burner is lit by looking through the  
matchlight hole on the front of the cooking box.  
1) Open the lid. Figure 2.  
ƽWARNING: 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.  
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 knob down and turn clockwise.)  
8) After the FRONT burner is lit you can turn on the other  
burner.  
ƽWARNING: The burner control knobs must be in the  
OFF position before turning on the LP tank valve. If  
they are not in the OFF position, when you turn on the  
LP tank valve, the excess flow control will activate,  
limiting the flow of gas from the LP tank. If this should  
occur, turn OFF the LP tank valve and burner control  
knobs and start over.  
Note - Always light the FRONT burner first. The other  
burner ignites 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.  
ƽ
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 flame-up which can cause  
serious bodily injury or death.  
1
Manual Lighting  
3
6
8
4
5
7
2
Figure 2  
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Storage and/or Nonuse continued  
Cooking  
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.  
ƽWARNING: Do not move the Weber Gas Barbecue  
when operating or hot.  
You can adjust the FRONT 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  
and BACK burners. For example, to sear steaks you would  
use (HH) (all burners at high). Then to complete cooking you  
would use (MM) (FRONT at medium, and BACK at medium).  
See your Weber cookbook for detailed cooking instructions.  
The Weber Gas Barbecue should be checked for  
gas leaks and any obstructions in the burner tubes  
before using. (See Sections "General and Annual  
Maintenance.")  
Check that the areas under the control panel and the  
bottom tray are free from debris that might obstruct  
the flow of combustion or ventilation air.  
The Spider Stopper Guards should also be checked for  
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.  
any obstructions. (See Section "Annual Maintenance.")  
Periodic Cleaning  
ƽCAUTION: Replace thermometer in lid when not in  
use. Do not leave thermometer in food while cooking.  
ƽWARNING: Turn your Weber Gas Barbecue OFF and  
wait for it to cool before cleaning.  
If burners go out during cooking, open lid, turn off all  
burners and wait 5 minutes before relighting.  
ƽCAUTION: 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 Products  
Service Center.  
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 (HH).  
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.  
Outside surfaces - Use a warm soapy water solution.  
ƽCAUTION: Do not use oven cleaner, abrasive  
cleansers (kitchen cleansers), cleaners that contain  
citrus products or abrasive cleaning pads on barbecue  
or cart surfaces.  
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.  
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.  
ƽWARNING: Check the bottom tray for grease build-  
up before each use. Remove excess grease to avoid a  
grease fire in the bottom tray.  
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.  
Storage and/or Nonuse  
The gas must be turned off at the LP tank when the  
Thermometer - Wipe with warm soapy water, clean with  
plastic scrub ball. Do not put in dishwasher or submerge in  
water.  
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.  
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.  
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.  
Molded table - Use any household cleaners on the table  
surface. DO NOT USE CLEANERS THAT CONTAIN ACID,  
MINERAL SPIRITS OR XYLENE. Rinse well after cleaning.  
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Connecting the filled LP tank  
Refilling the LP tank  
We recommend that you refill before the scale indicator  
reaches "E".  
ƽWARNING: Make sure that the LP tank valve is  
closed. Close by turning clockwise.  
Note - If you run out of fuel, check the indicator setting  
and/or adjust the fuel scale indicator setting with the scale  
setting wing nut, while the tank is empty so you do not run  
out again.  
ƽ DANGER  
Do not use an open flame to check for gas  
leaks. Be sure there are no sparks or open  
flames in the area while you check for  
leaks. This will result in a fire or explosion  
which can cause serious bodily injury or  
death and damage to property.  
Removal of the LP tank  
1) Close tank valve (turn clockwise). Figure 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.  
You will need: LP tank, a soap and water solution and a  
rag or brush to apply it.  
4) Lift tank off.  
Note - Since some leak test solutions, including soap and  
water, may be slightly corrosive, all connections should be  
rinsed with water after checking for leaks  
To refill take LP tank and tank filler adapter to a "Gas  
Propane" dealer.  
a) Lift and hook the tank onto the fuel scale.  
ƽWARNING: We recommend that your LP tank be  
filled at an authorized LP gas dealer, by a qualified  
attendant, who fills the tank by weight. IMPROPER  
FILLING IS DANGEROUS.  
b) Loosen the tank lock wing nut. Swing the tank lock  
down. Tighten the wing nut. Figure 4.  
ƽWARNING: 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.  
Scale setting wing nut  
Tank lock  
wing nut  
Figure 4  
(a)  
Tank valve  
Collar  
(b)  
Figure 3  
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c) Connect the hose to the tank. Route the hose so it  
does not interfere with the scale indicator rod. Slide  
back the collar of the quick disconnect on the tank  
valve. Figure 5 (a). Push the male fitting of the  
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 there is a leak turn off the gas, tighten the fitting, turn the  
gas back on and recheck with the soap and water  
solution.  
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.  
If leak does not stop, turn off the gas and contact  
Weber-Stephen Customer Service. Do not use the  
barbecue.  
(a)  
g) When leak checks are complete, turn gas supply OFF  
and rinse connections with water.  
LP Tank  
The LP tank manufacturer is responsible for the materials,  
workmanship and performance of the tank. If the tank has  
a defect, malfunctions, or you have a question regarding  
the tank, call the tank manufacturer's customer service  
center. The phone number is on the warning decal which is  
permanently attached to the tank. If the tank manufacturer  
has not resolved the issue to your satisfaction, then call  
Weber-Stephen Products Co., Customer Service Center.  
Male fitting  
Regulator  
Collar  
(b)  
Quick disconnect  
engaged  
Figure 5  
d) Mix soap and water.  
e) Open the tank valve. Figure 6.  
Figure 6  
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Liquid Propane (LP) Tank(s)  
Safe handling tips for LP Gas  
The LP tank and connections supplied with your  
Weber Gas Barbecue have been designed and tested  
to meet government, American Gas Association and  
Underwriters Laboratories requirements.  
Liquid Propane (LP) gas is a petroleum product as are  
gasoline and natural gas. LP gas is a gas at regular  
temperatures and pressures. Under moderate  
pressure, inside a cylinder, LP gas is a liquid. As the  
pressure is released the liquid readily vaporizes and  
becomes gas.  
Replacement LP tanks supplied by Weber satisfy the  
requirements. Check to be sure the tank has a D.O.T.  
certification, and has been tested within five years.  
Your LP gas supplier can do this for you. Figure 7.  
LP gas has an odor similar to natural gas. You should  
know this odor.  
If you have questions about spare LP tanks, please  
call Weber-Stephen Customer Service.  
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  
gas-propane in the phone book for other sources of  
LP gas.  
D.O.T. Certification (example)  
ƽWARNING: We recommend that your LP tank be  
filled at an authorized LP gas dealer, by a qualified  
attendant, who fills the tank by weight. IMPROPER  
FILLING IS DANGEROUS.  
DOT 4BA240  
1/97  
ƽWARNING: 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.  
20 lb LP tank  
Date Tested  
Air must be removed from a new LP tank before the  
initial filling. Your LP dealer is equipped to do this.  
Figure 7  
The LP tank must be installed, transported and stored  
in an upright position. LP tanks should not be dropped  
or handled roughly.  
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,  
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).  
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.).  
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 cylinder. Always  
close the tank valve before disconnecting.  
Do not use a damaged LP tank. Dented or rusty LP  
tanks or LP tanks with a damaged valve may be  
hazardous and should be replaced with a new one  
immediately.  
The joint where the hose connects to the LP tank must  
be leak tested each time the LP tank is reconnected.  
For example, test each time the LP tank is refilled.  
Be sure the regulator is mounted with the small vent  
hole pointed downward so it will not collect water. This  
vent should be free of dirt, grease, bugs etc.  
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Check:  
Annual Maintenance  
c) Valves to manifold connections. Figure 8 (c).  
d) The hose to regulator connection. Figure 8 (d).  
After a period of nonuse we recommend that you perform  
the following maintenance procedures for your safety.  
ƽWARNING: 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.  
ƽWARNING: Check hose before each use of barbecue  
for nicks, cracking, abrasions or cuts. If the hose is  
found to be damaged in any way, do not use the  
barbecue. Replace using only Weber authorized  
replacement manifold assembly. Order from Weber-  
Stephen Products Co., Customer Service Center or  
authorized dealer.  
When leak checks are complete, turn gas supply OFF at  
the source and rinse connections with water.  
(a)  
Inspect the burners for correct flame pattern. Clean if  
necessary, following the procedures outlined in the  
"General Maintenance" section of this manual.  
(b)  
Check all gas fittings for leaks.  
ƽ 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.  
(c)  
ƽWARNING: 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.  
(d)  
To perform leak checks: Make sure all burners are in the  
OFF position. Turn on gas supply.  
Figure 8  
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.  
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".)  
ƽWARNING: Do not ignite burners while leak checking.  
Check:  
a) Hose to manifold connection. Figure 8 (a).  
b) Regulator to tank connection. Figure 8 (b).  
ƽWARNING: 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.  
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Main Burner Flame Pattern  
General Maintenance  
Weber Spider Stopper Guards  
The Weber Gas Barbecue burners have been factory set  
for the correct air and gas mixture. The correct flame  
pattern is shown in Figure 11.  
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.  
Tips occasionally yellowish  
Burner inside  
cooking box  
Light blue  
Venturi  
Dark blue  
Flames  
Figure 11  
If the flames do not appear to be uniform the length of the  
burner tube, follow the burner cleaning procedures.  
Venturi fin  
Air shutter  
Figure 9  
Main Burner Cleaning Procedure  
Turn off the gas supply. Remove the manifold.  
(See Section “Replacing the main burners”.)  
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.  
Look inside each burner with a flashlight. Figure 12.  
Figure 12  
Weber Spider  
Stopper Guard  
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.  
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.  
Figure 13  
ƽCAUTION: Do not enlarge the burner ports when  
cleaning.  
2. Barbecue does not reach temperature.  
3. Barbecue heats unevenly.  
4. One or more of the burners do not ignite.  
Replacing Main Burners  
a) Your Weber Gas Barbecue must be OFF and cool.  
b) Turn gas OFF at source.  
ƽ
DANGER  
Failure to correct these symptoms may  
result in a fire which can cause serious  
bodily injury or death and cause damage  
to property.  
c) Remove control panel: take off the burner control  
knobs. Remove the screws holding the control panel  
in place. Lift off the control panel.  
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d) Unlatch the Spider Stopper Guards and remove.  
Figure 14.  
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  
h) To reinstall the burners, reverse steps c) through g).  
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.  
ƽCAUTION: The burner openings must be positioned  
properly over the valve orifices. Figure 18a.  
Check proper assembly before fastening manifold in  
place. Figure 18b.  
View from behind  
cooking box  
(a)  
Valve  
Wing nuts  
Figure 15  
Burner  
f) Slide the burner assembly out from under the guide  
screw and washer in the corners of the cooking box.  
Figure 16.  
(b)  
Guide screw  
Figure 16  
Figure 18  
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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.  
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.  
Check fit  
around valve  
Venturi fin  
White wire  
Black wire  
Check fit around burner  
Figure 19  
ƽCAUTION: If the Spider Stopper Guards do not fit  
tightly, contact Weber-Stephen Customer Service.  
Figure 20  
Check that the Crossover Ignition button pushes the  
ƽWARNING: After reinstalling the gas lines, they  
should be leak checked with a soap and water  
solution before using the barbecue. See Step“Check  
for gas leaks”.  
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.  
30  
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TROUBLESHOOTING  
Problem  
Check  
Cure  
Burners burn with a yellow or orange  
flame, in conjunction with the smell of gas. Guards for possible obstructions.  
Inspect Weber Spider Stopper  
Clean Weber Spider Stopper  
Guards. (See Section "Annual  
Maintenance".)  
(Blockage of holes.)  
Burners do not light. -or-  
The excess flow safety device,  
To reset the excess flow safety  
Burners have a small flickering flame in the which is part of the barbecue to tank device turn all burner control  
HIGH position. -or-  
Barbecue temperature only reaches 250˚ to  
300˚ degrees in the HIGH position.  
connection, may have activated.  
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”.  
Burner does not light, or flame is low in  
HIGH position.  
Is LP fuel low or empty?  
Refill LP tank.  
Is fuel hose bent or kinked?  
Straighten fuel hose.  
Does the Front burner light with a  
match?  
If you can light the Front burner  
with a match, then check the  
Crossover Ignition System.  
Experiencing flare-ups:  
Are you preheating barbecue in the All burners on high for 10 to 15  
prescribed manner?  
minutes for preheating.  
Are the cooking grates and  
Clean thoroughly. (See Section  
Flavorizer Bars heavily coated with "Periodic Cleaning".)  
burned-on grease?  
Is the bottom tray "dirty" and not  
allowing grease to flow into catch  
pan?  
Clean bottom tray.  
ƽCAUTION: Do not line the bottom tray  
with aluminum foil.  
Are burners clean?  
Clean burners. (See Section  
"General Maintenance".)  
Burner flame pattern is erratic. Flame is low  
when burner is on HIGH. Flames do not run  
the whole length of the burner tube.  
The lid is porcelain-on-steel, not  
Clean thoroughly. (See Section  
Inside of lid appears to be “peeling.”  
(Resembles paint peeling.)  
paint. It cannot “peel.” What you are "Periodic Cleaning".)  
seeing is baked on grease that has  
turned to carbon and is flaking off.  
THIS IS NOT A DEFECT.  
Fuel scale must be adjusted with  
an empty tank.  
Check adjustment of fuel scale.  
Fuel scale shows that there is gas in the LP  
tank, but tank is empty.  
If problems cannot be corrected by using these methods, please contact Weber-Stephen Customer Service.  
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1
2
28  
29  
30  
31  
3
4
32  
5
6
33  
34  
35  
36  
37  
38  
39  
40  
7
8
9
41  
10  
42  
43  
44  
11  
12-13  
14  
45  
46  
47  
15  
48-49  
16  
17  
50  
51  
E B  
E R  
W
W
E
B
R
E
24  
13  
26 27  
18 19 20 21  
22 23 25  
32  
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While we give much attention to our products, unfortunately  
an occasional error may occur. If a part is missing, do not  
go back to the store. Call the Weber Customer Service  
Center toll free 1-800-446-1071 to receive immediate  
assistance. Have your owner’s manual and serial number  
of the barbecue available for reference.  
Parts 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.  
Weber-Stephen Products Company  
Customer Service Center  
250 South Hicks Road  
Palatine, IL 60067-6241  
(800) 446-1071  
30 Hinge pins (2)  
31 Thermometer  
32 Thermometer holder  
33 Keps nut  
34 Cooking box  
35 Burner control knobs (2)  
36 Control panel  
37 Igniter button  
38 Phillips screws/washers (2)  
39 Crossover tube  
40 Front and back burners (2)  
41 1/4-20x1 inch stainless steel wing nuts (2)  
42 Spider Stopper Guards (2)  
43 Manifold assembly  
44 Manifold bracket  
45 Control panel inserts (2)  
46 Igniter assembly  
47 Right frame  
1
2
3
4
5
6
7
8
9
Left endcap  
Shroud assembly  
Lid handle  
Warming rack  
Flavorizer bars (5)  
Cooking grates (2)  
Work table  
Tubing plugs (8)  
1/4-20 x 2 inch bolt  
10 Spacer bracket  
11 Left frame  
12 1/4-20 x 1/2 inch bolts (6)  
13 1/4 inch nylon washers (11)  
14 Leg frame  
15 Bottom tray  
16 Catch pan holder  
17 Catch pan kit  
18 Accessory rack  
19 Frame connector  
20 Wheel hubcaps (2)  
21 Wheels (2)  
48 Fuel scale  
49 1/4-20 wing nuts (2)  
50 Filler adapter  
51 LP tank  
22 Tool holders (2)  
23 Wheel frame  
24 Front panel  
25 Plastic buttons (2)  
26 Tank panel assembly  
27 1/4-20 x 1 3/4 inch bolts (2)  
28 Right endcap  
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.  
29 Hair pin cotters (2)  
33  
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A FINAL WORD  
OF THANKS  
hank you for choosing a Weber Barbecue.  
T
Our family here at Weber has worked hard  
to produce the highest quality products  
for your satisfaction.  
While we give much attention to our products, an  
occasional error may occur. Our knowledgeable  
Customer Service staff is prepared to help you  
with any problems with parts or assembly.  
Call our toll free number 1-800-446-1071.  
For quicker service, please have your owner’s  
manual available for reference. We also welcome  
any comments or suggestions you might have  
regarding our products.  
We wish your family the  
best in outdoor cooking enjoyment.  
Weber-Stephen Products Company  
Customer Service Center  
200 East Daniels Road  
Palatine, Illinois 60067-6266  
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