Weber 3200 LP User manual

Serial Number
Please use this number in registering your warranty
and any correspondence with the factory.
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SKYLINE™3200
Natural Gas Barbecue
Owner’s Manual
98697 12/97
®
FOR YOUR SAFETY
Do not store or use gasoline or other
flammable vapors and liquids in the vicinity
of this or any other appliance.
NOTICE TO INSTALLER: These instructions
must be left with the owner and the owner
should keep them for future use.
WARNING: Follow all leak check procedures
carefully in this manual prior to barbecue
operation. Do this even if barbecue was
dealer assembled.
WARNING: Do not try to light this appliance
without reading "Lighting" instructions
section of this manual.
THIS GAS APPLIANCE IS DESIGNED FOR
OUTDOOR USE ONLY.
FOR YOUR SAFETY
If you smell gas:
1. Shut off gas to the appliance.
2. Extinguish any open flame.
3. Open lid.
4. If odor continues, immediately call your
gas supplier or your fire department.

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DANGER
Failure to follow the Dangers, Warnings and Cautions contained in this Owner’s Manual
may result in serious bodily injury or death, or in a fire or an explosion causing damage
to property.
WARNINGS
Do not store a spare or disconnected LP tank under or near this barbecue.
Improper assembly may be dangerous. Please carefully follow the assembly instructions in this manual.
After a period of storage, and/or nonuse, the Weber Gas Barbecue should be checked for gas leaks
and burner obstructions before using. See instructions in this manual for correct procedures.
Do not operate the Weber Gas Barbecue if there is a gas leak present.
Do not use a flame to check for gas leaks.
Combustible materials should never be within 24 inches of the top, bottom, back or sides of your
Weber Gas Barbecue.
Do not put a barbecue cover or anything flammable on or in the storage area under the barbecue.
Your Weber Gas Barbecue should never be used by children.
You should exercise reasonable care when operating your Weber Gas Barbecue. It will be hot during
cooking or cleaning, and should never be left unattended.
Should the burners go out during operation, turn all gas valves off. Open the lid and wait five minutes
before attempting to relight, using the lighting instructions.
Do not use charcoal or lava rock in your Weber Gas Barbecue.
Never lean over open grill or place hands or fingers on the front edge of the cooking box.
Should a grease fire occur, turn off all burners and leave lid closed until fire is out.
Do not enlarge valve orifices or burner ports when cleaning the valves or burners.
The Weber Gas Barbecue should be thoroughly cleaned on a regular basis.
LP gas is not natural gas. The conversion or attempted use of natural gas in an LP unit or LP gas in a
natural gas unit is dangerous and will void your warranty.
Do not attempt to disconnect any gas fitting while your barbecue is in operation.
Use heat-resistant barbecue mitts or gloves when operating barbecue.
LP GAS UNITS ONLY:
Use the regulator that is supplied with your Weber Gas Barbecue.
Do not attempt to disconnect the gas regulator or any gas fitting while your barbecue is in operation.
A dented or rusty LP tank may be hazardous and should be checked by your liquid propane supplier.
Do not use an LP tank with a damaged valve.
Although your LP tank may appear to be empty, gas may still be present, and the tank should be
transported and stored accordingly.
If you see, smell or hear the hiss of escaping gas from the LP tank:
1. Get away from LP tank.
2. Do not attempt to correct the problem yourself.
3. Call your fire department.

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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,
Recycled Work Surfaces, 10 years,
Cooking Grates and Flavorizer Bars, 3 years,
All Remaining Parts, 5 years,
when assembled and operated in accordance
with the printed instructions accompanying it.
Weber may require reasonable proof of your
date of purchase. THEREFORE, YOU SHOULD
RETAIN YOUR SALES SLIP OR INVOICE.
This Limited Warranty shall be limited to the
repair or replacement of parts which prove
defective under normal use and service and
which on examination shall indicate, to Weber's
satisfaction, they are defective. Before returning
any parts, contact Weber-Stephen Products Co.
Customer Service Center. If Weber confirms the
defect and approves the claim, Weber will elect
to replace such parts without charge. If you are
required to return defective parts, transportation
charges must be prepaid. Weber will return parts
to the purchaser, freight or postage prepaid.
This Limited Warranty does not cover any failures
or operating difficulties due to accident, abuse,
misuse, alteration, misapplication, vandalism,
improper installation or improper maintenance or
service, or failure to perform normal and routine
maintenance, including but not limited to damage
caused by insects within the burner tubes, as set
out in this owner's manual.
Deterioration or damage due to severe weather
conditions such as hail, hurricanes, earthquakes
or tornadoes, discoloration due to exposure to
chemicals either directly or in the atmosphere, is
not covered by this Limited Warranty.
There are no other express warrants except as
set forth herein and any applicable implied
warranties of merchantability and fitness are
limited in duration to the period of coverage of
this express written Limited Warranty. Some
states do not allow limitation on how long an
implied warranty lasts, so this limitation may not
apply to you.
Weber is not liable for any special, indirect or
consequential damages. Some states do not
allow the exclusion or limitation of incidental or
consequential damages, so this limitation or
exclusion may not apply to you.
Weber does not authorize any person or
company to assume for it any other obligation or
liability in connection with the sale, installation,
use, removal, return, or replacement of its
equipment; and no such representations are
binding on Weber.
This Warranty applies only to products sold
at retail.
WEBER-STEPHEN PRODUCTS CO.
Customer Service Center
250 South Hicks Road
Palatine, IL 60067-6241
[phone]
WARRANTY

© 1997 Weber. Weber, , Genesis, Flavorizer and Crossover are
registered U.S. trademarks; Perma-Mount, Gas Catcher,
FlameCheck, Steam-N-Chips, Spider Stopper, and Warm-Up are
U.S. trademarks of Weber-Stephen Products Co., 200 East Daniels
Road, Palatine, IL 60067-6266. U.S.A. Genesis Gas Barbecues
are covered under the following patent nos.: U.S.A. #4,677,964;
4,727,853; #4,777,927; #4,829,978; #4,860,724; #4,941,817;
#4,966,125; #5,070,776; #D293,067; #D316,355; Canada: Rd
1987 Reg. #58,034; #1,279,540; #1,283,586; #1,300,994;
#1,300,995. Printed in the U.S.A.
PATENTS AND TRADEMARKS
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Contents
WARNINGS................................................................ 2
Warranty & Patents.................................................. 3-4
General Instructions.................................................... 6
Assembly............................................................... 7-22
Operating Instructions
Lighting ....................................................... 23-25
Cooking............................................................ 26
Storage and/or Nonuse.................................... 26
Cleaning........................................................... 26
Troubleshooting & Maintenance
Annual Maintenance ........................................ 27
General Maintenance.................................. 28-30
Troubleshooting.......................................... 31-32
Parts Listing.............................................................. 35
FEATURES:
a) Convenient tables and racks.
b) Heavy gauge porcelain-on-steel lid seals in heat.
c) Rapid read thermometer for precision cooking
measures grill temperature, and can be removed and
inserted into the food.
d) Heavy gauge steel Flavorizer Bars distribute heat
within the grill. Flavorizer Bars heat just the right
amount of drippings for flavoring, letting excess fat
drip past to help prevent flare-ups.
e) Weber Warm-Up Basket for additional cooking or
warming space.
f) Separate burners for temperature control.
g) Side burner for making sauces, gravies, etc.,while
main grill is in use.
h) Crossover Ignition System with Gas Catcher Ignition
Chamber.
i) Catch pan catches excess grease.
j) Locking casters for additional portability.
a
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General Instructions
Your Weber Gas Barbecue is a portable outdoor cooking
appliance. With the Weber Gas Barbecue you can grill,
barbecue, roast and bake with results that are difficult to
duplicate with indoor kitchen appliances. The closed lid and
Flavorizer Bars produce that "outdoor" flavor in the food.
The Weber Gas Barbecue is portable so you can easily
change its location in your yard or on your patio. Portability
means you can take your Weber Gas Barbecue with you if
you move.
The natural gas supply is easy to use and gives you more
cooking control than charcoal fuel.
■These instructions will give you the minimum
requirements for assembling your Weber Gas
Barbecue. Please read the instructions carefully
before using your Weber Gas Barbecue. Improper
assembly can be dangerous.
■Not for use by children.
■If there are local codes that apply to 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.
■This Weber Gas Barbecue is designed for natural
(piped in city) gas only. Do not use Liquid Propane
(LP) bottled gas.The valves, orifices and hose are for
natural gas only.
■Do not use with charcoal fuel.
■Check that the area under the control panel and the
bottom tray are free from debris that might obstruct
the flow of combustion or ventilation air.
For Installation in Canada
These instructions, while generally acceptable, do not
necessarily comply with the Canadian Installation codes,
particularly with piping above and below ground. In
Canada the installation of this appliance must comply with
local codes and/or Standard CAN/CGA-B149.1 (Installation
Code for Natural Gas Burning Appliances and Equipment).
Storage
■The gas must be turned OFF at the natural gas supply
when the Weber Gas Barbecue is not in use.
■When the Weber Gas Barbecue is stored indoors, the
gas supply must be disconnected.
Operating area
WARNING: Only use this barbecue outdoors in a
well ventilated area. Do not use in a garage, building,
breezeway or any other enclosed area.
■Never use your Weber Gas Barbecue under an
unprotected combustible roof or overhang.
■Your Weber Gas Barbecue is not intended to be
installed in or on recreational vehicles and/or boats.
■Do not use combustible materials within 24 inches of
the top, bottom, back or sides of the grill.
■The entire cooking box gets hot when in use. Do not
leave unattended.
■Keep any electrical supply cord and the fuel supply
hose away from any heated surface.
■Keep the cooking area clear of flammable vapors and
liquids, such as gasoline, alcohol, etc., and
combustible materials.
Gas supply testing
■Disconnect your Weber Gas Barbecue when the gas
supply is being tested at high pressures. This appliance
and its individual shutoff valve must be disconnected
from the gas supply piping system during any pressure
testing of that system at test pressures in excess of
1/2 psig (3.5 kPa).
■Turn off your Weber Gas Barbecue when the gas
supply is being tested at low pressures. This appliance
must be isolated from the gas supply piping system by
closing its individual manual shutoff valve during any
pressure testing of the gas supply piping system at
the pressure equal to or less than 1/2 psig (3.5 kPa).

Step 1
Check package contents
Cooking box
(assembly)
Lid
(assembly)
Hose
Bottom tray
Work table
Accessory rack
Swing table
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Assembly
Tools needed
Screwdrivers, regular
and Phillips
Hammer
7/16 inch or an adjustable wrench
Pliers
Block of wood
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.

Control panel
Front panel
Left frame
Wheel frame
Two frame connectors
Five long Flavorizer Bars
Eight short Flavorizer Bars
Two wheels
Two aluminum drip pans
Catch pan
Axle
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Right frame
Caster frame
Two casters
Two cooking grates
Warming rack
Warm-Up Basket
Thermometer
Wire condiment basket
with tool holders
Left hand slide bar assembly
Assembly consists of:
Left hand slide bar
Support rod
Slide
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Two wheel hubcaps
(actual size)
Two hinge pins
(hardware size: 1/4 x 1 1/2 inch clevis pin)
(actual size)
Five 1/4-20 x 2 inch bolts
(actual size)
Six 1/4-20 x 1/2 inch bolts
(actual size)
Two 10-24 x 1 3/4 machine screws
(actual size)
Two 10-24 hex nuts
(actual size)
Fifteen 1/4 inch nylon washers
(actual size)
1/4-20 keps nut
Two hair pin cotters
Two swing table end brackets
Two Phillips screws/washers
Catch pan holder
Manifold bracket
Side burner assembly
Burner grate
Side burner knob
Two side burner locks
Note: The locks are
taped to the inside of
the side burner lid.
Spacer bracket
Check contents of hardware packs
Three burner control knobs
Five tubing plugs
(two are spares)
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Step 2
Assemble wheels
You will need: axle, two wheel hubcaps, two wheels,
wheel frame, hammer and a block of wood.
Place one end of the axle on the block of wood (or other
protected surface). Tap on one hubcap.
Put one wheel on the axle, WEBER side toward the
hubcap. Slide the axle through the frame. Add the other
wheel, WEBER side out. Tap on the hubcap. Figure 1.
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Figure 1
Step 3
Assemble frame
You will need: left frame, right frame, two nylon washers,
two 1/4-20 x 1/2 inch bolts and a 7/16 inch wrench.
Note - Work on carpeted area (on grass, or on one of the
boxes) to protect the finish during frame assembly.
Put the frame pieces so the leg tabs are up. Put the right
frame to your right and left frame to your left. Figure 2.
Slip the two frame halves together with the tabs inside,
until the tabs of the right frame are inside the left frame
and the holes align. Figure 2 (a).
Slip washers over bolts; insert and tighten bolts. (If you try
to insert a bolt and there are no holes, you have the left
frame turned the wrong way. Turn the left frame around.)
Figure 2 (b).
Left frame
Leg tabs Frame tabs
Figure 2
(a)
(b)
Right frame

Step 4
Continue frame assembly
You will need: frame assembly, wheel frame assembly,
front panel, caster frame, four 1/4-20 x 1/2 inch bolts, four
nylon washers and a 7/16 inch wrench.
Place the caster frame onto the tabs of the left frame with
the dimple to the inside. Figure 3. Place the wheel frame
onto the tabs of the right frame with the dimple to the
inside. Figure 3.
The leg tabs must be on the inside of the frames.
Add front panel with the large hole down and to your right.
Add the washers to the bolts, insert in the holes as shown
and tighten with the wrench. Figure 3. Only start the bolt at
the wheel frame/right joint opposite the front panel. Figure 3.
Dimples to
the inside
Only start
this bolt
Figure 3
Fully tighten
this bolt
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Step 5
Complete frame assembly
You will need: partial frame assembly, two frame
connectors, four 1/4-20 x 2 inch bolts, four nylon washers
and a 7/16 inch wrench.
Hold one frame connector between the caster and wheel
frame. Add nylon washers to the bolts. Put the bolts
through the frame and screw into frame connector. Tighten.
Repeat procedure with the other frame connector. Figure 4.
Figure 4
Step 6
Insert casters
You will need: frame assembly and two casters.
Push the casters firmly into the inserts in the ends of the
caster legs. Figure 5.
Figure 5

Burner tubes
Figure 7
Frame brace
Frame cross
piece
Spacer
bracket
Keps nut
Bolt Nylon
washer
Tab
Step 8
Add cooking box
You will need: frame assembly, cooking box assembly,
1/4-20 x 2 inch bolt, nylon washer, 1/4-20 acorn nut, pliers
and a 7/16 inch wrench.
Set the cooking box into the frame so the burner tubes are
under the frame brace. Figure 7.
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 8 (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 8 (b). Add keps nut. Tighten by holding the bolt with
pliers while you tighten the nut with the 7/16 inch wrench.
Figure 8
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Step 7
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 cut out of the lock slips down over the
bolt. Tighten with a wrench. Figure 6 (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 6 (b).
Figure 6
(a)
(b)

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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:
a) Do the valves fit into the ends of the burners?
Figure 9 (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 9 (b).
c) Are the wing nuts under the burner assembly hand
tight? Do not tighten with pliers. Figure 9 (c).
If you answered YES to a, b and c, the burners are
correctly aligned. If you answered NO, the burners are
misaligned. Contact Weber-Stephen Customer Service.
Do not use your barbecue.
Guide screw
Figure 9
(a)
(b)
(c)
Wing nuts
Step 9
Install gas supply
General Specifications for Piping
Note - Contact your local municipality for building
codes regulating outdoor gas 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.
Some of the following are general requirements taken
from ANSI Z223.1, for gas supply installations. Refer to
ANSI Z223.1 latest edition for complete specifications.
■This barbecue is designed to operate at 7 inches of
water column pressure (.2526 psi).
■A manual shut-off valve must be installed outdoors,
immediately ahead of the quick disconnect.
■An additional manual shut-off valve indoors should be
installed in the branch fuel line in an accessible
location near the supply line.
■ The quick disconnect connects to a 3/8 inch NPT
thread from the gas source. The quick disconnect
fitting is a hand-operated device that automatically
shuts OFF the flow of gas from the source when the
barbecue is disconnected.
■The quick disconnect fitting can be installed
horizontally, or pointing downward. Installing the fitting
with the open end pointing upward can result in
collecting water and debris.
■The dust covers (supplied plastic plugs) help keep the
open ends of the quick disconnect fitting clean while
disconnected.
■Pipe compound should be used which is resistant to
the action of natural gas when connections are made.
■The outdoor connector must be firmly attached to
rigid, permanent construction.
WARNING: Do not route the 12 foot hose under a
deck. The hose must be visible.

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Step 10
Install igniter
Note - The igniter wires are already attached to the Gas
Catcher Ignition Chamber and the igniter. This was done to
factory test the ignition system.
The igniter lock nut is on the igniter.
Insert the top of the igniter up through the large part of the
keyhole in the frame brace. Loosen the igniter lock nut and
slide the igniter into the small part of the keyhole. Tighten
the igniter lock nut. Figure 11.
Note - If the igniter works loose, carefully tighten the igniter
lock nut with an adjustable wrench or pliers.
Figure 11
Igniter lock nut
Keyhole in
frame brace
Small part of
keyhole in
frame brace
Frame brace
Frame brace
(a)
(b)
(c)
Gas line piping
■If the length of line required does not exceed 50 feet,
use a 5/8" O.D. tube. One size larger should be used
for lengths greater than 50 feet.
■Gas piping may be copper tubing, type K or L;
polyethylene plastic tube, with a minimum wall
thickness of .062 inch; or standard weight (schedule
40) steel or wrought iron pipe.
■Copper tubing must be tin-lined if the gas contains
more than 0.3 grams of hydrogen sulfide per 100
cubic feet of gas.
■Plastic tubing is suitable only for outdoor, underground
use.
■Gas piping in contact with earth, or any other material
which may corrode the piping, must be protected
against corrosion in an approved manner.
■Underground piping must have a minimum of 18" cover.
Test connections
All connections and joints must be thoroughly tested for
leaks in accordance with local codes and all listed
procedures in the latest edition of ANSI Z223.1.
Figure 10
The quick disconnect
is installed above ground
Gas supply
Shut off
Locking
shut off
Inside wall
Outside wall
Quick disconnect
Male fitting
To barbecue
 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.
Typical natural gas supply installation. Figure 10.

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Step 11
Check that all burner valves are off
You will need: one burner control knob.
(Valves are shipped in the OFF position, but you should
check to be sure.) Put the knob on each valve. Check by
pushing down and turning clockwise. If they do not turn
they are off, proceed to the next step. Figure 12.
Figure 12
Step 12
Install side burner
You will need: side burner assembly, burner grate,
manifold bracket, and an adjustable wrench.
WARNING: 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 13 (a). Figure 13 (b) shows the quick
disconnect engaged.Install burner grate. Check to be sure
the side burner valve is OFF. Push side burner control
knob down and turn clockwise. Figure 13.
Figure 13
Manifold side view
Manifold side view
Male fitting
Quick disconnect
engaged
Side burner hose
b)
a)

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Step 14
Check for gas leaks
 DANGER
Do not use an open flame to check for gas
leaks. Be sure there are no sparks or open
flames in the area while you check for
leaks. This will result in a fire or explosion
which can cause serious bodily injury or
death and damage to property.
Figure 15
Step 13
Install manifold bracket
You will need: manifold bracket
Hook the bracket onto the manifold at the center burner
valve. Figure 14. Place your hand underneath the bracket.
Lift the bracket, manifold and cooking box slightly as a unit
and hook onto the frame brace.
Frame brace
Manifold bracket
WARNING: You should check for gas leaks every
time you disconnect and reconnect a gas fitting.
Note - All factory made connections have been thoroughly
checked for gas leaks. The burners have been flame
tested. As a safety precaution you should recheck all
fittings for leaks before using your Weber Gas Barbecue.
Shipping and handling may have loosened or damaged a
gas fitting.
WARNING: Perform these leak checks even if your
barbecue was dealer or store assembled.
You will need: a soap and water solution and a rag or
brush to apply it.
Note - Since some leaks test solutions, including soap
and water, may be slightly corrosive, all connections
should be rinsed with water after checking for leaks.
Make sure side burner is OFF. Remove valve control knob
and screws. Remove porcelain top. Figure 15.
Figure 14

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To perform leak checks: Slide back the collar of the quick
disconnect. Push male fitting of the hose into the quick
disconnect, and maintain pressure. Figure 16 (a). Slide
the collar closed. Figure 16 (b). If it does not engage or
lock, repeat procedure. Gas will not flow unless the quick
disconnect is properly engaged.
Turn on gas supply.
Figure 16
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.
Male fitting
To barbecue
Quick disconnect
engaged
Collar
Locking shut off
Outside
house wall
(a)
(b)
Check:
a) Hose to manifold connection. Figure 17 (a).
b) Manifold to side burner hose connection.Figure 17 (b).
WARNING: If there is a leak at connection (a),
retighten the fitting with a wrench and recheck for
leaks with soap and water solution.
If a leak persists after retightening the fitting, turn OFF
the gas. DO NOT OPERATE THE BARBECUE. Contact
Weber-Stephen Customer Service.
c) Side burner hose to side burner connection.
Figure 17 (c).
d) Valves to manifold connections. Figure 17 (d).
e) Hose to quick disconnect connection. Figure 17 (e).
WARNING: If there is a leak at connections
(b), (c), (d) or (e), turn OFF the gas. DO NOT OPERATE
THE BARBECUE. Contact Weber-Stephen Customer
Service.
When leak checks are complete, turn gas supply OFF at
the source and rinse connections with water.
Figure 17
(a) (b)
(c)
(d)
(e)

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Step 16
Install the bottom tray
You will need: bottom tray, catch pan holder, catch pan and
one drip pan.
Figure 21
Figure 20
Figure 22
Bottom tray
Finger grip on front
edge of bottom tray
Finger grip
Front side of catch
pan holder
Step 15
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 18.
Figure 18
The open "U" of the cooking grates goes down. Set the
cooking grates onto the ledges in the cooking box. Figure 19.
Figure 19
Put the foil drip pan into the catch pan.
Slide the catch pan into the catch pan holder with its finger
grip towards you.
Slide the bottom tray onto the mounting rails under the
cooking box with finger grip toward you. Figure 22.
CAUTION: Do not line bottom tray with aluminum foil.
It can cause grease fires by trapping the grease and not
allowing grease to flow into the catch pan.
Hook the ends of the catch pan holder into the hole in the
bottom tray. Figure 21. The front of the catch pan holder
must be on the same side as the finger grip of the
bottom tray.

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Step 17
Install the 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 23.
Figure 23
Hair pin cotter
Hinge pin
Step 18
Install control panel and burner control knobs
You will need: control panel, two Phillips screws/washers,
a Phillips screwdriver, and three burner control knobs.
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 24 (a).
Push on the burner control knobs. Figure 24 (b).
Figure 24
(a)
(b)
Insert in
frame brace
Control panel
Phillips screws/
washers
Crossover
Ignition
Button

20
Figure 25
View from top
View from side
Step 19
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 25.
Caution: Make sure both locks have snapped into
place.
Note: The side burner is shown with the cover removed to
show the side burner locks.
Step 20
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 26 (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 26 (b). Check to see that the lower tab of the
bracket is hooked in the slot in the frame. Figure 26 (c).
To fully seat the bracket, you may have to tap it lightly with
a hammer.
WARNING: 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.
Slot in frame
(view from below)
Figure 26
(c)
(b)
Wire end
(a)