Weber Genesis 2300 Series User manual

Serial Number
Please use this number in registering your warranty
and any correspondence with the factory.
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GENESIS®2300 Series
LP Gas Barbecue
Owner’s Manual
®
92182 1/99
WARNING: Do not try to light this appliance
without reading "Lighting" instructions
section of this manual.
THIS GAS APPLIANCE IS DESIGNED FOR
OUTDOOR USE ONLY.
NOTICE TO INSTALLER: These instructions
must be left with the owner and the owner
should keep them for future use.
FOR YOUR SAFETY
If you smell gas:
1. Shut off gas to the appliance.
2. Extinguish any open flame.
3. Open lid.
4. If odor continues, immediately call your
gas supplier or your fire department.
FOR YOUR SAFETY
1. Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
2. An LP tank not connected for use shall
not be stored in the vicinity of this or
any other appliance.
WARNING: Follow all leak check procedures
carefully in this manual prior to barbecue
operation. Do this even if barbecue was
dealer assembled.

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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, 3 years,
Flavorizer Bars, 5 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]
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 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.
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
4
®

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Contents
WARNINGS................................................................ 2
Warranty & Patents.................................................. 3-4
General Instructions.................................................... 6
Assembly ............................................................... 7-21
Operating Instructions
Lighting ........................................................22-23
Cooking ............................................................ 24
Storage and/or Nonuse .................................... 24
Cleaning ........................................................... 24
LP Tank Information.................................... 25-27
Troubleshooting & Maintenance
Annual Maintenance ........................................ 28
General Maintenance.................................. 29-31
Troubleshooting ............................................... 32
Parts Listing .............................................................. 35
FEATURES:
a) Convenient tables and racks.
b) Heavy gauge porcelain-on-steel lid seals in heat.
c) Rapid read thermometer for precision cooking
measures grill temperature, and can be removed and
inserted into the food.
d) Heavy gauge steel Flavorizer Bars distribute heat
within the grill. Flavorizer Bars heat just the right
amount of drippings for flavoring, letting excess fat
drip past to help prevent flare-ups. Uncontrolled flare-
ups are eliminated (versus lava rock systems on other
grills). The heavy gauge steel Flavorizer Bars are
easy to clean.
e) Weber Warm-Up Basket for additional cooking or
warming space.
f) Separate burners for temperature control.
g) Crossover Ignition System with Gas Catcher Ignition
Chamber.
h) Fuel scale indicates LP gas supply.
i) Catch pan catches excess grease.
j) Locking casters for additional portability.
a
b
c
d
f
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j
IMPORTANT NEW FEATURES:
Your Weber Gas Barbecue is equipped with a new and
improved LP tank connection, that has additional
safety features. They are:
1. The connection of the barbecue to the LP tank can be
made without the use of tools.
2. The new connection will not permit the flow of gas
until a positive gas connection is made.
3. If an accidental fire occurs at the LP tank connection,
the flow of gas is stopped by a temperature activated
shutoff.
4. If the LP supply hose becomes damaged, cut,
punctured, or accidentally fire damaged, the barbecue
connection is equipped with an excess flow control
that will limit the flow of gas if leakage or a fire occurs.

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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.
Liquid Propane (LP) gas supply is easy to use and gives
you more cooking control than charcoal fuel.
■These instructions will give you the minimum
requirements for assembling your Weber Gas
Barbecue. Please read the instructions carefully
before using your Weber Gas Barbecue. Improper
assembly can be dangerous.
■Not for use by children.
■If there are local codes that apply to portable gas grills,
you will have to conform to them. If there are no local
codes, you must conform to the latest edition of the
National Fuel Gas Code: ANSI Z 223.1.
■The pressure regulator supplied with the Weber
Gas Barbecue must be used. This regulator is set
for 10.5 inches of water column (pressure).
■This Weber Gas Barbecue is designed for use with
liquid propane (LP) gas only. Do not use with natural
(piped in city) gas. The valves, orifices, hose and
regulator are for LP gas only.
■Do not use with charcoal fuel.
■Check that the area under the control panel and the
bottom tray are free from debris that might obstruct
the flow of combustion or ventilation air.
■The area around the LP tank must be free and clear
from debris.
For Installation in Canada
These instructions, while generally acceptable, do not
necessarily comply with the Canadian Installation codes,
particularly with piping above and below ground. In
Canada the installation of this appliance must comply with
local codes and/or Standard CAN/CGA-B149.2 (Installation
Code for Propane Burning Appliances and Equipment).
Storage
■The gas must be turned OFF at the LP tank when the
Weber Gas Barbecue is not in use.
■When the Weber Gas Barbecue is stored indoors, the
gas supply must be disconnected and the LP tank
stored outdoors in a well-ventilated space.
■LP tanks must be stored outdoors in a well-ventilated
area out of the reach of children. Disconnected LP
tanks must not be stored in a building, garage or any
other enclosed area.
■When the LP tank is not disconnected from the Weber
Gas Barbecue, the appliance and LP tank must be
kept outdoors in a well-ventilated space.
Operating area
WARNING: Only use this barbecue outdoors in a
well ventilated area. Do not use in a garage, building,
breezeway or any other enclosed area.
■Never use your Weber Gas Barbecue under an
unprotected combustible roof or overhang.
■Your Weber Gas Barbecue is not intended to be
installed in or on recreational vehicles and/or boats.
■Do not use combustible materials within 24 inches of
the top, bottom, back or sides of the grill.
■The entire cooking box gets hot when in use. Do not
leave unattended.
■Keep any electrical supply cord and the fuel supply
hose away from any heated surface.
■Keep the cooking area clear of flammable vapors
and liquids, such as gasoline, alcohol, etc., and
combustible materials.
■Never store an extra (spare) LP tank under or near
the Weber Gas Barbecue.

Step 1
Check package contents
Cooking box
(assembly)
Lid
(assembly)
LP tank
LP tank filler adapter
Bottom tray
Two work tables
Two accessory trays
Swing table
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Assembly
Tools needed
Regular screwdriver
Phillips screwdriver
Hammer
7/16 inch or an adjustable wrench
Pliers
Block of wood
Supplies needed
Your LP tank is shipped empty for safety. After setting the
LP fuel scale you will need to fill it. (See Step "Fill LP tank.")
You will need a soap and water solution to check for gas
leaks. (See Step "Check for gas leaks.")
Note - The hardware size of nuts, bolts and screws is given.
For example "1/4-20 x 2 inch bolt" means a bolt 1/4 inch in
diameter with 20 threads to the inch, 2 inches long. On a
small screw for example, "6-32 x 1/2 inch screw" means a
number 6 screw, with 32 threads to the inch, 1/2 inch long.
®® ®® ®® ®®
While we give much attention to our products,
unfortunately an occasional error may occur. If a part is
missing, do not go back to the store. Call the Weber
Customer Service Center toll free 1-800-446-1071 to
receive immediate assistance. Have your owner’s
manual and serial number of the barbecue available for
reference.

Control panel
Front panel
Left frame
Wheel frame
Two frame connectors
Tank panel assembly
Five long Flavorizer Bars
Eight short Flavorizer Bars
Two wheels
Two aluminum drip pans
Catch pan
Axle
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Right frame
Caster frame
Two casters
Two cooking grates
Warming rack
Warm-Up Basket
Thermometer
Left hand slide bar assembly
Assembly consists of:
Left hand slide bar
Support rod
Slide
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Five 1/4-20 x 2 inch bolts
(actual size)
Six 1/4-20 x 1/2 inch bolts
(actual size)
Two 1/4-20 wing nuts
(actual size)
Two 10-24 x 1 3/4 machine screws
(actual size)
Two 10-24 hex nuts
(actual size)
Eighteen 1/4 inch nylon washers
(actual size)
1/4-20 keps nut
1/4-20 x 1 1/4 inch bolt
(actual size)
1/4-20 hex nut
(actual size)
Two hair pin cotters
Swing table end bracket
Two Phillips screws/washers
Fuel scale assembly
Catch pan holder
Manifold bracket
Spacer bracket
Check contents of hardware packs
Three burner control knobs
Three tool holders
Five tubing plugs
(two are spares)
Two wheel hubcaps
(actual size)
Two hinge pins
(hardware size: 1/4 x 1 1/2 inch clevis pin)
(actual size)
9

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Figure 1
Left frame
Leg tabs Frame tabs
Figure 2
(a)
(b)
Right frame
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.
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).

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Dimples to
the inside
Fuel scale
decal
Figure 3
Figure 4
Figure 5
Step 4
Continue frame assembly
You will need: frame assembly, wheel frame assembly,
front panel, caster frame, four 1/4-20 x 1/2 inch bolts, four
nylon washers and a 7/16 inch wrench.
Place the caster frame onto the tabs of the left frame with
the dimple to the inside. Figure 3. Place the wheel frame
onto the tabs of the right frame with the dimple to the
inside. The fuel scale decal should face away as shown.
Figure 3.
The leg tabs must be on the inside of the frames.
Add front panel with large hole down and to your right.
Add the washers to the bolts, insert in the holes as shown
and tighten with the wrench. Figure 3.
Note - Fuel scale decal on wheel frame must be on the
same side as the front panel.
Step 5
Complete frame assembly
You will need: partial frame assembly, two frame
connectors, four 1/4-20 x 2 inch bolts, four nylon
washers and a 7/16 inch wrench.
Hold one frame connector between the caster and wheel
frame. Add nylon washers to the bolts. Put the bolt through
the frame and screw into frame connector. Tighten.
Repeat procedure with the other frame connector. Figure 4.
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.

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Burner tubes
Figure 6
Frame brace
Guide screw
Figure 8
(a)
(b)
(c)
Wing nuts
(a)
(b)
Spacer bracket
Keps nut
Ta b
Frame
cross piece
Nylon washer
Bolt
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.
Figure 7
Step 7
Add cooking box
You will need: frame assembly, cooking box assembly, 1/4-
20 x 2 inch bolt, 1/4 inch nylon washer, 1/4-20 keps nut,
pliers and a 7/16 inch wrench.
Turn frame assembly right side up.
Uncoil the hose.
Set the cooking box into the frame so the burner tubes are
under the frame brace. Figure 6.
Your Weber Gas Barbecue burner assembly has been
factory assembled, pressure and flame tested. As a safety
precaution we recommend you check the burner alignment:
a) Do the valves fit into the ends of the burners?
Figure 8 (a).
b) Are the ends of the burners under the washers at the
left rear and left front of the cooking box? The screws
are only guides. Do not tighten. Figure 8 (b).
c) Are the wing nuts under the burner assembly hand
tight? Do not tighten with pliers. Figure 8 (c).
If you answered YES to a, b and c, the burners are
correctly aligned. If you answered NO, the burners are
misaligned. Contact Weber-Stephen Customer Service.
Do not use your barbecue.

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Figure 10
(a)
(b)
Tabs on tank panel
Slot in frame brace
Frame brace
Cross brace
Figure 9
Frame brace
Manifold bracket
Step 9
Install tank panel assembly
You will need: tank panel assembly, 1 1/4 inch bolt,
1/4-20 hex nut, 1/4 inch nylon washer and a 7/16 inch
wrench.
Insert the tank panel tabs into the slots in the frame brace.
Slide up until the notch at the bottom of the tank panel fits
over the cross brace. Figure 10 (a).
Add the washer to the bolt. Put the bolt through panel and
frame brace, add hex nut and tighten with the 7/16 inch
wrench. Figure 10 (b).
Step 8
Install manifold bracket
You will need: manifold bracket
Hook the bracket onto the manifold at the center burner
valve. Figure 9. Place your hand underneath the bracket.
Lift the bracket, manifold and cooking box slightly as a unit
and hook onto the frame brace.

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Figure 12
Igniter lock nut
Keyhole in
frame brace
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Figure 11
View from front left View from front right
Small part of
keyhole in
frame brace
Frame brace
Frame brace
(a)
(b)
(c)
Step 11
Install igniter
Note - The igniter wires are already attached to the Gas
Catcher Ignition Chamber and the igniter. This was done to
factory test the ignition system.
The igniter lock nut is on the igniter.
Insert the top of the igniter up through the large part of
the keyhole in the frame brace. Figure 12 (b). Loosen the
igniter lock nut and slide the igniter into the small part of
the keyhole. Figure 12 (c). Tighten the igniter lock nut.
Figure 12.
Note - If the igniter works loose, carefully tighten the igniter
lock nut with an adjustable wrench or pliers.
Step 10
Add fuel scale assembly
You will need: fuel scale, two 1/4-20 wing nuts and two
nylon washers.
Slip the bolts on the back of the fuel scale assembly through
the two small holes in the tank panel. Make sure indicator
rod of fuel scale is on the left side of the wheel frame.
Add washers, then wing nuts and tighten. Figure 11.

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F
E
F
E
F
E
Figure 13
Tank lock
wing nut
(a) (b)
Scale setting
wing nut
Step 12
Set LP fuel scale
You will need: LP tank (empty).
Note - For accuracy, the fuel scale must be set with an
empty tank.
We utilize various LP tank manufacturers. Some of the
tanks we receive have differing top collar assemblies. (The
top collar is the metal protective ring around the valve.)
One series of tanks mounts with the valve facing the front.
The other tanks mount with the valve facing away from the
fuel scale. These types of tanks are illustrated in Figure
13.
Loosen the tank lock wing nut. Tighten so the lock is held
up out of the way. Figure 13 (a). Lift and hook the tank
onto the fuel scale. With an empty LP tank, adjust the fuel
scale setting to E by turning the scale setting (top) wing
nut. Figure 13 (b).
CAUTION: Do not remove adjustment wing nut from
tank scale.
After adjusting tank scale, push tank down a couple of
times to check that the tank scale is set on “E”.
Step 13
Fill LP tank
Note - The LP tank manufacturer is responsible for the
materials, workmanship and performance of the tank. If
the tank has a defect, malfunctions, or you have a
question regarding the tank, call the tank manufacturer's
customer service center. The phone number is on the
warning decal which is permanently attached to the tank.
If the tank manufacturer has not resolved the issue to your
satisfaction, then call Weber-Stephen Products Co.,
Customer Service Center.
To fill, take the LP tank and filler adapter to an RV center
or look up gas-propane in the phone book for other
sources of LP gas.
WARNING: We recommend that your LP tank be
filled at an authorized LP gas dealer by a qualified
attendant, who fills the tank by weight.
IMPROPER FILLING IS DANGEROUS.
Tell your LP dealer that this is a new LP tank. The air must
be removed from a new LP tank before the initial filling.
Your LP tank dealer is equipped to do this.
WARNING: If you exchange your LP tank, make
sure you get a similar tank in return. Your LP tank is
equipped with a quick-disconnect valve and an OPD
(Overfilling Prevention Device). Other LP tanks are not
compatible with your barbecue connection.
The LP tank must be installed, transported and stored in
an upright position. LP tank should not be dropped or
handled roughly.
Never store or transport the LP tank where temperatures
can reach 125° Fahrenheit (too hot to hold by hand – for
example: do not leave the LP tank in a car on a hot day).
For full instructions on safe handling of LP tanks, see
section "Operating Instructions".

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Figure 16
Turn so regulator vent
does not collect water
Hose
Tank lock
wing nut
Quick disconnect
engaged
Valve handwheel
close clockwise
Tank valve
Collar
Male
fitting
Pressure
relief valve
Tank
Regulator
Regulator
vent
(a)
(b)
(c)
Figure 15
Figure 14
F
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Route the hose so it will not interfere with the scale
indicator rod.
The hose and regulator are connected in the following
manner:
Slide back the collar of the quick disconnect on the tank
valve. Push the male fitting of the regulator into the quick
disconnect, and maintain pressure. Slide the collar closed.
Figure 16 (a). Figure 16 (b) shows the quick disconnect
engaged and various components of the tank and
regulator. Regulator vent hole should be at 3, 6, or 9
o'clock. It should not be pointed up. Figure 16 (c).
Step 14
Check that the burner valves are off
You will need: one burner control knob.
Valves are shipped in the OFF position, but you should
check to be sure. Put the knob on each valve. Check by
pushing down and turning clockwise. If they do not turn,
they are off, proceed to the next step. Figure 14.
Step 15
Connect LP tank
WARNING: Make sure that the LP tank valve is
closed. Close by turning clockwise.
Hook the LP tank onto the fuel scale. Loosen the tank lock
wing nut. Swing the tank lock down. Tighten the wing nut.
Figure 15.

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F
E
F
E
Figure 17
Figure 18
(a) (b)
(c)
(d)
Step 16
Check for gas leaks
 DANGER
Do not use an open flame to check for gas
leaks. Be sure there are no sparks or open
flames in the area while you check for
leaks. This will result in a fire or explosion
which can cause serious bodily injury or
death and damage to property.
WARNING: You should check for gas leaks every
time you disconnect and reconnect a gas fitting.
Note - All factory made connections have been thoroughly
checked for gas leaks. The burners have been flame
tested. As a safety precaution you should recheck all
fittings for leaks before using your Weber Genesis Gas
Barbecue. Shipping and handling may have loosened or
damaged a gas fitting.
WARNING: Perform these leak checks even if your
barbecue was dealer or store assembled.
You will need: a soap and water solution and a rag or
brush to apply it.
Note - Since some leaks test solutions, including soap
and water, may be slightly corrosive, all connections
should be rinsed with water after checking for leaks.
To perform leak checks: open tank valve by turning the
tank valve handwheel counterclockwise. Figure 17.
Check for leaks by wetting the connections with the soap
and water solution and watching for bubbles. If bubbles
form or if a bubble grows there is a leak.
WARNING: Do not ignite burners while leak checking.
Check:
a) Hose to manifold connection. Figure 18 (a).
b) Regulator to tank connection. Figure 18 (b).
WARNING: If there is a leak at connection (a),
retighten the fitting with a wrench and recheck for
leaks with soap and water solution.
If a leak persists after retightening the fitting, turn OFF
the gas. DO NOT OPERATE THE BARBECUE. Contact
Weber-Stephen Customer Service.
c) Valves to manifold connections. Figure 18 (c).
d) Hose to regulator connection. Figure 18 (d).
WARNING: If there is a leak at connections
(b), (c) or (d), turn OFF the gas. DO NOT OPERATE THE
BARBECUE. Contact Weber-Stephen Customer Service.
When leak checks are complete, turn gas supply OFF at
the source and rinse connections with water.

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Figure 19
Figure 20
Figure 22
Figure 21
Figure 23
Bottom tray
Finger grip on front
edge of bottom tray
Finger grip
Front side of catch
pan holder
Step 17
Install Flavorizer Bars and Cooking Grates
You will need: five long Flavorizer Bars, eight short
Flavorizer Bars and two cooking grates.
Set the long Flavorizer Bars side to side in the lower
position, then set the short Flavorizer Bars front to back in
the upper position in the cooking box. Figure 19.
The open "U" of the cooking grates goes down. Set the
cooking grates onto the ledges in the cooking box. Figure 20.
Step 18
Install the bottom tray
You will need: bottom tray, catch pan holder, catch pan and
one drip pan.
Hook the ends of the catch pan holder into the hole in the
bottom tray. Figure 22. The front of the catch pan holder
must be on the same side as the finger grip of the
bottom tray.
Slide the bottom tray onto the mounting rails under the
cooking box with finger grip toward you. Figure 23.
CAUTION: Do not line bottom tray with aluminum foil.
It can cause grease fires by trapping the grease and not
allowing grease to flow into the catch pan.
Put the foil drip pan into the catch pan.
Slide the catch pan into the catch pan holder with its finger
grip towards you.

19
Figure 24
Hair pin cotter
Hinge pin
Figure 25
Insert in
frame brace
Tool holders
(a)
(b)
Control panel
Phillips screws/
washers
Step 19
Install the lid
You will need: lid, two hinge pins and two hair pin cotters.
Set the lid in place from the rear of the barbecue. Close and
align the hinge at the rear. Insert hinge pins from the
outside through the hinge. Insert hair pin cotters into the
small holes in the hinge pins. Figure 24.
Step 20
Install tool holders, control panel and burner
control knobs
You will need: three tool holders, control panel, two Phillips
screws/washers, a Phillips screwdriver, and three burner
control knobs.
Hook the tool holders over the frame rail. Figure 25.
Set the control panel in place over both frame braces. (Hold
the Crossover Ignition button up while setting the control
panel in place.) Line up the holes in the control panel with
the holes in the inserts in the frame brace. Insert screws
and tighten with a Phillips screwdriver until snug. Do not
overtighten. Figure 25 (a).
Push on the burner control knobs. Figure 25 (b).
Crossover
Ignition Button

20
Slot in frame
(view from below)
Figure 27
(c)
View from rear
of barbecue
Hinge rod
(b)
(a)
Figure 26
(a)
(b) (c)
Support rod
Insert one end of the hinge rod into the hole in the frame.
Figure 27 (a).
Insert the other end into the hole in the swing table end
bracket. Figure 27 (b). Hold the end bracket at an angle so
the lower tab is inside the frame tube. Push the bracket into
the frame. Check to see that the lower tab of the bracket is
hooked in the slot in the frame. Figure 27 (c).
To fully seat the bracket, you may have to tap it lightly with
a hammer.
WARNING: If swing table end bracket is in any way
cracked or damaged, do not use swing table. Call our
Customer Service Center to order a new part.
WARNING: The load limit for the swing table is
30 pounds.
Step 21
Install swing table
You will need: swing table end bracket, two 10-24 hex
nuts, two 10-24 x 1 3/4 inch machine screws, slide bar
assembly, swing table, four nylon washers, screwdriver
and pliers.
Allow the slide bar to hang down. Push the support rod
into the lower support bracket. Figure 26 (a). Swing the
rod up so you can slide the rod all the way inside the
locking tab. Figure 26 (b). The rod should swing freely
inside the locking tab. Figure 26 (c).