Weber SP 100 LP User manual

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®
®®
F
E
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.
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.
SP-100 LP Gas Barbecue
Serial Number
Please use this number in registering your warranty and
any correspondence with the factory.
Owner's Manual
gama
National Association PROPANE GAS
®
6271801 10/94

2
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.
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.

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

© 1994 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.
4
PATENTS AND TRADEMARKS

5
Contents
WARNINGS................................................................ 2
Warranty & Patents.................................................. 3-4
General Instructions.................................................... 6
Assembly............................................................... 7-22
Operating Instructions
Lighting........................................................ 23-24
Cooking............................................................ 25
Storage and/or Nonuse.................................... 25
Cleaning .......................................................... 25
Troubleshooting & Maintenance
LP Tank Information.................................... 26-28
Annual Maintenance......................................... 29
General Maintenance.................................. 30-32
Troubleshooting................................................ 33
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) Separate burners for temperature control.
f) Crossover Ignition System with Gas Catcher Ignition
Chamber.
g) Fuel scale indicates LP gas supply.
h) Catch pan catches excess grease.
i) Locking casters for additional portability.
a
b
c
d
e
f
g
a
h
i
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.

6
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.
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: Onlyuse 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 near the
Weber Gas Barbecue.

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Step 1
Check package contents
Cooking box
(assembly)
Lid
(assembly)
LP tank
LP tank filler adapter
Bottom tray
Two cooking grates
Control panel
Assembly
Tools needed
Screwdriver
Hammer
7/16 and 7/8 inch open-end 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, unfor-
tunately 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.

Left frame
Right frame
Wheel frame
Caster frame
Two frame connectors
Work table
Swing table assembly
Support rod
Axle
Accessory rack
Warming rack
Five long Flavorizer Bars
Eight short Flavorizer Bars
Tank panel assembly
Front panel
Catch pan holder
Catch pan
Two drip pans
Manifold bracket
Thermometer
Two wheels
Fuel scale assembly
Two casters
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W
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B
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R
W
E
B
E
R
W
E
B
E
R
W
E
B
E
R

Two plastic buttons
(actual size)
1/4-20 keps nut
Two 1/4-20 wing nuts
(actual size)
Fourteen 1/4 inch nylon washers
Two hair pin cotters
Two wheel hubcaps
Check contents of hardware packs
Three burner control knobs
Three tool holders
Five tubing plugs
(two are spares)
Support rod holder
Swing table end bracket
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)
1/4-20 x 1 1/4 inch bolt
(actual size)
Six 1/4-20 x 1/2 inch bolts
(actual size)
1/4-20 hex nut
(actual size)
9

10
Figure 1
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.
W
E
B
E
R
W
E
B
E
R
Figure 2
Step 3
Assemble top frame
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.
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.
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 wrong way. Turn the left frame around.)
Leg tabs
Frame tabs
(a)
(b)
Right frame
Left frame

11
Figure 3
Step 4
Continue frame assembly
You will need: caster frame, wheel 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 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
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 leg and wheel
frame. Add the nylon washer to the bolt. Put the bolt
through the frame and screw into frame connector.
Tighten.
Repeat procedure with the other frame connector.
Figure 4.
Figure 4

12
Figure 6
Step 7
Add front panel
You will need: front panel and two plastic buttons.
Turn frame assembly right side up.
Align the panel with the holes in the frame and insert the
plastic buttons through the front panel and frame.
Figure 6.
View from rear
of barbecue
Plastic buttons
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

13
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 barbecue.
Guide screw
(a)
(b)
(c)
Wing nuts
View from
behind
cooking
box
Figure 9
Figure 7
Step 8
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.
Uncoil the hose.
Set the cooking box in the frame so the burner tubes are
under the frame brace. Figure 7.
Burner tubes
Frame brace
Slide the cooking box to the left within the frame. Put
washer on bolt. Insert the bolt through the cooking box
and frame with the head of the bolt outside the box.
Figure 8. Add the keps nut. Tighten by holding the bolt
with pliers while you tighten the nut with a wrench.
Figure 8

14
Frame brace Manifold bracket
Figure 10
Step 9
Install manifold bracket
You will need: manifold bracket
Hook the bracket onto the manifold at the center burner
valve. 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 10.
Step 10
Install tank panel assembly
You will need: tank panel assembly, 1/4-20 x 1 1/4 inch
bolt, 1/4-20 hex nut, nylon washer and a 7/16 inch
wrench.
Insert the tank panel tabs into the slots in the frame
brace. Figure 11.
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 and through the
wheel frame. Add hex nut and tighten with the 7/16 inch
wrench. Figure 12.
Figure 11
Figure 12
Cross brace
Tank panel tabs
Slots in frame brace Frame brace

15
Step 11
Add fuel scale assembly
You will need: fuel scale assembly, 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 13.
Figure 13
View from front left View from front right
F
E
F
E
Step 12
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 14 (b). Loosen the
igniter lock nut and slide the igniter into the small part of
the keyhole. Figure 14 (c). Tighten the igniter lock nut.
Figure 14.
Note - If the igniter works loose, carefully tighten the
igniter lock nut with an adjustable wrench or pliers.
Figure 14
Igniter lock nut
Keyhole in
frame brace
Small part of keyhole
in frame brace
Frame brace
Frame brace
(a)
(b)
(c)

16
Step 13
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
front. The other tanks mount with the valve facing away
from the fuel scale. These types of tanks are illustrated
in Figure 15.
Loosen the tank lock wing nut. Tighten so the lock is
held up out of the way. Figure 15 (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 15 (b).
CAUTION: Do not remove adjustment wing nut from
the tank scale.
After adjusting tank scale, push tank down a couple of
times to check that the tank scale is set on “E”.
F
E
F
E
F
E
Figure 15
Tank lock
wing nut
(a) (b)
Scale setting
wing nut
Step 14
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.
Take the LP tank to an RV center (or some other source
of LP gas) to fill the tank with 20 pounds of liquid
propane.
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.
CAUTION: 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. 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".

17
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 18 (a). Figure 18 (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 18 (c).
Step 16
Connect filled 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 17.
F
E
Figure 17
Figure 16
Step 15
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 16.
Figure 18
Turn so regulator vent
does not collect water
Hose
Quick disconnect
engaged
Valve handwheel
close clockwise
Tank valve
Collar
Male
fitting
Pressure
relief valve
Tank
Regulator
Regulator
vent
(a)
(b)
(c)

18
Step 17
Check for gas leaks
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.
To perform leak checks: open tank valve by turning the
tank valve handwheel counterclockwise. Figure 19.
Figure 19
DANGER
Do not use an open flame to check for
gas leaks. Be sure there are no sparks or
open flames in the area while you check
for leaks. This will result in a fire or
explosion which can cause serious bodily
injury or death and damage to property.
Check:
a) Hose to manifold connection. Figure 20 (a).
b) Regulator to tank connection. Figure 20 (b).
WARNING: If there is a leak at a or b, retighten the
fitting with a wrench and recheck for leaks with soap
and water solution.
If a leak persists after retightening the fitting, turn
OFF the gas. DO NOT OPERATE THE BARBECUE.
Contact Weber-Stephen Customer Service.
c) Valves to manifold connections. Figure 20 (c).
d) The hose to regulator connection. Figure 20 (d).
WARNING: If there is a leak at 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.
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.
WARNING: Do not ignite burners when leak checking.
(a)
Figure 20
(c)
(d)
(b)

19
Step 19
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 24. 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 25.
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.
Figure 24
Figure 23
Figure 25
Bottom tray
Finger grip on front
edge of bottom tray
Finger grip
Front side of catch
pan holder
Step 18
Install Flavorizer Bars and Cooking Grates
You will need: five long Flavorizer Bars, eight short
Flavorizer Bars and two cooking grates.
Set the long Flavorizer Bars side to side in the lower
position, then set the short Flavorizer Bars front to back
in the upper position in the cooking box. Figure 21.
Figure 21
Set the cooking grates onto the ledges in the cooking
box with the rounded side up. Figure 22.
Figure 22

20
Step 20
Install Lid
You will need: lid, two hinge pins and two hair pin
cotters.
Set the lid in place. Align the hinges at the rear of the
barbecue. Insert hinge pins from the outside. Insert hair
pin cotters into the small holes in the hinge pins.
Figure 26.
Hair pin cotter
Hinge pin
Figure 26
Step 21
Add tool holders, control panel and burner
control knobs
You will need: two tool holders, control panel and three
burner control knobs.
Hook the tool holders over the frame rail. Figure 27.
Set the control panel in place over both frame braces.
Hold the Crossover Ignition button up while setting the
control panel in place. Place your thumbs over the
control panel push-in buttons, and push them into the
frame brace until they snap into place. Figure 27 (a).
Push on the three burner control knobs. Figure 27 (b).
Figure 27
Tool holders
Hole in
frame brace
Control panel
push-in buttons
(a)
(b)