Weber 98615 manual

Serial Number Please use this number in registering your warranty and any correspondence with the factory. W E B E R W E B E R GENESIS ® 2000 Series LP Gas Barbecue Owner’ s Manual National Association PROPANE GAS ® 98615 10/97 W ARNING: Do not try to light this appliance without reading "Lighting" instructions section of this manual.[...]

2  D ANGER Failure to f ollow the Dangers, W arnings and Cautions contained in this Owner’ s Manual may result in serious bodil y injury or death, or in a fire or an explosion causing damage to property .  W ARNINGS  Do not store a spare or disconnected LP tank under or near this barbecue .  Improper assemb ly ma y be dang er ous. Ple[...]

3 Weber-Stephen Products Co. (W eber) 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[...]

© 1997 Weber . Weber , , Genesis, Flavorizer and Crossover are registered U.S. trademarks; Perma-Mount, Gas Catcher , FlameCheck, Steam-N-Chips, Spider Stopper , and W arm-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[...]

5 Contents WARNINGS ................................................................ 2 Warranty & Patents.................................................. 3-4 General Instructions .................................................... 6 Assembly ............................................................... 7-21 Operating Instructions Lighting [...]

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 por[...]

Step 1 Check package contents Cooking box (assembly) Lid (assembly) LP tank LP tank filler adapter Bottom tray T wo work tables T wo accessory trays Swing table 7 Assembl y T ools needed Screwdriver Phillips screwdriver Hammer 7/16 inch or an adjustable wrench Pliers Block of wood Supplies needed Y our LP tank is shipped empty for safety . After se[...]

Control panel Front panel Left frame Wheel frame T wo frame connectors T ank panel assembly Five long Flavorizer Bars Eight short Flavorizer Bars T wo wheels T wo aluminum drip pans Catch pan Axle 8 Right frame Caster frame T wo casters T wo cooking grates W arming rack W arm-Up Basket Thermometer Left hand slide bar assembly Assembly consists of: [...]

T wo 10-24 x 1 3/4 machine screws (actual size) T wo 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) T wo hair pin cotters Swing table end bracket Fuel scale assembly Catch pan holder Manifold bracket Check contents of hardware packs Three[...]

10 Step 2 Assemble wheels Y ou 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). T ap 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. T ap [...]

11 Step 4 Continue frame assembly Y ou 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 [...]

12 Burner tubes Figure 6 Frame brace Step 7 Add cooking box Y ou 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. T urn frame assembly right side up. Uncoil the hose. Set the cooking box into the frame so the burner tubes are under the frame brace. Figu[...]

13 Step 9 Install tank panel assembly Y ou 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 th[...]

14 Step 11 Install igniter Note - The igniter wires are already attached to the Gas Catcher Ignition Chamber and the igniter . This was done to f actory 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 [...]

15 Step 12 Set LP fuel scale Y ou will need: LP tank (empty). Note - F or 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 fac[...]

16 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 t[...]

17 Step 16 Check for gas leaks  D ANGER Do not use an open flame to chec k f or gas leaks. Be sure there are no sparks or open flames in the area while y ou chec k for leaks. This will result in a fire or e xplosion which can cause serious bodil y injury or death and damage to pr operty . Check: a) Hose to manifold connection. Figure 18 (a). b) [...]

18 Step 17 Install Flavorizer Bars and Cooking Grates Y ou 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. Figure 19 The open "U" o[...]

19 Step 19 Install the lid Y ou 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. Figure 24 Hair pin cotter Hinge pin Step[...]

20 Slot in frame (view from below) 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[...]

21 Position slide bar assembly on the outside of the caster frame. Put a nylon washer on each 1 3/4 inch screw , insert screws through frame and slide bar assembly and add nylon washers and hex nuts. T ighten nuts using a screwdriver and pliers. Figure 28. Figure 28 View from front of barbecue Notch to the front Slide bar T o lower table: Pull supp[...]

22 Lighting Summary lighting instructions are on the control panel. 2 1 7 3 4 5 6 8 Figure 1 Crossover Ignition System  W ARNING: The burner contr ol knobs must be in the OFF position before turning on the LP tank v alve. If they are not in the OFF position, when y ou turn on the LP tank valve, the excess flo w control will activ ate, limiting t[...]

23 4) Turn the tank on by turning the tank valve counterclockwise. 5) Strike a match and put the flame into the matchlight hole in the front of the cooking box.  W ARNING: Do not lean over open barbecue. Keep your face and bod y at least one foot a way fr om the matchlight hole when lighting the barbecue. 6) Push Front burner control knob down a[...]

24 Cooking  W ARNING: Do not move the W eber Gas Barbecue when operating or hot. Y ou can adjust the FRONT , CENTER and BACK burners as desired. The control settings High (H), Medium (M), Low (L), or Off (O) are described in your Weber cookbook. The cookbook uses these notations to describe the settings of the FRONT , CENTER, and BACK burners. F[...]

25 Scale setting wing nut T ank lock wing nut T ank valve Collar (a) (b) Figure 3 Refilling the LP tank We recommend that you refill before the scale indicator reaches "E". Note - If you run out of fuel, chec k the indicator setting and/or adjust the fuel scale indicator setting with the scale setting wing nut, while the tank is empty so [...]

26 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 regulator into the quick disconnect, and maintain pressure. Slide the collar closed. Figure 5 (b). If it does not engage or lock, repeat[...]

27 Safe handling tips f or LP Gas ■ 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 tank, LP gas is a liquid. As the pressure is released the liquid readily vaporizes and becomes gas. ■ LP gas has an odor similar to natural g[...]

28 Check: a) Hose to manifold connections. Figure 8 (a). b) Regulator to tank connection. Figure 8 (b).  W ARNING: If there is a leak at connection (a), retighten the fitting with a wrench and rechec k for leaks with soap and water solution. If a leak persists after retightening the fitting, turn OFF the gas . DO NO T OPERA TE THE BARBECUE. Cont[...]

29 General Maintenance W eber Spider Stopper Guards Y our 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 i[...]

30 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 View from behind cooking box Wing nuts Figure 15 Guide screw Figure 16 Figure 18 V alve Burner (a) (b) e) Remove the manifold bracket and unscrew the two wing nut[...]

31 Crosso ver 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. Figure 20 White wire Black wire[...]

32 Prob lem Burners b urn with a yellow or orange flame, in conjunction with the smell of gas. Burners do not light. -or - Burners ha ve a small flickering flame in the HIGH position. -or- Barbecue temperature only reaches 250˚ to 300˚ degrees in the HIGH position. Burner does not light, or flame is low in HIGH position. Experiencing flare-ups: ?[...]

[...]

34 ® ® ® ® ® ® ® ® W E B E R W E B E R 1 2 4 5 6 7 8 9 10-11 13 14 15, 11 22 24 26 27 28 29 30 31 32 64 62-63 56 55 8 53 51 50 49 48 47 45 44 43 42 41 40 39 54 11 33 11 38 34 52 46 25 12 23 16 17-18, 11 20 19 10 3 66 57 65[...]

35 1 Lid (assembly) 2 Lid handle 3 W arm-Up Basket 4 W arming rack 5 Short Flavorizer Bars (8) 6 Long Flavorizer Bars (5) 7 Cooking grates (2) 8 Work tables (2) 9 T ubing plugs (5) 10 1/4-20 x 2 inch bolts (5) 1 1 1/4 inch nylon washers (18) 12 Swing table end bracket 13 Left frame 14 Swing table 15 1/4-20 x 1/2 inch bolts (6) 16 Slide bar assembly[...]

A F INAL W ORD OF T HANKS hank you for choosing a W eber Barbecue. Our family her e at W eber 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 C ustomer Service staff is prepar ed to help you with any problems with parts or [...]