Weber Spirit 500 series User's Manual
Contents
1. 12 1 4 inches in diameter The LP tank must be constructed and marked in accordance with the specifications for LP gas cylinders of the U S Department of Transportation D O T Annual Maintenance After a period of nonuse we recommend that you perform the following maintenance procedures for your safety Z WARNING Check hose before each use of barbecue for nicks cracking abrasions or cuts If the hose is found to be damaged in any way do not use the barbecue Replace using only Weber authorized replacement manifold assembly Order from Weber Stephen Products Co Customer Service Center or authorized dealer M Inspect the burners for correct flame pattern Clean if necessary following the procedures outlined in the General Maintenance section of this manual mM Check all gas fittings for leaks A 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 Z WARNING You should check for gas leaks every time you disconnect and reconnect a gas fitting You will need a soap and water solution and a rag or brush to apply it To perform leak checks Make sure all burners are in the OFF position Turn on gas supply Check for leaks by wetting the connections with the soap and water solution and watching for bubbles If2. GG Burner Figure 14 e Remove the manifold bracket and unscrew the two wing nuts that hold the manifold to the cooking box Pull the manifold and valve assembly out of the burners and carefully set it down Figure 15 View from behind cooking box MMI 2S Wing nuts Figure 15 f Slide the burner assembly out from under the guide Figure 18 screw and washer in the corners of the cooking box Figure 16 i Reinstall the Spider Stopper Guards Slightly rotate the Spider Stopper Guards so that the seams are in line with the Venturi fins There should be no gaps in the seams or in the fit around the burners and valves Figure 19 Check fit around valve 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 19 Figure 17 h To reinstall the burners reverse steps c through g 29 AAWARNING If the Spider Stopper Guards do not fit tightly contact Weber Stephen Customer Service A CAUTION After reinstalling the gas lines they should be leak checked with a soap and water solution before using the barbecue See Step Check for gas leaks Crossover Ignition System Operations If the Crossover Ignition System fails to ignite the Front burner light the Front burner with a match If the Front burner lights with a match then check the Crossover Ignition System M Check that
3. Note Work table should rest between the frame rails and on the work table spacer installed in Add cooking box step Insert the thermometer into its holder Figure 27 d Insert the tubing plugs into the ends of the frame To fully seat the plugs you may have to tap them lightly with a hammer Figure 27 e Work table Work table spacer Figure 27 20 OPERATING INSTRUCTIONS Lighting Summary lighting instructions are on the control panel A DANGER Failure to open lid while igniting the barbecue or not waiting 5 minutes to allow the gas to clear if the barbecue does not light may result in an explosive flame up which can cause serious bodily injury or death Crossover Ignition System Note The Crossover Ignition System ignites the Front burner with a spark from the igniter electrode inside the Gas Catcher Ignition Chamber You generate the energy for the spark by pushing the Crossover Ignition Button until it clicks Z WARNING Check hose before each use of barbecue for nicks cracking abrasions or cuts If the hose is found to be damaged in any way do not use the barbecue Replace using only Weber authorized replacement manifold assembly Order from Weber Stephen Products Co Customer Service Center or authorized dealer Crossover Ignition System Figure 1 1 Open the lid Figure 1 2 Check that the fuel scale reads more than E Note E empty F full 3 Make sure
4. weber ____ Please use this number in registering your warranty and any correspondence with the factory SPIRIT 500 Series LP Gas Barbecue Owner s Manual DESIGN ERIC wy MEMBER G n WERK c 9 ERTIFI E National PROPANE GAS Association WARNING Follow all leak check procedures carefully in this manual prior to barbecue operation Do this even if barbecue was dealer assembled NOTICE TO INSTALLER These instructions must be left with the owner and the owner should keep them for future use THIS GAS APPLIANCE IS DESIGNED FOR OUTDOOR USE ONLY WARNING Do not try to light this appliance without reading Lighting instructions section of this manual 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 An LP tank not connected for use shall not be stored in the vicinity of this or any other appliance FOR YOUR SAFETY If you smell gas 1 Shut off gas to the appliance 2 Extinguish any open flame 3 Open lid 4 lf odor continues immediately call your gas supplier or your fire department 98567 10 97 gt gt gt gt PPP BP BP BP A A ADANGER 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 AWARNINGS Do not s
5. turn OFF the gas DO NOT OPERATE THE BARBECUE Contact Weber Stephen Customer Service Valves to manifold connections Figure 19 c The hose to regulator connection Figure 19 d When leak checks are complete turn gas supply OFF and rinse connections with water Step 17 Install Flavorizer Bars and Cooking Grates You will need five Flavorizer Bars and two cooking grates Set the Flavorizer Bars side to side in the cooking box Figure 20 Figure 20 Set the cooking grates onto the ledges in the cooking box with the rounded side up Figure 21 Figure 21 Step 18 Install the bottom tray You will need bottom tray catch pan holder catch pan and one drip pan Finger grip on front edge of bottom tray Front side of catch pan holder Figure 22 Hook the ends of the catch pan holder into the hole in the bottom tray Figure 23 The front of the catch pan holder must be on the same side as the finger grip of the bottom tray Finger grip Figure 23 Slide the bottom tray onto the mounting rails under the cooking box with finger grip toward you Figure 24 A 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 Figure 24 Put the foil drip pan into the catch pan Slide the catch pan into the catch pan holder with its finger grip towards you Step 19 Install Lid You will need lid tw
6. 6266 U S A Printed in the U S A Contents WARNINGS 6ississsscccaccees con cccssassetsiees teasacetraeaeaitsescatanes 2 Warranty amp Patent ccccceccessseeeeseeeeeseeeeeeaeeeeeas 3 4 General INStructiOns cccccsseeeceeseecceeeeeseeeessaaees 6 ASSOMDIY raea a a a ai 7 20 Operating Instructions EIORUN G mraint a COOKING aaeain aE eaaa Storage and or Nonuse GIGGING serne aaa EP Tank formatio sects xseteveestetocn inact devine 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 Troubleshooting amp Maintenance Annual Maintenance ccececeeceseeeeeeeeeeeees 2 General Maintenance ceceeeeeeeeeeeeeee 28 29 TrOUDIESNOOTING cccsecseseeesseeereseeneeeeneeeees 31 ANS EIUN esea 35 IMPORTANT NEW FEATURES Your Weber Gas Barbecue is equipped with a new and improved LP tank connection that has additional
7. 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 limit
8. a wrench Figure 7 12 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 barbecue View from behind cooking box Figure 8 Step 8 Install manifold bracket You will need manifold bracket Hook the bracket onto the manifold at approximately the center of the length of the manifold Place your hand underneath the bracket Lift the manifold bracket and cooking box slightly and hook the tab of the bracket onto the frame brace Figure 9 Frame brace Manifold bracket Figure 9 Step 9 Install tank panel assembly and frame connector You will need tank panel assembly frame connector two 1 4 20 x 1 3 4 inch bolts two nylon washers and a 7 16 inch wrench Insert the tank panel tabs into the slots in the frame brace Figure 10 Slots in frame brace Frame brace Tank panel tabs Figure 10 Slide t
9. 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 A WARNING Do not ignite burners while leak checking Check a Hose to manifold connection Figure 8 a b Regulator to tank connection Figure 8 b A 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 27 Check c Valves to manifold connections Figure 8 c d The hose to regulator connection Figure 8 d AAWARNING 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 Figure 8 Inspection and Cleaning of the Weber Spider Stopper Guards To inspect the Spider Stopper Guards remove the control panel and look to see if they have dust or dirt on their outside surfaces If they are dirty brush off the outside surface of the Spider Stopper Guards with a soft bristle brush an old toothbrush for example Check that there are no gaps in the Spider Stopper Guards seams or in the fit around the burn
10. 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 Ifan accidental fire occurs at the LP tank connection the flow of gas is stopped by a temperature activated shutoff 4 Ifthe 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 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 mM 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 E Not for use by children mM If there are local codes that apply to portable gas grills you will
11. 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 Figure 3 Step 5 Install tubing plugs You will need two tubing plugs and a hammer Insert tubing plugs into the ends of the leg frame Figure 4 To fully seat the plugs you may have to tap them lightly with a hammer Figure 4 11 Step 6 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 5 Plastic buttons View from rear of barbecue Figure 5 Step 7 Add cooking box You will need frame assembly cooking box assembly work table spacer 1 4 20 keps nut 1 4 20 x 2 inch bolt pliers and a 7 16 inch wrench Uncoil the hose Set the cooking box in the frame so the burner tubes are under the frame brace Figure 6 Burner tubes Frame brace Figure 6 Slide the cooking box to the left within the frame Hold the work table spacer up to the frame Insert the bolt through the hole in the work table spacer frame and cooking box with the head of the bolt outside the box Figure 7 Add keps nut Tighten by holding the bolt with pliers while you tighten the nut with
12. LP gas is not natural gas The conversion or attempted use of natural gas in an LP unit or LP gas ina 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 A A A 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 WARRANTY 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
13. ace LP tanks must be stored outdoors in a well ventilated area out of reach of children Disconnected LP tanks must not be stored in a building garage or any other enclosed area 23 Storage and or Nonuse continued Mm 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 The Weber Gas Barbecue should be checked for gas leaks and any obstructions in the burner tubes before using See Sections General and Annual Maintenance Check that the areas under the control panel and the bottom tray are free from debris that might obstruct the flow of combustion or ventilation air The Spider Stopper Guards should also be checked for any obstructions See Section Annual Maintenance Periodic Cleaning Z WARNING Turn your Weber Gas Barbecue OFF and wait for it to cool before cleaning ZA CAUTION Do not clean your Flavorizer Bars or cooking grates in a self cleaning oven Replacement cooking grates and Flavorizer Bars are available through your retailer or the Weber Stephen Products Service Center Outside surfaces Use a warm soapy water solution Z CAUTION Do not use oven cleaner abrasive cleansers kitchen cleansers cleaners that contain citrus products or abrasive cleaning pads on barbecue or cart surfaces Bottom tray Remove excess grease and then wash with warm soapy water Flavorizer Bars and Cooking Grates Clean wi
14. all burner control knobs are turned OFF Push control knob down and turn clockwise ZAAWARNING The burner control knobs must be in the OFF position before turning on the LP tank valve If they are not in the OFF position when you turn on the LP tank valve the excess flow control will activate limiting the flow of gas from the LP tank If this should occur turn OFF the LP tank valve and burner control knobs and start over A DANGER When the excess flow control is activated a small amount of gas is still flowing to the burners After turning OFF the tank and burner control knobs wait at least 5 minutes for the gas to clear before attempting to light the barbecue Failure to do so may result in an explosive flame up which can cause serious bodily injury or death 4 Turn the tank on by turning the tank valve counterclockwise A WARNING Do not lean over open barbecue Keep your face and body at least one foot away from the matchlight hole when lighting the barbecue 5 Push Front burner control knob down and turn to START HI 6 Push the Crossover Ignition Button several times so it clicks each time 7 Check that the burner is lit by looking through the matchlight hole on the front of the cooking box A WARNING If the burner does not light turn the Front burner control knob to OFF and wait 5 minutes to let the gas clear before you try again or try to light with a match 8 After the FRONT burner is lit you ca
15. ank panel up until notch at bottom of panel fits over the cross brace Insert one bolt with washer through the hole in the bottom of the tank panel through the wheel frame and into the end of the frame connector Insert the other bolt with washer through the leg frame and into the other end of the frame connector Hold the frame connector square and tighten the bolts Figure 11 connector Cross brace Figure 11 Step 10 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 12 View from front right View from front left Figure 12 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 13 b Loosen the igniter lock nut and slide the igniter into the small part of the keyhole Figure 13 c Tighten the igniter lock nut Figure 13 Note If the igniter works loose carefully tighten the igniter lock nut with an adjustable wrench or pliers Keyhole in Igniter lock nut fram
16. antities unless otherwise specified Parts can be ordered directly from Weber Stephen Products Company by phone or mail Note Do not return parts to Weber Stephen Products Co without first contacting the Customer Service Center by phone or mail Returning the part may not be necessary Lid assembly Lid handle Warming rack Flavorizer bars 5 Cooking grates 2 Work table spacer Work table Tubing plugs 8 1 4 20 x 2 inch bolt Left frame 1 4 20 x 1 2 inch bolts 6 1 4 inch nylon washers 11 Leg frame Bottom tray Catch pan holder Catch pan Drip pans 2 Accessory rack Frame connector Wheel hubcaps 2 Wheels 2 Tool holders 2 Wheel frame Front panel Plastic buttons 2 Tank glides 2 Glide axle Glide hubcaps 2 Tank panel 1 4 20 x 1 3 4 inch bolts 2 OOnNDOABRWHNDN gt 33 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 Weber Stephen Products Company Customer Service Center 250 South Hicks Road Palatine IL 60067 6241 800 446 1071 Hair pin cotters 2 Hinge pins 2 Thermometer Keps nut Cooking box Burner control knobs 2 Control panel Igniter button Phillips screw washer 2 Cros
17. are off proceed to the next step Figure 15 Figure 15 Step 15 Connect LP tank A 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 16 Tank lock wing nut ZO PY Tree N Figure 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 17 a Figure 17 b shows the quick disconnect engaged and various components of the tank and regulator Regulator vent hole should be at 3 6 or 9 o clock It should not be pointed up Figure 17 c a Male fitting Hose b Valve handwheel close clockwise Tank valve Regulator Pressure relief valve i Regulator vent Quick disconnect engaged Turn so regulator vent does not collect water Figure 17 Step 16 Check for gas leaks A 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 Z WARNING You should check for gas leaks e
18. ation 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 800 446 1071 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 W eber Stephen Products Co Customer Service Center PATENTS AND TRADEMARKS 1997 Weber Weber Flavorizer and Crossover are registered U S trademarks Spirit Gas Catcher FlameCheck and Spider Stopper are U S trademarks of W eber Stephen Products Co 200 East Daniels Road Palatine IL 60067
19. both the white and black ignition wires are attached properly Figure 20 White wire Black wire Figure 20 M Check that the Crossover Ignition button pushes the igniter button down and returns to the up position mM Check to see if the igniter is loose in the frame Tighten if necessary see Step Install igniter for correct procedure If the Crossover Ignition System still fails to light contact Weber Stephen Customer Service 30 TROUBLESHOOTING Problem Check Burners burn with a yellow or orange Inspect Weber Spider Stopper flame in conjunction with the smell of gas Guards for possible obstructions Blockage of holes Burners do not light or The excess flow safety device Burners have a small flickering flame in the which is part of the barbecue to tank HIGH position or connection may have activated Barbecue temperature only reaches 250 to 300 degrees in the HIGH position Burner does not light or flame is low in Is LP fuel low or empty HIGH position Is fuel hose bent or kinked Does the Front burner light with a match Experiencing flare ups Are you preheating barbecue in the prescribed manner Are the cooking grates and Flavorizer Bars heavily coated with burned on grease Is the bottom tray dirty and not A CAUTION Do not line the bottom tray allowing grease to flow into catch with aluminum foil pan Burner flame pattern is erratic Flame is low Are burners clean
20. buttons actual size Two 1 4 20 wing nuts actual size Ten 1 4 inch nylon washers Two hair pin cotters Two wheel hubcaps A Work table spacer 1 4 20 keps nut Two Phillips screws washers G Step 2 Assemble wheel frame You will need wheel frame two wheels two wheel hubcaps hammer and a block of wood Set one end of wheel frame on the block of wood or other hard protected surface Put one wheel on axle WEBER side facing up and tap on one hubcap Figure 1 Repeat with other wheel and hubcap Figure 1 10 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 Frame tabs Step 4 Continue frame assembly You will need leg frame wheel frame four 1 4 20 x 1 2 inch bolts four nylon washers and a 7 16 inch wrench Place the leg frame onto the tabs of the left frame with the dimple to the inside Figure 3 Place the wheel frame onto the tabs of the right frame with
21. e brace Frame brace Small part of keyhole in frame brace 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 front The other tanks mount with the valve facing away from the fuel scale These types of tanks are illustrated in Figure 14 Loosen the tank lock wing nut Tighten so the lock is held up out of the way Figure 14 a Lift and hook the tank onto the fuel scale With an empty LP tank adjust the fuel scale setting to E with scale setting top wing nut Figure 14 b A 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 Scale setting Tank lock wing nut wing nut A Tile Figure 14 15 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
22. e 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 W eber 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 Step 1 Check package contents Cooking box assembly Lid assembly LP tank Bottom tray Two cooking grates LP tank filler adapter Control panel Left frame Tank panel assembly Right frame Front panel Catch pan holder Ro Catch pan ES Wheel frame Leg frame Frame connector SS Two drip pans Molded work table Manifold bracket Q S Thermometer Accessory rack aa Two wheels CD Warming rack Fuel scale assembly Five Flavorizer Bars Check contents of hardware packs Two burner control knobs Two tool holders LU Eight tubing plugs two are spares Two hinge pins hardware size 1 4 x 1 1 2 inch clevis pin actual size 1 4 20 x 2 inch bolt Two 1 4 20 x 1 3 4 inch bolts actual size Six 1 4 20 x 1 2 inch bolts actual size actual size Conn Two plastic
23. er Gas Barbecue burners have been factory set for the correct air and gas mixture The correct flame pattern is shown in Figure 11 Tips occasionally yellowish Burner inside cooking box F Flames Light blue Dark blue Figure 11 If the flames do not appear to be uniform the length of the burner tube follow the burner cleaning procedures Main Burner Cleaning Procedure Turn off the gas supply Remove the manifold See Section Replacing the main burners Look inside each burner with a flashlight Figure 12 ZO Figure 12 Clean the inside of the burners with a wire a straightened out coat hanger will work Figure 13 Check and clean the air shutter opening at the ends of the burners Check and clean the valve orifices at the base of the valves Use a brass bristle brush to clean outside of burners This is to make sure all the burner ports are fully open Figure 13 ACAUTION Do not enlarge the burner ports when cleaning Replacing Main Burners a Your Weber Gas Barbecue must be OFF and cool b c Turn gas OFF at source Remove control panel take off the burner control knobs Remove the screws holding the control panel in place Lift off the control panel d Unlatch the Spider Stopper Guards and remove A CAUTION The burner openings must be positioned Figure 14 properly over the valve orifices Figure 18a Check proper assembly before fastening manifold in place Figure 18b Valve
24. ers or valves See Section General Maintenance General Maintenance Weber Spider Stopper Guards Your Weber Gas Barbecue as well as any outdoor gas appliance is a target for spiders and other insects They can nest in the venturi section of the burner tubes This blocks the normal gas flow and can cause the gas to flow back out of the air shutter Figure 9 This could result in a fire in and around the air shutters under the control panel Causing serious damage to your barbecue Venturi Air shutter Venturi fin Figure 9 The Weber Spider Stopper Guard is factory installed It fits tightly around the air shutter section of the burner tube and the valve thereby preventing spiders and other insects access to the burner tubes through the air shutter openings Figure 10 Weber Spider Stopper Guard Figure 10 We recommend that you inspect the Weber Spider Stopper Guards at least once a year See Section Annual Maintenance Also inspect and clean the Spider Stopper Guards if any of the following symptoms should ever occur 1 The smell of gas in conjunction with the burner flames appearing yellow and lazy Barbecue does not reach temperature Barbecue heats unevenly One or more of the burners do not ignite A DANGER Failure to correct these symptoms may result in a fire which can cause serious bodily injury or death and cause damage to property 28 Main Burner Flame Pattern The Web
25. 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 mM The pressure regulator supplied with the Weber Gas Barbecue must be used This regulator is set for 10 5 inches of water column pressure Mm 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 M 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 mM 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 E The gas must be turned OFF at the LP tank when the Weber Gas Barbecue is not in use Mm 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 Mm LP tanks must be stored outdoors in a well ventilated area out of the reach of children Disconnected LP tanks must not be
26. n turn on the other burner Note Always light the FRONT burner first The other burner ignites from the FRONT burner To Extinguish Turn gas supply OFF at the source then push down and turn each burner control knob clockwise to OFF Manual Lighting A DANGER Failure to open lid while igniting the barbecue or not waiting 5 minutes to allow the gas to clear if the barbecue does not light may result in an explosive flame up which can cause serious bodily injury or death 1 Open the lid Figure 2 2 Check that fuel scale reads more than E Note E empty F full Make sure all burner control knobs are turned OFF Push each knob down and turn clockwise ZAAWARNING The burner control knobs must be in the OFF position before turning on the LP tank valve If they are not in the OFF position when you turn on the LP tank valve the excess flow control will activate limiting the flow of gas from the LP tank If this should occur turn OFF the LP tank valve and burner control knobs and start over 3 A DANGER When the excess flow control is activated a small amount of gas is still flowing to the burners After turning OFF the tank and burner control knobs wait at least 5 minutes for the gas to clear before attempting to light the barbecue Failure to do so may result in an explosive flame up which can cause serious bodily injury or death Manual Lighting 22 4 Turn the tank on by tu
27. nect and maintain pressure Slide the collar closed Figure 5 b If it does not engage or lock repeat procedure Gas will not flow unless the quick disconnect is properly engaged c a Male fitting Regulator Si Collar lt i b Quick disconnect engaged Figure 5 d Mix soap and water e Open the tank valve Figure 6 Figure 6 25 Check for leaks by wetting the fitting with the soap and water solution and watching for bubbles If bubbles form or if a bubble grows there is a leak f If there is a leak turn off the gas tighten the fitting turn the gas back on and recheck with the soap and water solution If leak does not stop turn off the gas and contact Weber Stephen Customer Service Do not use the barbecue g When leak checks are complete turn gas supply OFF and rinse connections with water LP Tank The LP tank manufacturer is responsible for the materials workmanship and performance of the tank If the tank has a defect malfunctions or you have a question regarding the tank call the tank manufacturer s customer service center The phone number is on the warning decal which is permanently attached to the tank If the tank manufacturer has not resolved the issue to your satisfaction then call Weber Stephen Products Co Customer Service Center Safe handling tips for LP Gas mM Liquid Propane LP gas is a petroleum product as are gasoline and natural gas LP gas Is a gas a
28. o 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 25 Hair pin cotter Hinge pin Figure 25 19 Step 20 Add tool holders control panel and burner control knobs You will need two tool holders control panel two Phillips screws washers a Phillips screwdriver and two burner control knobs Hook the tool holders over the frame rail Figure 26 Set the control panel in place over both frame braces Hold the Crossover Ignition button up while setting the control panel in place Line up the holes in the control panel with the holes in the inserts in the frame brace Insert screws and tighten with Phillips screwdriver until snug Do not overtighten Figure 26 a Push on the burner control knobs Figure 26 b Insert in frame brace Crossover Ignition Button Control panel Phillips screws washers Tool holders Figure 26 Step 21 Complete accessory installation You will need work table accessory rack warming rack four tubing plugs and thermometer Set the accessory rack across the bottom braces in front of the frame connector Figure 27 a Open the lid and set the warming rack into the slots at the rear of the cooking box Figure 27 b Set the work table onto the left side rails and work table spacer Figure 27 c
29. ped to do this E The LP tank must be installed transported and stored in an upright position LP tanks should not be dropped or handled roughly mM Never store or transport the LP tank where temperatures can reach 125 F too hot to hold by hand for example do not leave the LP tank in a car on a hot day E Note A refill will last about 20 hours of cooking time at normal use The fuel scale will indicate the propane supply so you can refill before running out You do not have to run out before you refill E Treat empty LP tanks with the same care as when full Even when the LP tank is empty of liquid there still may be gas pressure in the cylinder Always close the tank valve before disconnecting Mm Do not use a damaged LP tank Dented or rusty LP tanks or LP tanks with a damaged valve may be hazardous and should be replaced with a new one immediately mM The joint where the hose connects to the LP tank must be leak tested each time the LP tank is reconnected For example test each time the LP tank is refilled M Be sure the regulator is mounted with the small vent hole pointed downward so it will not collect water This vent should be free of dirt grease bugs etc 26 call Weber Stephen Customer Service D O T Certification example 20 Ib LP tank Date Tested Figure 7 All LP tank supply systems must include a collar to protect the tank valve The LP tank must be a 20 Ib size 18 1 4 inches high
30. rning the tank valve counterclockwise 5 Strike a match and put the flame into the matchlight hole in the front of the cooking box A WARNING Do not lean over open barbecue Keep your face and body at least one foot away from the matchlight hole when lighting the barbecue 6 Push Front burner control knob down and turn to START HI 7 Check that the burner is lit by looking through the matchlight hole on the front of the cooking box Z WARNING If the burner does not light turn the Front burner control knob to OFF and wait 5 minutes to let the gas clear before you try again or try to light with a match 8 After the FRONT burner is lit you can turn on the other burner Note Always light the FRONT burner first The other burner ignites from the FRONT burner To Extinguish Turn gas supply OFF at the source then push down and turn each burner control knob clockwise to OFF Cooking AAWARNING Do not move the Weber Gas Barbecue when operating or hot You can adjust the FRONT and BACK burners as desired The control settings High H Medium M Low L or Off O are described in your Weber cookbook The cookbook uses these notations to describe the settings of the FRONT and BACK burners For example to sear steaks you would use HH all burners at high Then to complete cooking you would use MM FRONT at medium and BACK at medium See your Weber cookbook for detailed cooking instructions Note The
31. 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 AWARNING 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 A 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 Safe handling tips for LP gas Step 14 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
32. sover tube Front and back burners 2 1 4 20x1 inch stainless steel wing nuts 2 Spider Stopper Guards 2 Manifold assembly Manifold bracket Right frame Igniter Igniter lock nut Gas catcher ignition chamber Igniter wire black Igniter wire white Fuel scale 1 4 20 wing nuts 2 LP tank Filler Adapter Control panel inserts 2 AWARNING Use only Weber factory authorized parts The use of any part that is not factory authorized can be dangerous This will also void your warranty A FINAL WORD OF THANKS Teank you for choosing a Weber Barbecue Our family bere at Weber bas worked hard to produce the highest quality products for your satisfaction While we give much attention to our products an occasional error may occur Our knowledgeable Customer Service staff is prepared to help you with any problems with parts or assembly Call our toll free number 1 800 446 1071 For quicker service please bave your owner s manual available for reference We also welcome any comments or suggestions you might bave regarding our products We wish your family the best in outdoor cooking enjoyment Weber Stepben Products Company Customer Service Center 200 East Daniels Road Palatine Illinois 60067 6266
33. stored in a building garage or any other enclosed area Mm 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 A WARNING Only use this barbecue outdoors in a well ventilated area Do not use in a garage building breezeway or any other enclosed area Mm Never use your Weber Gas Barbecue under an unprotected combustible roof or overhang M Your Weber Gas Barbecue is not intended to be installed in or on recreational vehicles and or boats M Do not use combustible materials within 24 inches of the top bottom back or sides of the grill mM The entire cooking box gets hot when in use Do not leave unattended E Keep any electrical supply cord and the fuel supply hose away from any heated surface E Keep the cooking area clear of flammable vapors and liquids such as gasoline alcohol etc and combustible materials Mm Never store an extra Spare LP tank under or near the Weber Gas Barbecue Assembly Tools needed meme lt 7 16 open end or an adjustable wrench Pliers tooo SSQ Block of wood v Phillips Screwdriver 0m 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 siz
34. t an authorized LP gas dealer by a qualified attendant who fills the tank by weight IMPROPER FILLING IS DANGEROUS A 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 Scale setting wing nut Tank lock wing nut Tank valve Figure 3 24 Connecting the filled LP tank A WARNING Make sure that the LP tank valve is closed Close by turning clockwise A 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 You will need LP tank a soap and water solution and a rag or brush to apply it 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 a Lift and hook the tank onto the fuel scale b Loosen the tank lock wing nut Swing the tank lock down Tighten the wing nut Figure 4 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 discon
35. t regular temperatures and pressures Under moderate pressure inside a cylinder LP gas is a liquid As the pressure is released the liquid readily vaporizes and becomes gas m LP gas has an odor similar to natural gas You should know this odor Liquid Propane LP Tank s The LP tank and connections supplied with your Weber Gas Barbecue have been designed and tested to meet government American Gas Association and Underwriters Laboratories requirements Replacement LP tanks supplied by Weber satisfy the requirements Check to be sure the tank has a D O T certification and has been tested within five years Your LP gas supplier can do this for you Figure 7 If you have questions about spare LP tanks please Mm LP gas is heavier than air Leaking LP gas may collect in low areas that prevent dispersion E To fill take the LP tank to an RV center or look up gas propane in the phone book for other sources of LP gas AWARNING 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 A 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 Air must be removed from a new LP tank before the initial filling Your LP dealer is equip
36. temperatures inside your cooking box for the first few uses while surfaces are still very reflective may be hotter than those shown in your cookbook Cooking conditions may require the adjustment of the burner controls to attain the correct cooking temperatures Z CAUTION Replace thermometer in lid when not in use Do not leave thermometer in food while cooking If burners go out during cooking open lid turn off all burners and wait 5 minutes before relighting Preheating Your Weber Gas Barbecue is an energy efficient appliance It operates at a low B T U rate for economy To preheat after lighting close lid and turn all burners to high HH Preheating to between 500 and 550 F 260 and 290 C will take 10 to 15 minutes depending on conditions such as air temperature and wind Drippings and grease The Flavorizer Bars are designed to smoke the right amount of drippings for flavorful cooking Excess drippings and grease accumulate in the catch pan under the bottom tray Disposable foil liners are available that fit the catch pan Z WARNING Check the bottom tray for grease build up before each use Remove excess grease to avoid a grease fire in the bottom tray Storage and or Nonuse E The gas must be turned off at the LP tank when the Weber Gas Barbecue is not in use Mm When the Weber Gas Barbecue is stored indoors the gas supply must be DISCONNECTED and the LP tank stored outdoors in a well ventilated sp
37. th a suitable brass bristle brush As needed remove from grill and wash with warm soapy water Catch pan Disposable foil trays are available or you can line the catch pan with aluminum foil To clean the catch pan wash with warm soapy water Thermometer Wipe with warm soapy water clean with plastic scrub ball Do not put in dishwasher or submerge in water Inside cooking box Brush any debris off of burners tubes DO NOT ENLARGE BURNER PORTS OPENINGS Wash inside of cooking box with warm soapy water Inside Lid While lid is warm wipe inside with paper towel to prevent flaking due to grease build up Molded table Use any household cleaners on the table surface DO NOT USE CLEANERS THAT CONTAIN ACID MINERAL SPIRITS OR XYLENE Rinse well after cleaning Refilling the LP tank We recommend that you refill before the scale indicator reaches E Note If you run out of fuel check the indicator setting and or adjust the fuel scale indicator setting with the scale setting wing nut while the tank is empty so you do not run out again Removal of the LP tank 1 Close tank valve turn clockwise Figure 3 a 2 Slide the collar back on the quick disconnect to disengage the fitting Figure 3 b 3 Loosen tank lock wing nut and turn tank lock up out of the way 4 Lift tank off To refill take LP tank and tank filler adapter to a Gas Propane dealer AWARNING We recommend that your LP tank be filled a
38. tore 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
39. very 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 Z 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 18 Figure 18 Check for leaks by wetting the connections with the soap and water solution and watching for bubbles If bubbles form or if a bubble grows there is a leak Note Since some leak test solutions including soap and water may be slightly corrosive all connections should be rinsed with water after checking for leaks Z WARNING Do not ignite burners when leak checking 17 Check a Hose to manifold connection Figure 19 a b Regulator to tank connection Figure 19 b A 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 d AWARNING If there is a leak at connections b c or d
40. when burner is on HIGH Flames do not run the whole length of the burner tube Inside of lid appears to be peeling The lid is porcelain on steel not Resembles paint peeling paint It cannot peel What you are seeing is baked on grease that has turned to carbon and is flaking off THIS IS NOT A DEFECT Fuel scale shows that there is gas in the LP Check adjustment of fuel scale tank but tank is empty Cure Clean Weber Spider Stopper Guards See Section Annual Maintenance To reset the excess flow safety device turn all burner control knobs and the tank valve OFF Disconnect the regulator from the tank Turn burner control knobs to HIGH Wait at least 1 minute Turn burner control knobs OFF Reconnect the regulator to the tank Turn tank valve on slowly Refer to Lighting Instructions Refill LP tank Straighten fuel hose If you can light the Front burner with a match then check the Crossover Ignition System All burners on high for 10 to 15 minutes for preheating Clean thoroughly See Section Periodic Cleaning Clean bottom tray Clean burners See Section General Maintenance Clean thoroughly See Section Periodic Cleaning Fuel scale must be adjusted with an empty tank If problems cannot be corrected by using these methods please contact Weber Stephen Customer Service 31 26 29 30 18 19 20 21 22 23 25 Parts List All items are single qu
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