Weber Spirit 500 Lx Users Manual NG Owners Guide 98643 11/1997 PDF File

500 LX to the manual 63e56ee2-2579-42d1-997b-dc6c0e967c67

2015-01-05

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SPIRIT™500 LX Series
Natural Gas Barbecue
Serial Number
Please use this number in registering your warranty and
any correspondence with the factory.
Owner’s Manual
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 you 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
Do not store or use gasoline or other
flammable vapors and liquids in the vicinity
of this or any other appliance.
®
98643 11/97
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.
Use heat-resistant barbecue mitts or gloves when operating barbecue.
LP GAS UNITS ONLY:
Use the regulator that is supplied with your Weber Gas Barbecue.
Do not attempt to disconnect the gas regulator or any gas fitting while your barbecue is in operation.
A dented or rusty LP tank may be hazardous and should be checked by your liquid propane supplier.
Do not use an LP tank with a damaged valve.
Although your LP tank may appear to be empty, gas may still be present, and the tank should be
transported and stored accordingly.
If you see, smell or hear the hiss of escaping gas from the LP tank:
1. Get away from LP tank.
2. Do not attempt to correct the problem yourself.
3. Call your fire department.
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
(800) 446-1071
WARRANTY
© 1997 Weber. Weber, , Flavorizer and Crossover are registered
U.S. trademarks; Spirit, Gas Catcher, FlameCheck, and Spider
Stopper are U.S. trademarks of Weber-Stephen Products Co., 200
East Daniels Road, Palatine, IL 60067-6266. U.S.A. Spirit is
covered under the following patent nos.: U.S.A. #4,677,964;
4,727,853; #4,829,978; #4,941,817; and #4,966,125; Canada:
#1,279,540; #1,300,994; and #1,300,995. Printed in the U.S.A.
PATENTS AND TRADEMARKS
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Contents
WARNINGS................................................................ 2
Warranty & Patents.................................................. 3-4
General Instructions.................................................... 6
Assembly ............................................................... 7-18
Operating Instructions
Lighting........................................................ 19-20
Cooking ............................................................ 21
Storage and/or Nonuse .................................... 21
Cleaning .......................................................... 21
Troubleshooting & Maintenance
Annual Maintenance......................................... 22
General Maintenance.................................. 23-24
Troubleshooting................................................ 26
Parts Listing .............................................................. 29
FEATURES:
a) Convenient tables and racks.
b) Heavy gauge porcelain-on-steel lid seals in heat.
c) Rapid read thermometer for precision cooking.
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) Catch pan catches excess grease.
a
b
c
d
e
f
a
g
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General Instructions
Your Weber Gas Barbecue is a portable outdoor cooking
appliance. With the Weber Gas Barbecue you can grill,
barbecue, roast and bake with results that are difficult to
duplicate with indoor kitchen appliances. The closed lid and
Flavorizer Bars produce that "outdoor" flavor in the food.
The Weber Gas Barbecue is portable so you can easily
change its location in your yard or on your patio. Portability
means you can take your Weber Gas Barbecue with you if
you move.
The natural gas supply is easy to use and gives you more
cooking control than charcoal fuel.
■These instructions will give you the minimum
requirements for assembling your Weber Gas
Barbecue. Please read the instructions carefully
before using your Weber Gas Barbecue. Improper
assembly can be dangerous.
■Not for use by children.
■If there are local codes that apply to portable gas
grills, you will have to conform to them. If there are no
local codes, you must conform to the latest edition of
the National Fuel Gas Code: ANSI Z 223.1.
■This Weber Gas Barbecue is designed for natural
(piped in city) gas only. Do not use Liquid Propane
(LP) bottled gas.The valves, orifices and hose are for
natural gas only.
■Do not use with charcoal fuel.
■Check that the area under the control panel and the
bottom tray are free from debris that might obstruct
the flow of combustion or ventilation air.
For Installation in Canada
These instructions, while generally acceptable, do not
necessarily comply with the Canadian Installation codes,
particularly with piping above and below ground. In
Canada the installation of this appliance must comply with
local codes and/or Standard CAN/CGA-B149.1 (Installation
Code for Natural Gas Burning Appliances and Equipment).
Storage
■The gas must be turned OFF at the natural gas supply
when the Weber Gas Barbecue is not in use.
■When the Weber Gas Barbecue is stored indoors, the
gas supply must be disconnected.
Operating area
WARNING: 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.
Gas supply testing
■Disconnect your Weber Gas Barbecue when the gas
supply is being tested at high pressures. This appliance
and its individual shutoff valve must be disconnected
from the gas supply piping system during any pressure
testing of that system at test pressures in excess of
1/2 psig (3.5 kPa).
■Turn off your Weber Gas Barbecue when the gas
supply is being tested at low pressures. This appliance
must be isolated from the gas supply piping system by
closing its individual manual shutoff valve during any
pressure testing of the gas supply piping system at
the pressure equal to or less than 1/2 psig (3.5 kPa).
7
Step 1
Check package contents
Cooking box
(assembly)
Lid
(assembly)
Hose
Bottom tray
Two cooking grates
Control panel
Work table
Five Flavorizer Bars
Assembly
Tools needed
Hammer
7/16 and 3/4 inch open-end or an adjustable wrench
Pliers
Block of wood
Phillips screwdriver
Supplies needed
You will need a soap and water solution to check for gas
leaks. (See Step "Check for gas leaks.")
Note - The hardware size of nuts, bolts and screws is
given. For example "1/4-20 x 2 inch bolt" means a bolt
1/4 inch in diameter with 20 threads to the inch, 2 inches
long. On a small screw for example, "6-32 x 1/2 inch
screw" means a number 6 screw, with 32 threads to the
inch, 1/2 inch long.
While we give much attention to our products,
unfortunately an occasional error may occur. If a part is
missing, do not go back to the store. Call the Weber
Customer Service Center toll free 1-800-446-1071 to
receive immediate assistance. Have your owner’s
manual and serial number of the barbecue available
for reference.
Left frame
Right frame
Wheel frame
Leg frame
Frame connector
Accessory rack
Warming rack
Front panel
Catch pan holder
Catch pan
Two drip pans
Thermometer
Two wheels
Spacer bracket
Check contents of hardware packs
Two burner control knobs
Two tool holders
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
(actual size)
Two 1/4-20 x 1 3/4 inch bolts
(actual size)
Six 1/4-20 x 1/2 inch bolts
(actual size)
Two plastic buttons
(actual size)
Nine 1/4 inch nylon washers
Two hair pin cotters
Two wheel hubcaps
Manifold bracket
1/4-20 keps nut
Two Phillips Screws/Washers
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Figure 1
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Figure 2
Leg tabs
Frame tabs
(a)
(b)
Right frame
Left frame
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.
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.)
10
Figure 3
Figure 4
Figure 5
View from rear
of barbecue
Dimples to
the inside
Plastic buttons
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 the dimple to the inside.
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.
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.
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.
11
Guide screw
(a)
(b)
(c)
Wing nuts
View from
behind
cooking
box
Figure 8
Figure 6
Burner tubes
Frame brace
(a)
(b)
Spacer bracket
Keps nut
Tab
Frame
cross piece
Nylon washer
Bolt
Slide the cooking box to the left within the frame. Put the
washer on the bolt. Take the spacer bracket and hold it up
to the frame making sure both tabs fit underneath the
frame cross piece. Figure 7 (a). Insert the bolt through the
center hole in the spacer bracket, frame and cooking box
with the head of the bolt outside the spacer bracket.
Figure 7 (b). Add keps nut. Figure 7. Tighten by holding
the bolt with pliers while you tighten the nut with a wrench.
Figure 7
Step 7
Add cooking box
You will need: frame assembly, cooking box assembly, work
table spacer, 1/4-20 keps nut, 1/4-20 x 2 inch bolt, pliers
and a 7/16 inch wrench.
Set the cooking box in the frame so the burner tubes are
under the frame brace. Figure 6.
Your Weber Gas Barbecue burner assembly has been
factory assembled, pressure and flame tested. As a safety
precaution we recommend you check the burner alignment:
a) Do the valves fit into the ends of the burners?
Figure 8 (a).
b) Are the ends of the burners under the washers at the
left rear and left front of the cooking box? The screws
are only guides. Do not tighten. Figure 8 (b).
c) Are the wing nuts under the burner assembly hand
tight? Do not tighten with pliers. Figure 8 (c).
If you answered YES to a, b and c, the burners are
correctly aligned. If you answered NO, the burners are
misaligned. Contact Weber-Stephen Customer Service.
Do not use barbecue.
12
Frame brace Manifold bracket
Figure 9
Figure 10
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.
Step 9
Install frame connector
You will need: frame connector, two 1/4-20 x 1 3/4 inch
bolts, two nylon washers and a 7/16 inch wrench.
Slip a washer on a bolt and insert through the hole in the
cross brace and into the end of the frame connector. Insert
the other bolt and washer into the other end through the
cross brace and into the frame connector. Hold the frame
connector square and tighten the bolts. Figure 10.
Step 10
Install gas supply
General Specifications for Piping
Note - Contact your local municipality for building
codes regulating outdoor gas barbecue installations.
In absence of Local Codes, you must conform to the
latest edition of ANSI Z223.1. WE RECOMMEND THAT
THIS INSTALLATION BE DONE BY A PROFESSIONAL.
Some of the following are general requirements taken
from ANSI Z223.1, for gas supply installations. Refer to
ANSI Z223.1 latest edition for complete specifications.
■This barbecue is designed to operate at 7 inches of
water column pressure (.2526 psi).
■A manual shut-off valve must be installed outdoors,
immediately ahead of the quick disconnect.
■An additional manual shut-off valve indoors should be
installed in the branch fuel line in an accessible
location near the supply line.
■ The quick disconnect connects to a 3/8 inch NPT
thread from the gas source. The quick disconnect
fitting is a hand-operated device that automatically
shuts OFF the flow of gas from the source when the
barbecue is disconnected.
■The quick disconnect fitting can be installed
horizontally, or pointing downward. Installing the fitting
with the open end pointing upward can result in
collecting water and debris.
■The dust covers (supplied plastic plugs) help keep the
open ends of the quick disconnect fitting clean while
disconnected.
■Pipe compound should be used which is resistant to
the action of natural gas when connections are made.
■The outdoor connector must be firmly attached to
rigid, permanent construction.
WARNING: Do not route the 12 foot hose under a
deck. The hose must be visible.
13
Typical natural gas supply installation. Figure 11. Test connections
All connections and joints must be thoroughly tested for
leaks in accordance with local codes and all listed
procedures in the latest edition of ANSI Z223.1.
DANGER
Do not use an open flame to check for gas
leaks. Be sure there are no sparks or open
flames in the area while you check for gas
leaks. This will result in a fire or explosion
which can cause serious bodily injury or
death, and damage to property.
Figure 11
The quick disconnect is
installed above ground
Gas supply
Inside wall
Outside wall
Quick disconnect
Male fitting
To barbecue
Shut off
Locking
shut off
Install gas supply (continued)
■Pipe compound should be used which is resistant to
the action of natural gas when NPT connections are
made.
■The outdoor connector must be firmly attached to
rigid, permanent construction.
Gas line piping
■If the length of line required does not exceed 50 feet,
use a 5/8" O.D. tube. One size larger should be used
for lengths greater than 50 feet.
■Gas piping may be copper tubing, type K or L;
polyethylene plastic tube, with a minimum wall
thickness of .062 inch; or standard weight (schedule
40) steel or wrought iron pipe.
■Copper tubing must be tin-lined if the gas contains
more than 0.3 grams of hydrogen sulfide per 100 cubic
feet of gas.
■Plastic tubing is suitable only for outdoor, underground
use.
■Gas piping in contact with earth, or any other material
which may corrode the piping, must be protected
against corrosion in an approved manner.
■Underground piping must have a minimum of 18" cover.
14
Figure 13
Figure 12
Igniter lock nut
Keyhole in
frame brace
Figure 14
(a)
Small part of keyhole
in frame brace
Frame brace
(c)
(b)
(a)
Step 11
Install igniter
Note - The igniter wires are already attached to the Gas
Catcher Ignition Chamber and the igniter. This was done to
factory test the ignition system.
The igniter lock nut is on the igniter.
Insert the top of the igniter up through the large part of
the keyhole in the frame brace. Figure 12 (b). Loosen the
igniter lock nut and slide the igniter into the small part of
the keyhole. Figure 12 (c). Tighten the igniter lock nut.
Figure 12.
Note - If the igniter works loose, carefully tighten the igniter
lock nut with an adjustable wrench or pliers.
Step 12
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 13.
Step 13
Connect flexible hose to manifold
You will need: the 12 foot natural gas supply hose and a
3/4 inch wrench.
Thread fitting end of hose onto manifold. Figure 14 (a).
Tighten with wrench.
15
(a)
Figure 16
Figure 15
(c)
(b)
Male fitting
To barbecue
Quick disconnect
engaged
Collar
Outside
house wall
Locking shut off
(a)
(b)
Step 14
Check for gas leaks
DANGER
Do not use an open flame to check for gas
leaks. Be sure there are no sparks or
open flames in the area while you check
for leaks. This will result in a fire or
explosion which can cause serious bodily
injury or death and damage to property.
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: Slide back the collar of the quick
disconnect. Push male fitting of the hose into the quick
disconnect, and maintain pressure. Figure 15 (a). Slide
the collar closed. Figure 15 (b). If it does not engage or
lock, repeat procedure. Gas will not flow unless the quick
disconnect is properly engaged.
Turn on gas supply.
WARNING: Do not ignite burners while leak checking.
Check for leaks by wetting the connections with the soap
and water solution and watching for bubbles. If bubbles
form or if a bubble grows there is a leak.
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.
Check:
a) Hose to manifold connection. Figure 16 (a).
WARNING: If there is a leak at the hose to manifold
connection, Figure 16 (a), retighten the hose 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.
b) Valves to manifold connections. Figure 16 (b).
c) The hose to quick disconnect connection.
Figure 16 (c).
WARNING: If there is a leak at connections b or c,
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.
16
Figure 17
Figure 18
Figure 20
Figure 19
Figure 21
Bottom tray
Finger grip on front
edge of bottom tray
Finger grip
Front side of catch
pan holder
Step 15
Install Flavorizer Bars and Cooking Grates
You will need: five Flavorizer Bars and two cooking grates.
Set the Flavorizer Bars side to side in the cooking box.
Figure 17.
Set the cooking grates onto the ledges in the cooking box
with the rounded side up. Figure 18.
Step 16
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 20. 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 21.
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.
17
Hair pin cotter
Hinge pin
Figure 22
Figure 23
Tool holders
Insert in
frame brace
Control panel
Phillips screws/
washers
(a)
(b)
Step 17
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 22.
Step 18
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 23.
Set the control panel in place over both frame braces.
(Hold the Crossover Ignition button up while setting the
control panel in place.) Line up the holes in the control
panel with the holes in the inserts in the frame brace.
Insert screws and tighten with a Phillips screwdriver until
snug. Do not overtighten. Figure 23 (a).
Push on the burner control knobs. Figure 23 (b).
Crossover
Ignition
Button
(a)
(c)
(d)
(b)
18
Step 19
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 24 (a).
Open the lid and set the warming rack into the slots at the
rear of the cooking box. Figure 24 (b).
Set the work table onto the left side rails. Figure 24 (c).
Insert the thermometer into its holder. Figure 24 (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 24 (e).
Figure 24
(e)
19
1
2
3
6
5
7
4
Figure 1
Crossover Ignition System
Lighting
Summary lighting instructions are on the control panel.
1) Open the lid. Figure 1.
2) Make sure all burner control knobs are turned OFF.
(Push each burner control knob down and turn
clockwise.)
3) Turn the gas supply valve on.
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.
4) Push Front burner control knob down and turn to
START/ HI.
5) Push the Crossover Ignition Button several times, so it
clicks each time.
6) Check that the burner is lit by looking through the
matchlight hole on the front of the cooking box.
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.
7) 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.
OPERATING INSTRUCTIONS
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.
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 hose. Order from Weber-Stephen Products
Co., Customer Service Center or authorized dealer.
20
1
2
3
4
7
5
6
Figure 2
Manual Lighting
Manual Lighting
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.
7) 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.
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) Make sure all burner control knobs are turned OFF.
(Push each burner control knob down and turn
clockwise.)
3) Turn the gas supply valve on.
4) Strike a match and put the flame into the matchlight
hole in the front of the cooking box.
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) Check that the burner is lit by looking through the
matchlight hole on the front of the cooking box.
21
Cooking
WARNING: 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.
If burners go out during cooking, open lid, turn off all
burners and wait 5 minutes before relighting.
Note: The 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.
CAUTION: Replace thermometer in lid when not in
use. Do not leave thermometer in food while cooking.
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.
WARNING: Check the bottom tray for grease build-
up before each use. Remove excess grease to avoid a
grease fire in the bottom tray.
Periodic Cleaning
WARNING: Turn your Weber Gas Barbecue OFF and
wait for it to cool before cleaning.
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.
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 with 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.
Storage and/or Nonuse
■When storing the Weber Gas Barbecue, make sure
that the inside shut off valve and/or locking outdoor
shut off valve is secured in the OFF position. When
the Weber Gas Barbecue is stored indoors, the gas
supply MUST BE DISCONNECTED.
■After a period of storage and/or nonuse the Weber
Gas Grill 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.")
22
Annual Maintenance
After a period of nonuse we recommend that you perform
the following maintenance procedures for your safety.
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 hose. Order from Weber-Stephen Products
Co., Customer Service Center or authorized dealer.
■Inspect the burners for correct flame pattern. Clean if
necessary, following the procedures outlined in the
"General Maintenance" section of this manual.
■Check all gas fittings for leaks.
DANGER
Do not use an open flame to check for gas
leaks. Be sure there are no sparks or open
flames in the area while you check for
leaks. This will result in a fire or explosion
which can cause serious bodily injury or
death, and damage to property.
WARNING: You should check for gas leaks every
time you disconnect and reconnect a gas fitting.
Note - All factory made connections have been thoroughly
checked for gas leaks. The burners have been flame
tested. As a safety precaution you should recheck all
fittings for leaks before using your Weber 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: Plug end of gas supply hose into
the quick disconnect, then turn on gas supply.
WARNING: Do not ignite burners while leak checking.
Check for leaks by wetting the connections with the soap
and water solution and watching for bubbles. If bubbles
form or if a bubble grows there is a leak.
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.
Check:
a) Hose to manifold connection. Figure 3 (a).
WARNING: If there is a leak at the hose to manifold
connection, Figure 3 (a), retighten the hose 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.
b) Valves to manifold connections. Figure 3 (b).
c) The hose to quick disconnect connection. Figure 3 (c).
WARNING: If there is a leak at connections b or c,
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.
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 burners or valves. (See Section "General
Maintenance".)
(a)
Figure 3
(c)
(b)
2323
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 4. This could result in a
fire in and around the air shutters, under the control panel,
causing serious damage to your barbecue.
Main Burner Flame Pattern
The Weber Gas Barbecue burners have been factory set
for the correct air and gas mixture. The correct flame
pattern is shown in Figure 6.
Burner inside
cooking box
Flames Figure 6 Dark blue
Light blue
Tips occasionally yellowish
Figure 4
Venturi
Air shutter Venturi fin
Weber Spider
Stopper Guard
Figure 5
DANGER
Failure to correct these symptoms may
result in a fire which can cause serious
bodily injury or death and cause damage
to property.
Figure 7
Figure 8
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 5.
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.
2. Barbecue does not reach temperature.
3. Barbecue heats unevenly.
4. One or more of the burners do not ignite.
Clean the inside of the burners with a wire (a straightened
out coat hanger will work). Figure 8. 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.
CAUTION: Do not enlarge the burner ports when
cleaning.
Replacing Main Burners
a) Your Weber Gas Barbecue must be OFF and cool.
b) Turn gas OFF at source.
c) Remove control panel: take off the burner control
knobs. Remove the screws holding the control panel
in place. Lift off the control panel.
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 7.
24
View from behind
cooking box
Wing nuts
Figure 10
Guide screw
Figure 11
Crossover tube
Figure 12
Figure 9
d) Unlatch the Spider Stopper Guards and remove.
Figure 9. g) Lift and twist the burner assembly slightly, to separate
the crossover tube from the burners. Figure 12.
Remove the burners from the cooking box.
f) Slide the burner assembly out from under the guide
screw and washer in the corners of the cooking box.
Figure 11.
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 10.
h) To reinstall the burners, reverse steps c) through g).
CAUTION: The burner openings must be positioned
properly over the valve orifices. Figure 13a.
Check proper assembly before fastening manifold in
place. Figure 13b.
Figure 13
Valve
Burner
(a)
(b)
2525
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 14.
Venturi fin
Figure 14
Check fit
around valve
Check fit around burner
Figure 15
White wire
Black wire
CAUTION: If the Spider Stopper Guards do not fit
tightly, contact Weber-Stephen Customer Service.
WARNING: 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”).
■Check that the Crossover Ignition button pushes the
igniter (button) down, and returns to the up position.
■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, See
Section "Manual Lighting", and contact Weber-Stephen
Customer Service.
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.
■Check that both the white and black ignition wires are
attached properly. Figure 15.
26
Problem
Burners burn with a yellow or orange flame, in
conjunction with the smell of gas.
Burner does not light, or flame is low in HIGH
position.
Experiencing flare-ups:
CAUTION: Do not line the bottom tray with
aluminum foil.
Burner flame pattern is erratic. Flame is low
when burner is on HIGH. Flames do not run the
whole length of the burner tube.
Inside of lid appears to be “peeling.”
(Resembles paint peeling.)
Check
Inspect Weber Spider Stopper
Guards for possible obstructions.
(Blockage of holes.)
Is fuel hose bent or kinked?
Does the Front burner light with a
match?
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
allowing grease to flow into catch
pan?
Are burners clean?
The lid is porcelain-on-steel, not
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.
Cure
Clean Weber Spider Stopper
Guards. (See Section "Annual
Maintenance".)
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".)
TROUBLESHOOTING
If problem cannot be corrected by using these methods, please contact Weber-Stephen Customer Service.
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2929
1 Lid (assembly)
2 Lid handle
3 Warming rack
4 Flavorizer bars (5)
5 Cooking grates (2)
6 Work table
7 Tubing plugs (8)
8 1/4-20 x 2 inch bolt
9 Spacer bracket
10 Left frame
11 1/4-20 x 1/2 inch bolts (6)
12 1/4 inch nylon washers (9)
13 Leg frame
14 Bottom tray
15 Catch pan holder
16 Catch pan
17 Drip pans (2)
18 Accessory rack
19 Frame connector
20 Wheel hubcaps (2)
21 Wheels (2)
22 Tool holders (2)
23 Wheel frame
24 Front panel
25 Plastic buttons (2)
26 1/4-20 x 1 3/4 inch bolts (2)
27 Hair pin cotters (2)
28 Hinge pins (2)
29 Thermometer
30 1/4-20 keps nut
31 Cooking box
32 Burner control knobs (2)
33 Control panel
34 Igniter button
35 Phillips screws/washers (2)
36 Crossover tube
37 Front and back burners (2)
38 1/4-20 stainless steel wing nuts (2)
39 Spider Stopper Guards (2)
40 Manifold assembly
41 Manifold bracket
42 Igniter
43 Igniter lock nut
44 Gas catcher ignition chamber
45 Right frame
46 Igniter wire (black)
47 Igniter wire (white)
48 Hose (includes quick disconnect)
49 Control panel inserts (2)
WARNING: 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.
Parts List
All items are single quantities 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.
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
A FINAL WORD
OF THANKS
hank you for choosing a Weber Barbecue.
Our family here at Weber 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 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 have your owner’s manual
available for reference. We also welcome any comments or
suggestions you might have regarding our products.
We wish your family the
best in outdoor cooking enjoyment.
Weber-Stephen Products Company
Customer Service Center
200 East Daniels Road
Palatine, Illinois 60067-6266
T

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