Weber 500 Series manual

W E B E R W E B E R SPIRIT ™ 500 Series LP Gas Barbecue Owner’ s Manual National Association PROPANE GAS ® 98987 11´/98 Serial Number Please use this number in registering your w arranty and any correspondence with the f actory .  W ARNING 1. Do not store spare LP Cylinder within 10 feet (3m) of this appliance. 2. Do not store or use gasol[...]

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

3 W eber-Stephen Products Co. (W eber) hereby warr ants to the ORIGINAL PURCHASER of this W eber Gas Barbecue that it will be free of def ects in mater ial and workmanship from the date of purchase as f ollows: Aluminum Castings , 10 years , Recycled W or k Surfaces , 10 years Cooking Grates and Fla vorizer Bars, 3 y ears, All Remaining P ar ts, 5 [...]

© 1998 W eber . W eber , , Flav orizer and Crossov er 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, P alatine, IL 60067-6266. U .S.A. Spirit is cov ered under the follo wing patent nos.: U .S.A. #4,677,964; 4,727,853; #4,829,978; #4[...]

5 Contents WARNINGS ................................................................ 2 W arranty & P atents .................................................. 3-4 General Instructions .................................................... 6 Assembly ............................................................... 7-20 Operating Instructions Lighti[...]

6 General Instructions Y our W eber Gas Barbecue is a por table outdoor cooking appliance. With the W eber Gas Barbecue you can grill, barbecue, roast and bak e with results that are difficult to duplicate with indoor kitchen appliances. The closed lid and Flav or izer Bars produce that "outdoor" fla v or in the food. The W eber Gas Barbe[...]

7 Step 1 Check pac kage contents Cooking bo x (assembly) Lid (assembly) LP tank Bottom tra y T wo cooking grates LP tank filler adapter Control panel Assembl y T ools needed Hammer 7/16 open-end or an adjustable wrench Pliers Block of w ood Phillips screwdriv er Supplies needed Y our LP tank is shipped empty f or saf ety . After setting the LP fuel[...]

Left frame Right frame Wheel frame Leg frame F rame connector W ork table Accessor y rack W ar ming rack Five Fla vorizer Bars T ank panel assembly F ront panel Catch pan holder Catch pan T wo dr ip pans Manif old brac ket Ther mometer T wo wheels Fuel scale assembly Spacer brac ket 8 W E B E R W E B E R W E B E R W E B E R[...]

T wo plastic buttons (actual size) T wo 1/4-20 wing nuts (actual size) Ele v en 1/4 inch nylon w ashers T wo hair pin cotters T wo wheel hubcaps 1/4-20 keps n ut T wo phillips screws/washers Check contents of hardw are packs T wo burner control knobs T wo tool holders Eight tubing plugs (two are spares) T wo hinge pins (hardware siz e: 1/4 x 1 1/2 [...]

10 Figure 1 W E B E R W E B E R Figure 2 Leg tabs F rame tabs (a) (b) Right frame Left frame Step 2 Assemble wheel fr ame Y ou will need: wheel frame, tw o wheels , tw o wheel hubcaps , hammer and a bloc k of wood. Set one end of wheel frame on the b lock of w ood (or other hard, protected surf ace). Put one wheel on axle, WEBER side f acing up , a[...]

11 Figure 3 Figure 4 Figure 5 View from rear of barbecue Dimples to the inside Fuel scale decal Plastic buttons Step 5 Install tubing plugs Y ou will need: two tubing plugs and a hammer . Inser t tubing plugs into the ends of the leg frame.Figure 4. T o fully seat the plugs, you ma y hav e to tap them lightly with a hammer . Step 4 Continue frame a[...]

Guide screw (a) (b) (c) Wing Nuts View from behind cooking bo x Figure 8 12 Figure 6 Burner tubes F rame brace (a) (b) Spacer brac ket K eps nut Ta b F rame cross piece Nylon washer Bolt Slide the cooking bo x to the left within the frame. Put the washer on the bolt. T ake the spacer brac ket and hold it up to the frame making sure both tabs fit un[...]

F rame brace Manif old brack et 13 Figure 9 Figure 10 Figure 11 F rame connector Cross brace T ank panel tabs Slots in frame brace F rame brace Step 8 Install manif old brack et Y ou will need: manif old brac ket Hook the brac ket onto the manif old at approximately the center of the length of the manif old. Place your hand underneath the bracket. [...]

14 Figure 12 View from front right View from front left F E F E Figure 13 Igniter lock n ut Small par t of keyhole in frame brace F rame brace F rame brace K eyhole in frame brace (a) (b) (c) Step 10 Add fuel scale assembly Y ou will need: fuel scale assembly , two 1/4-20 wing nuts and two nylon w ashers. Slip the bolts on the back of the fuel scal[...]

15 F E F E F E Figure 14 T ank lock wing nut (a) (b) Scale setting wing nut Step 12 Set LP fuel scale Y ou will need: LP tank (empty). Note - F or accuracy , the fuel scale must be set with an empty tank. W e utilize v ar ious LP tank manuf acturers. Some of the tanks we receiv e have diff er ing top collar assemblies . (The top collar is the metal[...]

16 Figure 17 T ur n so regulator vent does not collect water Hose T ank lock wing nut Quick disconnect engaged V alve handwheel close clockwise T ank valv e Collar Male fitting Pressure relief valv e T ank Regulator Regulator vent (a) (b) (c) Figure 16 Figure 15 F E Step 15 Connect LP tank  W ARNING: Make sure that the LP tank valve is closed. C[...]

17 Figure 18 (a) Figure 19 (c) (d) (b)  W ARNING: Y ou should check f or gas leaks every time you disconnect and reconnect a gas fitting. Note - All f actor y made connections hav e been thoroughly check ed for gas leaks . The burners hav e been flame tested. As a saf ety precaution you should rechec k all fittings f or leaks bef ore using your [...]

18 Figure 20 Figure 21 Figure 23 Figure 22 Figure 24 Bottom tra y Finger grip on front edge of bottom tra y Finger grip F ront side of catch pan holder Step 17 Install Flav orizer Bars and Cooking Grates Y ou will need: five Fla vorizer Bars and two cooking g rates. Set the Flav or izer Bars side to side in the cooking bo x. Figure 20. Set the cook[...]

19 Hair pin cotter Hinge pin Figure 25 Figure 26 T ool holders Inser t in frame brace Control panel Phillips screws/ washers (a) (b) Step 19 Install Lid Y ou 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. Inser t hinge pins from the outside. Insert hair pin cotters into [...]

20 Step 21 Complete accessor y installation Y ou will need: work table , accessor y rack, w ar ming rack, f our tubing plugs and thermometer . Set the accessor y rack across the bottom br aces 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 bo x. Figure 27 (b). Set the[...]

21 1 3 2 4 7 6 8 5 Figure 1 Crosso ver Ignition System OPERA TING INSTR UCTIONS Lighting Summar y lighting instructions are on the control panel.  D ANGER Failure to open lid while igniting the barbecue, or not waiting 5 minutes to allow the gas to c lear if the barbecue does not light, may result in an e xplosive flame-up which can cause seriou[...]

22 1 3 2 4 5 8 6 7 Figure 2 Manual Lighting Manual Lighting 4) T ur n the tank on by turning the tank valv e counterclockwise . 5) Str ike a match and put the flame into the matchlight hole in the front of the cooking bo x.  W ARNING: Do not lean over open barbecue. Keep your face and bod y at least one foot awa y fr om the matchlight hole when [...]

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

24 Scale setting wing nut T ank lock wing nut T ank valv e Collar (a) (b) Figure 3 Figure 4 Refilling the LP tank W e recommend that y ou 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 i[...]

25 Figure 6 Male fitting Regulator Collar Quick disconnect engaged Figure 5 (a) (b) c) Connect the hose to the tank. Route the hose so it does not interf ere with the scale indicator rod. Slide back the collar of the quic k disconnect on the tank valv e. Figure 5 (a). Push the male fitting of the regulator into the quick disconnect, and maintain pr[...]

26 26 Safe handling tips f or LP Gas ■ Liquid Propane (LP) gas is a petroleum product as are gasoline and natural gas. LP gas is a gas at regular temperatures and pressures. Under moder ate pressure, inside a cylinder , LP gas is a liquid. As the pressure is released the liquid readily vaporizes and becomes gas. ■ LP gas has an odor similar to [...]

Annual Maintenance After a period of nonuse we recommend that you perf or m the f ollowing maintenance procedures f or y our safety .  W ARNING: Check hose bef ore each use of barbecue for nic ks, cracking, abrasions or cuts. If the hose is found to be d ama ged i n a ny wa y , do not use the barbecue. Replace using only W eber authorized replac[...]

28 Burner inside cooking bo x Figure 11 Dark blue Light blue Tips occasionally yello wish Figure 9 V entur i Air shutter V entur i fin W eber Spider Stopper Guard Figure 10 Flames Figure 12 Figure 13 General Maintenance W eber Spider Stopper Guards Y our W eber Gas Barbecue , as w ell as an y outdoor gas appliance, is a target f or spiders and othe[...]

29 e) Remov e the manifold brac ket and unscrew the tw o wing nuts that hold the manif old to the cooking box. Pull the manif old and v alve assemb ly out of the burners and carefully set it down. Figure 15. View from behind cooking bo x Wing nuts Figure 15 Guide screw Figure 16 Crossov er tube Figure 17 Figure 14 d) Unlatch the Spider Stopper Guar[...]

30 30 Figure 20 White wire Black wire  C A UTION : If the Spider Stopper Guards do not fit tightly , contact Weber -Stephen Customer Ser vice .  W ARNING: Af ter r ei ns ta lling the gas lines, they should be leak chec ked with a soap and water solution before using the barbecue. See Step“Check for gas leaks”. ■ Check that the Crosso ve[...]

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

32 W E B E R W E B E R 3 1 2 4 5 6 9 7 8 14-15 18 19 16 49 50 51 38 31 39 40 41 42 43 44-45 46 36 34 33 32 31 29 28 27 47-48 37 35 20 21 22 30 10 11 12 13 17 23 24 25 26 ® ® ® ® ® ® ® ®[...]

33 1 Hair Pin Cotters (2) 2 Hinge pins (2) 3 Left Endcap 4 Shroud (Assembly) 5 Lid Handle 6 W ar ming rack 7 Flav or izer bars (5) 8 Cooking grates (2) 9 W ork table 10 T ubing plugs (8) 11 1/4-20 x 2 inch bolt 12 Spacer brac ket 13 Left frame 14 1/4-20 x 1/2 inch bolts (6) 15 1/4 inch nylon w ashers (11) 16 Leg frame 17 F rame connector 18 Bottom [...]

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A F INAL W ORD OF T HANKS hank you for choosing a W eber Barbecue. Our family here at W eber has worked hard to produce the highest quality products for your satisfaction. While we give much attention to our products, an occasional error may occur . Our knowledgeable Customer Service staff is prepar ed to help you with any problems with parts or as[...]