Serial Number
Please use this number in registering your warranty and
any correspondence with the factory.
™
SPIRIT 500 Series
LP Gas Barbecue
Owner’s Manual
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NationalPROPANEGAS Association
WARNING: Follow all leak check procedures
carefully in this manual prior to barbecue
operation. Do this even if barbecue was
dealer assembled.
FOR YOUR SAFETY
1. Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
2. An LP tank not connected for use shall
not be stored in the vicinity of this or
any other appliance.
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:
THIS GAS APPLIANCE IS DESIGNED FOR
OUTDOOR USE ONLY.
1. Shut off gas to the appliance.
2. Extinguish any open flame.
3. Open lid.
4. If odor continues, immediately call your
gas supplier or your fire department.
WARNING: Do not try to light this appliance
without reading "Lighting" instructions
section of this manual.
98567
10/97
WARRANTY
Weber-Stephen Products Co. (Weber) hereby
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.
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,
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.
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.
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 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 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
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.
LP Tank
The LP tank manufacturer is responsible for the
materials, workmanship and performance of the tank. If
the tank has a defect, malfunctions, or you have a
question regarding the tank, call the tank manufac-
turer's customer service center. The phone number is
on the warning decal which is permanently attached to
the tank. If the tank manufacturer has not resolved the
issue to your satisfaction, then call Weber-Stephen
Products Co., Customer Service Center.
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.
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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 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.
4
Contents
Troubleshooting & Maintenance
WARNINGS................................................................ 2
Warranty & Patents.................................................. 3-4
General Instructions.................................................... 6
Assembly ............................................................... 7-20
Annual Maintenance......................................... 27
General Maintenance.................................. 28-29
Troubleshooting................................................ 31
Parts Listing .............................................................. 35
Operating Instructions
Lighting........................................................ 21-22
Cooking ............................................................ 23
Storage and/or Nonuse .................................... 23
Cleaning .......................................................... 23
LP Tank Information .................................... 24-26
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IMPORTANT NEW FEATURES:
FEATURES:
Your Weber Gas Barbecue is equipped with a new and
improved LP tank connection, that has additional
safety features. They are:
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.
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.
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.
3. If an accidental fire occurs at the LP tank connection,
the flow of gas is stopped by a temperature activated
shutoff.
e) Separate burners for temperature control.
4. If the LP supply hose becomes damaged, cut,
punctured, or accidentally fire damaged, the barbecue
connection is equipped with an excess flow control
that will limit the flow of gas if leakage or a fire occurs.
f) Crossover Ignition System with Gas Catcher Ignition
Chamber.
g) Fuel scale indicates LP gas supply.
h) Catch pan catches excess grease.
5
General Instructions
Storage
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 gas must be turned OFF at the LP tank when the
Weber Gas Barbecue is not in use.
■ When the Weber Gas Barbecue is stored indoors, the
gas supply must be disconnected and the LP tank
stored outdoors in a well-ventilated space.
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.
■ LP tanks must be stored outdoors in a well-ventilated
area out of the reach of children. Disconnected LP
tanks must not be stored in a building, garage or any
other enclosed area.
Liquid Propane (LP) gas supply is easy to use and gives
you more cooking control than charcoal fuel.
■ 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.
■ 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.
Operating area
■ Not for use by children.
ƽWARNING: Only use this barbecue outdoors in a
well ventilated area. Do not use in a garage, building,
breezeway or any other enclosed area.
■ 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.
■ Never use your Weber Gas Barbecue under an
unprotected combustible roof or overhang.
■ The pressure regulator supplied with the Weber
Gas Barbecue must be used. This regulator is set
for 10.5 inches of water column (pressure).
■ Your Weber Gas Barbecue is not intended to be
installed in or on recreational vehicles and/or boats.
■ This Weber Gas Barbecue is designed for use with
liquid propane (LP) gas only. Do not use with natural
(piped in city) gas. The valves, orifices, hose and
regulator are for LP gas only.
■ Do not use 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.
■ Do not use with charcoal fuel.
■ Keep any electrical supply cord and the fuel supply
■ 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.
hose away from any heated surface.
■ Keep the cooking area clear of flammable vapors
and liquids, such as gasoline, alcohol, etc., and
combustible materials.
■ The area around the LP tank must be free and clear
from debris.
■ Never store an extra (spare) LP tank under or near
For Installation in Canada
the Weber Gas Barbecue.
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).
6
Step 1
Assembly
Tools needed
Check package contents
Hammer
Cooking box
(assembly)
7/16 open-end or an adjustable wrench
Pliers
Lid
Block of wood
(assembly)
Phillips Screwdriver
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.")
LP tank
You will need a soap and water solution to check for gas
leaks. (See Step "Check for gas leaks.")
Note - The hardware size of nuts, bolts and screws is
given. For example "1/4-20 x 2 inch bolt" means a bolt
1/4 inch in diameter with 20 threads to the inch, 2 inches
long. On a small screw for example, "6-32 x 1/2 inch
screw" means a number 6 screw, with 32 threads to the
inch, 1/2 inch long.
Bottom tray
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.
Two cooking grates
LP tank filler adapter
Control panel
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Left frame
Tank panel assembly
Front panel
Right frame
Wheel frame
Leg frame
Catch pan holder
Catch pan
Frame connector
Molded work table
Two drip pans
Manifold bracket
Thermometer
Accessory rack
Warming rack
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Two wheels
Fuel scale assembly
Five Flavorizer Bars
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Check contents of hardware packs
Two plastic buttons
(actual size)
Two burner control knobs
Two 1/4-20 wing nuts
(actual size)
Two tool holders
Ten 1/4 inch nylon washers
Two hair pin cotters
Eight tubing plugs
(two are spares)
Two hinge pins
(hardware size: 1/4 x 1 1/2 inch clevis pin)
(actual size)
Two wheel hubcaps
Work table spacer
1/4-20 x 2 inch bolt
(actual size)
Two 1/4-20 x 1 3/4 inch bolts
(actual size)
1/4-20 keps nut
Six 1/4-20 x 1/2 inch bolts
(actual size)
Two Phillips screws/washers
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