Weber Spirit 500 series manual

W E B E R W E B E R SPIRIT ™ 500 Series LP Gas Barbecue Serial Number Please use this number in registering your warranty and any correspondence with the factory . Owner’ s Manual W ARNING: Do not try to light this appliance without reading "Lighting" instructions section of this manual. THIS GAS APPLIANCE IS DESIGNED FOR OUTDOOR USE [...]

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

3 Weber-Stephen Products Co. (W eber) hereby warrants to the ORIGINAL PURCHASER of this Weber Gas Barbecue that it will be free of defects in material and workmanship from the date of purchase as follows: Aluminum Castings, 10 years, Cooking Grates and Flavorizer Bars, 3 years, All Remaining Parts, 5 years, when assembled and operated in accordance[...]

© 1997 Weber . Weber , , 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 60067-6266. U.S.A. Printed in the U.S.A. P A TENTS AND TRADEMARKS 4[...]

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

6 General Instructions Y our 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 po[...]

7 Step 1 Check package contents Cooking box (assembly) Lid (assembly) LP tank Bottom tray 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 wood Supplies needed Y our LP tank is shipped empty for safety . After setting the LP fuel scale you will need to fill[...]

Left frame Right frame Wheel frame Leg frame Frame connector Molded work table Accessory rack W arming rack Five Flavorizer Bars T ank panel assembly Front panel Catch pan holder Catch pan T wo drip pans Manifold bracket Thermometer T wo wheels Fuel scale assembly 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) T en 1/4 inch nylon washers T wo hair pin cotters T wo wheel hubcaps Work table spacer 1/4-20 keps nut Check contents of hardware packs T wo burner control knobs T wo tool holders Eight tubing plugs (two are spares) T wo hinge pins (hardware size: 1/4 x 1 1/2 inch clevis pin) (a[...]

10 Figure 1 Step 2 Assemble wheel frame Y ou 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. W E B E R W E B E R Figur[...]

11 Figure 3 Step 4 Continue frame assembly Y ou 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. The fuel scale [...]

Y our 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 [...]

Frame brace Manifold bracket 13 Figure 9 Step 8 Install manifold bracket Y ou 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. Figu[...]

14 Step 10 Add fuel scale assembly Y ou 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. Fig[...]

15 Step 12 Set LP fuel scale Y ou will need: LP tank (empty). Note - F or accuracy , the fuel scale must be set with an empty tank. We utilize various LP tank manufacturers. Some of the tanks we receive have differing top collar assemblies. (The top collar is the metal protective ring around the valve.) One series of tanks mounts with the valve fac[...]

16 Route the hose so it will not interfere with the scale indicator rod. The hose and regulator are connected in the following manner: Slide back the collar of the quick disconnect on the tank valve. Push the male fitting of the regulator into the quick disconnect, and maintain pressure. Slide the collar closed. Figure 17 (a). Figure 17 (b) shows t[...]

17  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 recheck all fittings f or leaks before using y our Weber Gas Barbecue . Shipping and han[...]

18 Step 17 Install Flavorizer Bars and Cooking Grates Y ou 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 Y ou will need: bott[...]

19 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. 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 Step 20 Add tool holders, control panel and burner[...]

20 Step 21 Complete accessory installation Y ou 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 tab[...]

21 Lighting Summary lighting instructions are on the control panel. 1 3 2 4 7 6 8 5 Figure 1 Crosso ver Ignition System 1) Open the lid. Figure 1. 2) Check that the fuel scale reads more than “E”. Note - E = empty; F = full. 3) Make sure all burner control knobs are turned OFF . (Push control knob down and turn clockwise.)  W ARNING: The bur[...]

22 Manual Lighting 4) Turn the tank on by turning the tank valve counterclockwise. 5) Strike a match and put the flame into the matchlight hole in the front of the cooking box.  W ARNING: Do not lean o ver open barbecue . K eep y our face and bod y at least one f oot awa y fr om the matchlight hole when lighting the barbecue. 6) Push Front burne[...]

23 Cooking  W ARNING: Do not move the W eber Gas Barbecue when operating or hot. Y ou 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[...]

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

25 c) Connect the hose to the tank. Route the hose so it does not interfere with the scale indicator rod. Slide back the collar of the quick disconnect on the tank valve. Figure 5 (a). Push the male fitting of the regulator into the quick disconnect, and maintain pressure. Slide the collar closed. Figure 5 (b). If it does not engage or lock, repeat[...]

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 moderate 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 n[...]

27 Check: c) V alves to manifold connections. Figure 8 (c). d) The hose to regulator connection. Figure 8 (d).  W ARNING: If there is a leak at connections (b), (c) or (d), turn OFF the gas . DO NO T OPERA TE THE B ARBECUE. Contact W eber-Stephen Customer Service . When leak checks are complete, turn gas supply OFF at the source and rinse connec[...]

28 General Maintenance W eber Spider Stopper Guards Y our Weber Gas Barbecue, as well as any outdoor gas appliance, is a target for spiders and other insects. They can nest in the venturi section of the burner tubes. This blocks the normal gas flow , and can cause the gas to flow back out of the air shutter . Figure 9. This could result in a fire i[...]

29 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 Wing nuts Figure 15 Guide screw Figure 16 Crossover tube Figure 17 V enturi fin Figure 19 Check fit around valve Check f[...]

30 30  W ARNING: If the Spider Stopper Guards do not fit tightly , contact Weber -Stephen Customer Service .  CA UTION: A fter reinstalling 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”. Crosso ver Ignition System Operations If the Crossover Ignition Sys[...]

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

32 W E B E R W E B E R ® ® ® ® ® ® ® ® 1 2 3 4 5 7 9 8 11-12 15 16 13 18 19 20 21 23 24 25 26-29 47-51 56 46 44 42 41 40 39 37 36 35 33 32 31 52-53 45 43 22 17 12 30 38 10 14 6 34 55 54[...]

33 1 Lid (assembly) 2 Lid handle 3 W arming rack 4 Flavorizer bars (5) 5 Cooking grates (2) 6 Work table spacer 7 Work table 8 T ubing plugs (8) 9 1/4-20 x 2 inch bolt 10 Left frame 1 1 1/4-20 x 1/2 inch bolts (6) 12 1/4 inch nylon washers (1 1) 13 Leg frame 14 Bottom tray 15 Catch pan holder 16 Catch pan 17 Drip pans (2) 18 Accessory rack 19 Frame[...]

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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[...]