Weber 500 - Manuals

6 General Instructions Your Weber Gas Barbecue is a portable outdoor cookingappliance. With the Weber Gas Barbecue you can grill,barbecue, roast and bake with results that are difficult toduplicate with indoor kitchen appliances. The closed lid andFlavorizer Bars produce that "outdoor" flavo...

7 Step 1 Check package contents Cooking box (assembly) Lid (assembly) Hose Bottom tray Two cooking grates Control panel Molded 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 Supplies needed You will need a soap and...

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 Check contents of hardware packs Two burner control knobs Two tool holders Eight tubing plugs(two are spares) Two hinge pins(hardware s...

9 Figure 1 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 otherhard, protected surface). Put one wheel on axle, WEBERside facing up, and tap on one hubcap.Figure 1. Repeat with othe...

10 Figure 3 Step 4 Continue frame assembly You will need: leg frame, wheel frame, four 1/4-20 x 1/2 inchbolts, four nylon washers and a 7/16 inch wrench. Place the leg frame onto the tabs of the left frame with thedimple to the inside. Figure 3. Place the wheel frame ontothe tabs of the right frame ...

11 Your Weber Gas Barbecue burner assembly has beenfactory assembled, pressure and flame tested. As a safetyprecaution 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 l...

12 Frame brace Manifold bracket Figure 9 Step 8 Install manifold bracket You will need: manifold bracket Hook the bracket onto the manifold at approximately thecenter of the length of the manifold. Place your handunderneath the bracket. Lift the manifold, bracket andcooking box slightly and hook the...

13 Typical natural gas supply installation. Figure 11. Test connections All connections and joints must be thoroughly tested forleaks in accordance with local codes and all listedprocedures in the latest edition of ANSI Z223.1.  DANGER Do not use an open flame to check for gasleaks. Be sure there a...

14 Figure 13 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 shouldcheck to be sure. Put the knob on each valve. Check bypushing down and turning clockwise. If they do not turnthey are off, proceed to the next step....

15 Step 14 Check for gas leaks  DANGER Do not use an open flame to check for gasleaks. Be sure there are no sparks oropen flames in the area while you checkfo r l e a k s . T h i s w i l l r e s u l t i n a f i r e o rexplosion which can cause serious bodilyinjury or death and damage to property. ...

16 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. Figure 17 Set the cooking grates onto the ledges in the cooking boxwith the rounded side up. Figure 18. Figure 18 Step ...

17 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 thebarbecue. Insert hinge pins from the outside. Insert hair pincotters into the small holes in the hinge pins. Figure 22. Hair pin cotter Hinge pin Figure 22 Ste...

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 frontof the frame connector. Figure 24 (a). Open the lid and set the warming rack into the slots at therear of the ...

19 Lighting Summary lighting instructions are on the control panel. 1 2 3 6 5 7 4 Figure 1 Crossover Ignition System 1) Open the lid. Figure 1. 2) Make sure all burner control knobs are turned OFF. (Push each burner control knob down and turnclockwise.) 3) Turn the gas supply valve on.  WARNING: Do...

20 Manual Lighting  WARNING: If the burner does not light, turn the Front burner control knob to OFF and wait 5 minutes to letthe gas clear before you try again or try to light with amatch. 7) After the FRONT burner is lit you can turn on the other burner. Note - Always light the FRONT burner first...

22 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 witha wrench and recheck for leaks with soap and watersolution. If a leak persists after retightening the fitting, turn OFFthe gas. DO NO...

23 General Maintenance Weber Spider Stopper Guards Your Weber Gas Barbecue, as well as any outdoor gasappliance, is a target for spiders and other insects. Theycan nest in the venturi section of the burner tubes. Thisblocks the normal gas flow, and can cause the gas to flowback out of the air shutte...

Figure 11 24 24 View from behindcooking box Wing nuts Figure 10 Guide screw Crossover tube Figure 12 Figure 9 d) Unlatch the Spider Stopper Guards and remove. Figure 9. h) To reinstall the burners, reverse steps c) through g). g) Lift and twist the burner assembly slightly, to separate the crossover...

25 i) Reinstall the Spider Stopper Guards. Slightly rotatethe Spider Stopper Guards so that the seams are inline with the Venturi fins. There should be no gaps inthe seams or in the fit around the burners and valves.Figure 14. Venturi fin Figure 14 Check fitaround valve Check fit around burner Figur...

26 Problem Burners burn with a yellow or orange flame, inconjunction with the smell of gas. Burner does not light, or flame is low in HIGHposition. Experiencing flare-ups:  CAUTION: Do not line the bottom tray with aluminum foil. Burner flame pattern is erratic. Flame is lowwhen burner is on HIGH. ...

29 1 Lid (assembly) 2 Lid handle 3 Warming rack 4 Flavorizer bars (5) 5 Cooking grates (2) 6 Work table spacer 7 Work table 8 Tubing plugs (8) 9 1/4-20 x 2 inch bolt 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 pa...

A F INAL W ORD OF T HANKS 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 ...