Weber 500 Series - Manual

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) LP tank Bottom tray Two cooking grates LP tank filler adapter Control panel Assembly Tools needed Hammer 7/16 open-end or an adjustable wrench Pliers Block of wood Phillips screwdriver Supplies needed Your LP tank is shipped empty...

Two plastic buttons(actual size) Two 1/4-20 wing nuts(actual size) Eleven 1/4 inch nylon washers Two hair pin cotters Two wheel hubcaps 1/4-20 keps nut Two phillips screws/washers Check contents of hardware packs Two burner control knobs Two tool holders Eight tubing plugs(two are spares) Two hinge ...

10 Figure 1 W E B E R W EB ER 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 otherhard, protected surface). Put one wheel...

11 Figure 3 Figure 4 Figure 5 View from rear of barbecue Dimples to the inside Fuel scaledecal Plastic buttons 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 light...

Guide screw (a) (b) (c) Wing Nuts View frombehindcookingbox Figure 8 12 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 thewasher on the bolt. Take the spacer bracket and hold it upto th...

Frame brace Manifold bracket 13 Figure 9 Figure 10 Figure 11 Frameconnector Cross brace Tank panel tabs Slots in frame brace Frame brace 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 ...

14 Figure 12 View from front right View from front left F E F E Figure 13 Igniter lock nut Small part of keyholein frame brace Frame brace Frame brace Keyhole inframe brace (a) (b) (c) Step 10 Add fuel scale assembly You will need: fuel scale assembly, two 1/4-20 wing nutsand two nylon washers. Slip...

15 F E F E F E Figure 14 Tank lockwing nut (a) (b) Scale settingwing nut Step 12 Set LP fuel scale You will need: LP tank (empty). Note - For accuracy, the fuel scale must be set with anempty tank. We utilize various LP tank manufacturers. Some of thetanks we receive have differing top collar assemb...

16 Figure 17 Turn so regulator ventdoes not collect water Hose Tank lockwing nut Quick disconnectengaged Valve handwheelclose clockwise Tank valve Collar Malefitting Pressurerelief valve Tank Regulator Regulatorvent (a) (b) (c) Figure 16 Figure 15 F E Step 15 Connect LP tank  WARNING: Make sure tha...

17 Figure 18 (a) Figure 19 (c) (d) (b)  WARNING: You should check for gas leaks every time you disconnect and reconnect a gas fitting. Note - All factory made connections have been thoroughlychecked for gas leaks. The burners have been flametested. As a safety precaution you should recheck allfitti...

18 Figure 20 Figure 21 Figure 23 Figure 22 Figure 24 Bottom tray Finger grip on frontedge of bottom tray Finger grip Front side of catch pan holder Step 17 Install Flavorizer Bars and Cooking Grates You will need: five Flavorizer Bars and two cooking grates. Set the Flavorizer Bars side to side in t...

19 Hair pin cotter Hinge pin Figure 25 Figure 26 Tool holders Insert in frame brace Control panel Phillips screws/ washers (a) (b) Step 19 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 fro...

20 Step 21 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 27 (a). Open the lid and set the warming rack into the slots at therear of the ...

21 1 3 2 4 7 6 8 5 Figure 1 Crossover Ignition System OPERATING INSTRUCTIONS Lighting Summary lighting instructions are on the control panel.  DANGER Fa i l u r e t o o p e n l i d w h i l e i g n i t i n g t h ebarbecue , or not waiting 5 minutes toallow the gas to clear if the barbecuedoes not li...

22 1 3 2 4 5 8 6 7 Figure 2 Manual Lighting 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.  WARNING: Do not lean over open barbecue. Keep your face and body at least one fo...

23 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 cookbookuses these notations to describe the settings of the FR...

24 Scale setting wing nut Tank lockwing nut Tank valve Collar (a) (b) Figure 3 Figure 4 Refilling the LP tank We recommend that you refill before the scale indicatorreaches "E". Note - If you run out of fuel, check the indicator settingand/or adjust the fuel scale indicator setting with the ...

25 Figure 6 Male fitting Regulator Collar Quick disconnectengaged Figure 5 (a) (b) c) Connect the hose to the tank. Route the hose so itdoes not interfere with the scale indicator rod. Slideback the collar of the quick disconnect on the tankvalve. Figure 5 (a). Push the male fitting of theregulator ...

26 26 Safe handling tips for LP Gas ■ Liquid Propane (LP) gas is a petroleum product as aregasoline and natural gas. LP gas is a gas at regulartemperatures and pressures. Under moderatepressure, inside a cylinder, LP gas is a liquid. As thepressure is released the liquid readily vaporizes andbecomes...

Annual Maintenance After a period of nonuse we recommend that you performthe following maintenance procedures for your safety.  WARNING: Check hose before each use of barbecue for nicks, cracking, abrasions or cuts. If the hose isfound to be damaged in any way, do not use thebarbecue. Replace using...

28 Burner insidecooking box Figure 11 Dark blue Light blue Tips occasionally yellowish Figure 9 Venturi Air shutter Venturi fin Weber SpiderStopper Guard Figure 10 Flames Figure 12 Figure 13 General Maintenance Weber Spider Stopper Guards Your Weber Gas Barbecue, as well as any outdoor gasappliance,...

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 theburners and carefully set it down. Figure 15. View from behindcooking box Wing nuts Figure 15 Guide screw Figure 16 Crossover tube Figure 17 Figure...

30 30 Figure 20 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 watersolution before using the barbecue. See Step“Checkfor gas leaks”. ■ ...

Problem Burners burn with a yellow or orange flame, in conjunction with the smell of gas. Burners do not light. -or-Burners have a small flickering flame in theHIGH position. -or-Barbecue temperature only reaches 250˚ to300˚ degrees in the HIGH position. Burner does not light, or flame is low inHIGH...

33 1 Hair Pin Cotters (2) 2 Hinge pins (2) 3 Left Endcap 4 Shroud (Assembly) 5 Lid Handle 6 Warming rack 7 Flavorizer bars (5) 8 Cooking grates (2) 9 Work table 10 Tubing plugs (8)11 1/4-20 x 2 inch bolt 12 Spacer bracket13 Left frame 14 1/4-20 x 1/2 inch bolts (6) 15 1/4 inch nylon washers (11) 16 ...

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 ...