Weber 500 Series manual

W E B E R W E B E R 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 ONL Y . NO TICE TO INST ALLER: These instructions must be left with the o wner and the owner should keep them for future use. FOR Y OUR SAFETY If y ou smell gas: 1.[...]

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 W ARRANTY 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 [...]

© 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. 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 ............................................................... 7-18 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) Hose Bottom tray T wo cooking grates Control panel Molded work table Five Flavorizer Bars Assembl y T ools needed Hammer 7/16 and 3/4 inch open-end or an adjustable wrench Pliers Block of wood Supplies needed Y ou will need a soap and water solution to check for gas leaks. (See S[...]

Left frame Right frame Wheel frame Leg frame Frame connector Accessory rack W arming rack Front panel Catch pan holder Catch pan T wo drip pans Thermometer T wo wheels 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) (actual [...]

9 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 Figure[...]

10 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. Figure 3. The l[...]

11 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 on[...]

12 Frame brace Manifold bracket 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[...]

13 T ypical natural gas supply installation. Figure 11. T est connections All connections and joints must be thoroughly tested for leaks in accordance with local codes and all listed procedures in the latest edition of ANSI Z223.1.  D ANGER Do not use an open flame to chec k for gas leaks. Be sure there are no sparks or open flames in the area w[...]

14 Figure 13 Step 12 Check that all burner valves are off Y ou will need: one burner control knob. V alves are shipped in the OFF position, but you should check to be sure. Put the knob on each valve. Check by pushing down and turning clockwise. If they do not turn they are off, proceed to the next step. Figure 13. Step 11 Install igniter Note - Th[...]

15 Step 14 Check for gas leaks  D ANGER Do not use an open flame to chec k for gas leaks. Be sure there are no sparks or open flames in the area while y ou chec k for leaks. This will result in a fire or explosion whic h can cause serious bodily injury or death and damage to property .  W ARNING: Do not ignite burner s while leak chec king. C[...]

16 Step 15 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 17. Figure 17 Set the cooking grates onto the ledges in the cooking box with the rounded side up. Figure 18. Figure 18 Step 16 Install the bottom tray Y ou will need: bott[...]

17 Step 17 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 22. Hair pin cotter Hinge pin Figure 22 Step 18 Add tool holders, control panel and burner[...]

18 Step 19 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 24 (a). Open the lid and set the warming rack into the slots at the rear of the cooking box. Figure 24 (b). Set the work tab[...]

19 Lighting Summary lighting instructions are on the control panel. 1 2 3 6 5 7 4 Figure 1 Crosso ver 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 turn clockwise.) 3) Turn the gas supply valve on.  W ARNING: Do not lean o ver open barbecue. Keep y our fa[...]

20 Manual Lighting  W ARNING: If the b urner does not light, turn the Front burner contr ol knob to OFF and wait 5 minutes to let the gas clear bef ore you try a gain or try to light with a match. 7) After the FRONT burner is lit you can turn on the other burner . Note - Alwa ys light the FRONT burner first. The other burner ignites from the FRO[...]

21 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[...]

22 Check: a) Hose to manifold connection. Figure 3 (a).  W ARNING: If there is a leak at the hose to manifold connection, Figure 3 (a), retighten the hose fitting with a wrench and rechec k for leaks with soap and water solution. If a leak persists after retightening the fitting, turn OFF the gas . DO NO T OPERA TE THE BARBECUE. Contact W eber-S[...]

23 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 4. This could result in a fire i[...]

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

25 i) Reinstall the Spider Stopper Guards. Slightly rotate the Spider Stopper Guards so that the seams are in line with the V enturi fins. There should be no gaps in the seams or in the fit around the burners and valves. Figure 14. V enturi fin Figure 14 Check fit around valve Check fit around burner Figure 15 White wire Black wire  CA UTION: If[...]

26 Prob lem Burners b urn with a yellow or orange flame, in conjunction with the smell of gas. Burner does not light, or flame is low in HIGH position. Experiencing flare-ups:  CA UTION: Do not line the bottom tray with aluminum f oil. Burner flame pattern is erratic. Flame is low when burner is on HIGH. Flames do not run the whole length of the[...]

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28 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 48 42 46 45 40 38 37 36 35 33 32 31 29 28 27 41 39 22 17 11 26 34 10 14 30 6[...]

29 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 (9) 13 Leg frame 14 Bottom tray 15 Catch pan holder 16 Catch pan 17 Drip pans (2) 18 Accessory rack 19 Frame c[...]

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