Serial Number Please use this number in registering your warranty and any correspondence with the factory. GENESIS 5500 Series ® Perma-Mount Natural Gas Barbecue ™ Owner’s Manual ® WARNING: Follow all leak check procedures carefully in this manual prior to barbecue operation. Do this even if barbecue was dealer assembled. NOTICE TO INSTALLER: These instructions must be left with the owner and the owner should keep them for future use.
DANGER Failure to follow the Dangers, Warnings and Cautions contained in this Owner’s Manual may result in serious bodily injury or death, or in a fire or an explosion causing damage to property. WARNINGS ■ Do not store a spare or disconnected LP tank under or near this barbecue. ■ Improper assembly may be dangerous. Please carefully follow the assembly instructions in this manual.
WARRANTY Weber-Stephen Products Co. (Weber) 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: 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.
PATENTS AND TRADEMARKS © 1996 Weber. Weber, , Genesis, Flavorizer and Crossover are registered U.S. trademarks; Per ma-Mount, Gas Catcher, FlameCheck, Steam-N-Chips, Spider Stopper, and Warm-Up are U.S. trademarks of Weber-Stephen Products Co., 200 East Daniels Road, Palatine, IL 60067-6266. U.S.A. Printed in the U.S.A.
Contents WARNINGS ................................................................ 2 Warranty & Patents .................................................. 3-4 General Instructions.................................................... 6 Assembly ............................................................... 7-34 Operating Instructions Lighting........................................................ 35-37 Cooking ............................................................ 37 After a Period of Nonuse .........
General Instructions Storage Your Weber Gas Barbecue is a stationary 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. ■ Operating area The natural gas supply is easy to use and gives you more cooking control than charcoal fuel.
Notice Before Installation Contact your local municipality for any building codes regulating outdoor barbecue installations. In absence of local codes, you must conform to the latest edition of ANSI Z223.1. WE RECOMMEND THAT THIS INSTALLATION BE DONE BY A PROFESSIONAL. General Specifications for Piping Outside underground piping Outside underground piping may be copper tubing, type K or L (ASTM B88) or polyethylene plastic tube PE3306 (Minimum wall thickness .
Typical natural gas supply installation to a concrete patio or pad Typical natural gas supply installation over an existing post View from behind barbecue View from behind barbecue Outside Outside Accessible Locking Shut off Accessible Locking Shut off Inside Indoor Shut off Inside Gas Supply Indoor Shut off Figure 1 Figure 3 CAUTION: Follow "General Specifications for Piping" in this manual. WARNING: Turn off the natural gas supply at the source before working on the post.
Recommended concrete pad requirements Typical installation of the base for an existing concrete patio or a new pad We recommend a pad a minimum of 40 inches left to right, 20 inches front to back and 4 inches deep (1.85 cubic feet). Figure 4. After assembling the base (see Steps 2 and 3), position the base assembly on your concrete patio for mounting. Note - Cubic feet is determined by multiplying length times width times depth and dividing by 1728.
Method 2 Typical base installation for a wood deck A concrete lag bolt, a minimum of 3/8 inch x 2 1/2 inches long with a 3/8 inch diameter long lag shield and a 3/8 inch flat washer. Figure 7. After assembling the base according to the assembly instructions, position the base assembly on your deck for anchoring. Note - Use a 5/8 inch concrete drill bit for drilling the hole for the lag shield.
Assembly Step 1 Check package contents Tools needed Screwdrivers, regular and Cooking box (assembly) Phillips Hammer Lid (assembly) Two 7/16 inch, one 5/8, 11/16, and 3/4 inch open end or two adjustable wrenches ® ® Pliers Bottom tray Level Electric drill Front panel Supplies needed Accessory tray 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.
Work table Left frame Two swing tables Upright frame Left end panel (#1) 1 Brace panel Panels and doors are identified with removable stickers. Please leave on during assembly.
Right hand slide bar assembly Two left/right base panels Assembly consists of: Warm-Up Basket Right hand slide bar Five long Flavorizer Bars Support rod Seven short Flavorizer Bars Slide Two cross brace assemblies Left hand slide bar assembly Assemblies consist of: Assembly consists of: Left hand slide bar 7/16-14 square lock nuts (actual size) Support rod 7/16-14 x 2 1/2 inch hex head bolts (actual size) Slide Mount plates Side burner assembly Cross brace Burner grate Side burner knob Two sid
Check contents of hardware packs Right frame Three burner control knobs Upright frame FlameCheck Button Warming rack Three tool holders Cooking grate Eight tubing plugs (two are spares) Narrow cooking grate Manifold bracket Catch pan holder Four 10-24 x 1 3/4 inch machine screws (actual size) Catch pan Four 10-24 hex nuts (actual size) Two drip pans Two hinge pins (hardware size: 1/4 x 1 1/2 inch clevis pin) (actual size) Thermometer Five 1/4-20 x 2 inch bolts (actual size) Eleven 1/4-20 x 1/2 inch
1/4-20 keps nut Thirteen 1/4-20 hex nuts (actual size) Forty two nylon washers (actual size) Nine 1/4-20 x 1 1/2 inch bolts (actual size) Two hair pin cotters (actual size) Four 1/4 inch fender washers (actual size) Gas line bracket Four plastic buttons Two swing table end brackets 15
Step 2 Step 3 Assemble base Finish base assembly You will need: left/right base panels, front/back base panels, four 1/4-20 x 1/2 inch bolts, eight nylon washers and four 1/4-20 hex nuts. You will need: partial base assembly, two cross brace assemblies, four 1/4-20 x 1 1/2 inch bolts, four nylon washers, four 1/4 inch fender washers, four 1/4-20 hex nuts and two 7/16 inch wrenches. Position a left/right base panel with a front/back base panel (flanges down) with left/right base panel on the outside.
Step 4 Turn the base assembly over or right side up. (Flanges are now up.) Level the base Set the base in position on your deck, concrete pad, or patio for anchoring. To level, set a level on the top flange of a front/back base panel. Hold the mounting plate up and use a 5/8 inch wrench to turn the hex head of the leveling bolts until level. Figure 4. You will need: base assembly, level, 5/8 inch and 3/4 inch wrenches. Using the 3/4 inch wrench, loosen the locking nuts (square nuts). Figure 3.
Step 5 Step 6 Assemble the frame Continue frame assembly You will need: left frame, right frame, two nylon washers, two 1/4-20 x 1/2 inch bolts and a 7/16 inch wrench. You will need: frame assembly, two upright frames, front panel, four 1/4-20 x 1/2 inch bolts, four nylon washers and a 7/16 inch wrench. Note - Work on carpeted area (on grass, or on one of the boxes) to protect the finish during frame assembly.
Step 7 Step 8 Complete frame assembly Insert bottom tubing plugs You will need: partial frame assembly, one frame connector with bushings, one frame connector without bushings, four 1/4-20 x 2 inch bolts, four nylon washers and a 7/16 inch wrench. You will need: frame assembly, four tubing plugs and a hammer. Insert the tubing plugs into the ends of the two upright frames. To fully seat the plugs, you may have to tap them lightly with a hammer. Figure 9.
Step 10 Step 11 Secure frame assembly to anchored base Install left end panel You will need: completed frame assembly, four 1/4-20 x 1 1/2 inch bolts, eight nylon washers, four 1/4-20 hex nuts, four plastic buttons and a 7/16 inch wrench. You will need: frame assembly and left end panel (Number 1). Place the bottom of the left end panel on the upright frame lower cross piece. Set the end panel upright in place. Figure 12.
Step 14 Repeat the procedure with the other two back panels. When in place they should be flush with each other. Figure 14. Install side burner locks You will need: frame assembly, two side burner locks and a 7/16 inch wrench. Right upright Loosen the right rear 1/4 x 20 bolt. Install the side burner lock. The “U” shape cut out of the lock slips down over the bolt. Tighten with a wrench. Figure 16 (a). Loosen the right front 1/4 x 20 bolt. The side burner lock fits between the front panel and the frame.
Step 15 Your Weber Gas Barbecue burner assembly has been factory assembled, pressure and flame tested. As a safety precaution we recommend you check the burner alignment: Add cooking box You will need: frame assembly, cooking box assembly, 1/4-20 x 2 inch bolt, nylon washer, 1/4-20 keps nut, pliers and a 7/16 inch wrench. a) Do the valves fit into the ends of the burners? Figure 19 (a). Set the cooking box into the frame so the burner tubes are under the frame brace. Figure 17.
Step 16 Step 17 Install side burner Install manifold bracket You will need: side burner assembly, 5/8 inch, 11/16 inch and 3/4 inch or two adjustable wrenches. You will need: manifold bracket. Hook the bracket onto the manifold at the center burner valve. Figure 21. Place your hand underneath the bracket. Lift the bracket, manifold and cooking box slightly as a unit and hook onto the frame brace. Figure 21 (a). WARNING: No sealant is required on the side burner fitting.
Step 18 Step 19 Check that all burner valves are off Connect barbecue gas supply line to the natural gas supply You will need: one burner control knob. (Valves 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 show. Figure 23. Note - We recommend that the connection between the barbecue gas supply line and the natural gas supply be flare to flare.
Step 20 Install igniter Step 21 Purge air from gas lines Note - The igniter wires are already attached to the Gas Catcher Ignition Chamber and the igniter. This was done to factory test the ignition system. The igniter lock nut is on the igniter. Insert the top of the igniter up through the large part of the key hole in the frame brace. Loosen the igniter lock nut and slide the igniter into the small part of the keyhole. Tighten the igniter lock nut. Figure 24.
Step 22 Check: Check for gas leaks a) Barbecue gas supply line to FlameCheck valve connection. Figure 27 (a). DANGER b) Manifold to side burner hose connection. Figure 27 (b). Do not use an open flame to check for gas leaks. Be sure there are no sparks or open flames in the area while you check for leaks. This will result in a fire or explosion which can cause serious bodily injury or death and damage to property. c) Barbecue gas supply line to natural gas supply connection. Figure 27 (c).
Step 23 Put a nylon washer on a 1/4-20 x 1 1/2 inch bolt, and insert through the brace and end panel assembly and the frame brace. Add the gas line bracket and hex nut. Tighten with the 7/16 inch wrench. Figure 30. The side burner hose should be at the top front of the right end panel.
Step 25 Step 26 Insert Flavorizer Bars and Steam-N-Chips Smoker Install cooking grates You will need: five long Flavorizer Bars, seven short Flavorizer Bars, Steam-N-Chips Smoker body and flue. The open "U" of the cooking grates goes down. The wide cooking grate goes to the right, narrow grate goes to the left side of the cooking box. Set the cooking grates onto the ledges in the cooking box. Figure 34. You will need: two cooking grates.
Step 27 Insert one end of the hinge rod into the hole in the frame. Figure 36 (a). Install left hand swing table Insert the other end into the hole in the swing table end bracket. Figure 36 (b). Hold the end bracket at an angle so the lower tab is inside the frame tube. Push the bracket into the frame. Check to see that the lower tab of the bracket is hooked in the slot in the frame. Figure 36 (c).
Step 28 Position slide bar assembly on the outside of the caster frame. Put a nylon washer on each 1 3/4 inch screw, insert screws through frame and slide bar assembly and add nylon washers and hex nuts. Tighten nuts using a screwdriver and pliers. Figure 37. Install right hand swing table You will need: swing table end bracket, two 10-24 hex nuts, two 10-24 x 1 3/4 inch machine screws, right hand slide bar assembly, swing table, four nylon washers, screwdriver and pliers.
Position slide bar assembly on the outside of the wheel frame. Put a nylon washer on each 1 3/4 inch screw, insert screws through frame and slide bar assembly and add nylon washers and hex nuts. Tighten nuts using a screwdriver and pliers. Figure 41. Insert one end of the hinge rod into the hole in the frame. Figure 40 (a). Insert the other end into the hole in the swing table end bracket. Figure 40 (b). Hold the end bracket at an angle so the lower tab is inside the frame tube.
Step 29 Install the bottom tray Step 30 You will need: bottom tray, catch pan holder, catch pan and one drip pan. You will need: lid, two hinge pins and two hair pin cotters. Finger grip on front edge of bottom tray Install the lid Set the lid in place from the rear of the barbecue. Close and align the hinge at the rear. Insert hinge pins from the outside through the hinge. Insert hair pin cotters into the small holes in the hinge pins. Figure 46.
Step 31 Step 32 Install the control panel, burner control knobs, FlameCheck button and tool holders Secure the side burner Pull the right hand swing table up. Stand to the right side of the barbecue. Slightly pull back both side burner locks. Slide the side burner toward the control panel. The locks will snap into the slots in the front and back of the side burner. Figure 48. Caution: Make sure both locks have snapped into place.
Step 33 Step 34 Install glass doors Complete accessory installation You will need: one LH glass door assembly and two RH glass door assemblies. You will need: work table, serving tray, Warm-Up Basket, warming rack, thermometer, two tubing plugs and a hammer. Start with the LH door assembly. Insert the long hinge pin at the top of the door into the plastic bushing in the underside of the left frame. Insert the bottom (short) hinge pin into the bushing in the frame connector.
OPERATING INSTRUCTIONS Lighting 3) Turn the gas supply valve on. Summary lighting instructions are on the control panel. 4) Push Front burner control knob down and turn to START/HI. WARNING: Do not lean over open barbecue. Keep your face and body at least one foot away from the matchlight hole when lighting the barbecue.
Manual Lighting 5) Open the center glass door. Strike a match and put the flame into the matchlight hole in the front of the cooking box. 6) Push down and hold the FlameCheck button down. Summary lighting instructions are on the control panel. DANGER Failure to open lid while igniting the barbecue, or not waiting 5 minutes to allow the gas to clear if the barbecue does not light, may result in an explosive flame-up which can cause serious bodily injury or death.
Lighting the side burner Cooking The side burner has a separate ignition system from the main cooking box. You can adjust the FRONT, CENTER, 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, CENTER, and BACK burners. For example, to sear steaks you would use (HHH) (all burners at high).
After a Period of Nonuse Periodic Cleaning ■ CAUTION: Turn your Weber Gas Barbecue OFF and wait for it to cool before cleaning. The Weber Gas Barbecue should be checked for gas leaks and any obstructions in the burner tubes before using. (See Sections "General and Annual Maintenance.") ■ Check that the areas under the control panel and the bottom tray are free from debris that might obstruct the flow of combustion or ventilation air.
Using the Steam-N-Chips Smoker DANGER Do not use any flammable fluid in the Steam-N-Chips Smoker to ignite the wood. This will cause serious bodily injury. The Steam-N-Chips Smoker cooks with both Weber FireSpice Wood Chips and Chunks. For best results with faster cooking foods like steaks, burgers and chops, etc., we recommend using the FireSpice Chips because they ignite and create smoke faster. For longer cooking foods such as roasts, chicken and turkeys, etc.
Annual Maintenance Put the FlameCheck button on the FlameCheck valve. After a period of nonuse, we recommend that you perform the following maintenance procedures, for your safety. To perform leak checks: Turn the gas supply on. WARNING: Do not ignite burners while leak checking. WARNING: Check gas supply line before each use of barbecue for nicks or cracking. If the gas supply line is found to be unserviceable, do not use barbecue. Replace using only Weber authorized replacement gas supply line.
General Maintenance (a) (b) Weber Spider Stopper Guards Your 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 8. This could result in a fire in and around the air shutters, under the control panel, causing serious damage to your barbecue.
Main Burner Flame Pattern e) Unlatch the Spider Stopper Guards and remove. Figure 13. The Weber Gas Barbecue burners have been factory set for the correct air and gas mixture. The correct flame pattern is shown in Figure 10. Burner inside cooking box Tips occasionally yellowish Light blue Figure 13 Flames Dark blue f) Figure 10 If the flames do not appear to be uniform the length of the burner tube, follow the burner cleaning procedures.
ij) Crossover Ignition System Operations To reinstall burners, reverse steps c) through i). If the Crossover Ignition System fails to ignite the Front burner, light the Front burner with a match. If the Front burner lights with a match, then check the Crossover Ignition System. ■ Check that both the white and black ignition wires are attached properly. Figure 19. CAUTION: The burner openings must be positioned properly over the valve orifices. Figure 17a.
TROUBLESHOOTING Problem Check Cure Burners burn with a yellow or orange flame, in conjunction with the smell of gas. Inspect Weber Spider Stopper Guards for possible obstructions. (Blockage of holes.) Clean Weber Spider Stopper Guards. (See Section "Annual Maintenance".) Burner does not light, or flame is low in HIGH position. Is natural gas supply on? Turn on natural gas supply.
Side Burner Troubleshooting WARNING: Before attempting any troubleshooting steps, all gas controls and supply valves should be in the OFF position. Problem Check Cure Side burner does not light. Is gas supply off? Is the Front burner on? Turn supply on. Light front burner. Flame is low in HIGH position. Is fuel hose bent or kinked? Straighten hose. Flame is very yellow in conjunction with the smell of gas, Inspect the Weber Spider Stopper Guard for possible obstructions. (Blockage of holes.
1 53 54 ® ® 55 2 3 4-6 56 57 58 7 8 9 59 60 10 11 61 12 13 14 62 63 64 66 65 2 15 2 73 16 17 2 68 69 50 18 67 19-20 70 1 21 71-72 52 23 73 75 22-24 76 15 34 25 3 26 17 18 27 28 LH RH 29 RH 30 32 31 45 33 34 36 37 38 39 40 41 46 43 44 42 46 51 35 20 39 19 47 49 20 23 48 39 24
Parts List 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. All items are single quantities unless otherwise specified. Parts can be ordered directly from Weber-Stephen Products Co. by phone or mail.
A FINAL WORD OF THANKS Thank 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 to help you with any problems with parts or assembly. Call our toll free number 1-800-446-1071. For quicker service, please have your owner’s manual available for reference.
