Weber Genesis 5500 Series Owner's Manual
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Weber Genesis 5500 Series Owner's Manual

Weber Genesis 5500 Series Owner's Manual

Perma-mount natural gas barbecue
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GENESIS
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.
FOR YOUR SAFETY
Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
5500 Series
®
™
Serial Number
Please use this number in registering your warranty
and any correspondence with the factory.
WARNING: Do not try to light this
appliance without reading "Lighting"
instructions section of this manual.
THIS GAS APPLIANCE IS DESIGNED FOR
OUTDOOR USE ONLY.
FOR YOUR SAFETY
If you smell gas:
1. Shut off gas to the appliance.
2. Extinguish any open flame.
3. Open lid.
4. If odor continues, immediately call
your gas supplier or your fire
department.
86033
6/96

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Summary of Contents for Weber Genesis 5500 Series

  • Page 1 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.

  • Page 2: Warnings

    Do not put a barbecue cover or anything flammable on or in the storage area under the barbecue. Your Weber Gas Barbecue should never be used by children. You should exercise reasonable care when operating your Weber Gas Barbecue. It will be hot during cooking or cleaning, and should never be left unattended.

  • Page 3: Warranty & Patents

    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: Aluminum Castings, 10 years, Cooking Grates, 3 years,...

  • Page 4: Patents And Trademarks

    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. Genesis Gas Barbecues are covered under the following patent nos.: U.S.A. #4,677,964;...

  • Page 5: Table Of Contents

    Separate burners for temperature control. Crossover Ignition System with Gas Catcher Ignition Chamber. g) Weber Warm-Up Basket for additional cooking or warming space. h) FlameCheck Safety System automatically shuts off gas to the burners if the flame goes out.

  • Page 6: General Instructions

    Equipment). Storage The gas must be turned OFF at the natural gas supply when the Weber Gas Barbecue is not in use. Operating area WARNING: Only use this barbecue outdoors in a well ventilated area. Do not use in a garage, building, breezeway or any other enclosed area.
  • Page 7 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 American National Standards Institute (ANSI) Recommendations for gas supply installations: Connections:...
  • Page 8 Typical natural gas supply installation to a concrete patio or pad Accessible Locking Shut off Indoor Shut off Gas Supply Figure 1 CAUTION: Follow "General Specifications for Piping" in this manual. We recommend that this installation be done by a professional.
  • Page 9 Recommended concrete pad requirements 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. Note - Cubic feet is determined by multiplying length times width times depth and dividing by 1728. 20”...
  • Page 10 Method 2 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. Note - Use a 5/8 inch concrete drill bit for drilling the hole for the lag shield.

  • Page 11: Assembly

    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.
  • Page 12 Work table Two swing tables Left end panel (#1) Panels and doors are identified with removable stickers. Please leave on during assembly. Three back panels (#2) Right end panel (#3) Left hand glass door assembly (LH) Two right hand glass door assemblies (RH) Serving tray Barbecue gas supply line...
  • Page 13 Two left/right base panels Warm-Up Basket Five long Flavorizer Bars Seven short Flavorizer Bars Two cross brace assemblies Assemblies consist of: 7/16-14 square lock nuts (actual size) 7/16-14 x 2 1/2 inch hex head bolts (actual size) Mount plates Cross brace Right hand slide bar assembly Assembly consists of: Right hand slide bar...
  • Page 14 Right frame Upright frame Warming rack Cooking grate Narrow cooking grate Catch pan holder Catch pan Two drip pans Thermometer Check contents of hardware packs Three burner control knobs FlameCheck Button Three tool holders Eight tubing plugs (two are spares) Manifold bracket Four 10-24 x 1 3/4 inch machine screws (actual size)
  • Page 15 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...
  • Page 16 Step 2 Assemble base 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. Position a left/right base panel with a front/back base panel (flanges down) with left/right base panel on the outside.
  • Page 17 Step 4 Level the base 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. Figure 3 Turn the base assembly over or right side up. (Flanges are now up.) Set the base in position on your deck, concrete pad, or patio for anchoring.
  • Page 18 Step 5 Assemble the frame 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. Note - Work on carpeted area (on grass, or on one of the boxes) to protect the finish during frame assembly. Put the frame pieces so the leg tabs are up.
  • Page 19 Bushings Check the frame assembly down To avoid having to disassemble your Weber Gas Barbecue in a later step, check the positioning of both frame connectors before continuing with the assembly. Turn the frame assembly over. The bushings in the front frame connector should correspond with Figure 10.
  • Page 20 Step 10 Secure frame assembly to anchored base 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. CAUTION: The base must be anchored at all four anchor points prior to mounting the frame to the base.
  • Page 21 Repeat the procedure with the other two back panels. When in place they should be flush with each other. Figure 14. Left upright Figure 14 Step 13 Install bottom accessory trays You will need: two accessory trays. Set the accessory tray without the “notched” board between the two frame connectors.
  • Page 22 Figure 18. Add the keps nut. Tighten by holding the bolt with pliers while you tighten the nut with the 7/16 inch wrench. Figure 18 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: a) Do the valves fit into the ends of the burners? Figure 19 (a).
  • Page 23 Step 16 Install side burner You will need: side burner assembly, 5/8 inch, 11/16 inch and 3/4 inch or two adjustable wrenches. WARNING: No sealant is required on the side burner fitting. Do not use pipe dope, tape or any other type of sealant on the fitting or hose.

  • Page 24: Gas Supply

    Step 18 Connect barbecue gas supply line to the natural gas supply Note - We recommend that the connection between the barbecue gas supply line and the natural gas supply be flare to flare. A 3/8-inch flare fitting has been included with the barbecue gas supply line of your Perma-Mount Gas Barbecue.
  • Page 25 Step 20 Install igniter 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.
  • Page 26 Note - All factory made connections have been thoroughly checked for gas leaks. The burners have been flame tested. As a safety precaution you should recheck all fittings for leaks before using your Weber Gas Barbecue. Shipping and handling may have loosened or damaged a gas fitting.
  • Page 27 Step 23 Install brace panel and right end panel You will need: brace panel, right end panel, 1/4-20 x 1 1/2 inch bolt, 1/4-20 hex nut, 1/4-20 x 1/2 inch bolt, 1/4-20 wing nut, three nylon washers, gas line bracket and a 7/16 inch wrench. Position the right end panel with the flange at the top facing away from the barbecue, and the bottom flange toward the barbecue.
  • Page 28 Step 25 Insert Flavorizer Bars and Steam-N-Chips Smoker You will need: five long Flavorizer Bars, seven short Flavorizer Bars, Steam-N-Chips Smoker body and flue. Place the three long Flavorizer Bars in the rear of the cooking box. Insert the remaining two bars through the Steam-N-Chips Smoker flue and set into place in the cooking box.
  • Page 29 Step 27 Install left 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, left hand slide bar assembly, swing table, four nylon washers, screwdriver and pliers. Allow the slide bar to hang down. Push the support rod into the lower support bracket.
  • Page 30 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.
  • Page 31 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.
  • Page 32 Step 29 Install the bottom tray You will need: bottom tray, catch pan holder, catch pan and one drip pan. Finger grip on front edge of bottom tray Figure 43 Hook the ends of the catch pan holder into the hole in the bottom tray.
  • Page 33 Step 31 Install the control panel, burner control knobs, FlameCheck button and tool holders You will need: control panel, three burner control knobs, FlameCheck button and three tool holders. Hook the tool holders over the frame rail. Figure 47. Set the control panel in place over both frame braces. (Hold the Crossover Ignition button up while setting the control panel in place.) Place your thumbs over the control panel push-in buttons, and push them into the...
  • Page 34 Insert one end of the Weber Warm-Up Basket into the hole in the right end of the lid and the other end into the slot in the left end of the lid. Figure 50 (a).

  • Page 35: Operating Instructions

    If the gas supply line is found to be unserviceable, do not use barbecue. Replace using only Weber authorized replacement gas supply line. Order from Weber- Stephen Products Co., Customer Service Center or authorized dealer.

  • Page 36: Manual Lighting

    Manual Lighting 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.

  • Page 37: Cooking

    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.

  • Page 38: After A Period Of Nonuse

    After a Period of Nonuse 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.

  • Page 39: Steam-N-Chips Smoker

    To a lesser degree a "smoke" residue will accumulate on the inside of your Weber Gas Barbecue. This residue need not be removed and will not adversely affect the function of your barbecue.

  • Page 40: Annual Maintenance

    If the gas supply line is found to be unserviceable, do not use barbecue. Replace using only Weber authorized replacement gas supply line. Order from Weber- Stephen Products Co., Customer Service Center or authorized dealer.

  • Page 41: General Maintenance

    "General Maintenance".) General Maintenance 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.
  • Page 42 CAUTION: Do not enlarge the burner ports when cleaning. Replacing Main Burners a) Your Weber Gas Barbecue must be OFF and cool. b) Turn gas OFF at source. c) Remove control panel: take off the burner control knobs. Put your fingers under the edge of the control panel at the control panel push-in buttons and pull toward you.
  • Page 43 Check fit around burner Figure 18 CAUTION: If the Spider Stopper Guards do not fit tightly, contact Weber-Stephen Customer Service. CAUTION: After reinstalling the gas lines, they should be leak checked with a soap and water solution before using the barbecue. (See Step "Check for gas leaks".)

  • Page 44: Troubleshooting

    HIGH. Flames do not run the whole length of the burner tube. Inside of lid appears to be “peeling.” (Resembles paint peeling.) If the problem cannot be corrected using these methods, please contact Weber-Stephen Customer Service. TROUBLESHOOTING Check Inspect Weber Spider Stopper Guards for possible obstructions.
  • Page 45 Figure 21 Check Is gas supply off? Is the Front burner on? Is fuel hose bent or kinked? Inspect the Weber Spider Stopper Guard for possible obstructions. (Blockage of holes.) Does burner light with a match? Igniter wire Igniter Cure Turn supply on.
  • Page 46 19-20 22-24 33 34 43 44 20 39 71-72...

  • Page 47: Parts Listing

    Parts can be ordered directly from Weber-Stephen Products Co. by phone or mail. Note - Do not return parts to Weber-Stephen Products Co. without first contacting the Customer Service Center by phone or mail. Returning the part may not be necessary.
  • Page 48 INAL 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 to help you with any problems with parts or assembly.

This manual is also suitable for:

Genesis 5500 ng

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