Weber 5500 manual

GENESIS ® 5500 Series Per ma-Mount ™ Natural Gas Barbecue Serial Number Please use this number in registering your w arranty and any correspondence with the f actory . Owner’ s Manual FOR Y OUR SAFETY Do not store or use gasoline or other flammable v apors and liquids in the vicinity of this or any other appliance. NO TICE T O INST ALLER: Thes[...]

2  D ANGER  Failure to f ollo w the Dangers, W arnings and Cautions contained in this Owner’ s Manual ma y result in serious bodily 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 ero[...]

3 W eber-Stephen Products Co. (W eber) hereby warr ants to the ORIGINAL PURCHASER of this W eber Gas Barbecue that it will be free of def ects in mater ial and workmanship from the date of purchase as f ollows: Aluminum Castings , 10 years , Cooking Grates , 3 years , Stainless Steel Flav orizer Bars, 5 y ears, All Remaining P ar ts, 5 y ears, when[...]

4 © 1996 W eber . Weber , , Genesis, Fla v orizer and Crossov er are registered U .S. trademarks; P er ma-Mount, Gas Catcher , FlameCheck, Steam-N-Chips , Spider Stopper , and W ar m-Up are U .S. trademarks of W eber-Stephen Products Co ., 200 East Daniels Road, P alatine, IL 60067-6266. U .S.A. Printed in the U .S.A. P A TENTS AND TRADEMARKS[...]

5 Contents WARNINGS ................................................................ 2 W arranty & P atents .................................................. 3-4 General Instructions .................................................... 6 Assembly ............................................................... 7-34 Operating Instructions Lighti[...]

6 General Instructions Y our W eber Gas Barbecue is a stationar y outdoor cooking appliance. With the W eber Gas Barbecue you can grill, barbecue, roast and bak e with results that are difficult to duplicate with indoor kitchen appliances. The closed lid and Flav or izer Bars produce that "outdoor" flav or in the food. The natural gas sup[...]

7 General Specifications f or Piping American National Standards Institute (ANSI) Recommendations for gas suppl y installations: Connections: ■ This barbecue is designed to operate at 7 inches of water column pressure (.2526 psi). ■ A manual shut-off v alv e must be installed outdoors , immediately ahead of any connections or change in pipe mat[...]

8 T ypical natural gas supply installation to a concrete patio or pad View from behind barbecue Accessible Locking Shut off Outside Inside Gas Supply Indoor Shut off Figure 1  CA UTION: Follow "General Specifications for Piping" in this manual. W e recommend that this installation be done by a prof essional.  CA UTION: Comb ustible [...]

9 Recommended concrete pad requirements W e recommend a pad a minimum of 40 inches left to right, 20 inches front to back and 4 inches deep (1.85 cubic f eet). Figure 4. Note - Cubic f eet is determined by multiplying length times width times depth and dividing by 1728. 20 ” 4 ” 40 ” Figure 4 If you use a concrete bag mix, use the mix f or ma[...]

10 Method 3 A 3/8 inch machine screw anchor , using a 3/8-16 x 1 1/2 inch machine screw and a flat w asher . Figure 8. Note - Use a 3/4 inch diameter concrete drill bit for drilling the hole f or the screw base . The machine screw anchor requires a setting tool. 3/8-16 x 1 1/2 machine screw 3/8 inch flat washer Mount plate 3/8 inch screw anchor Dri[...]

11 Assembl y T ools needed Screwdriv ers, regular and Phillips Hammer T wo 7/16 inch, one 5/8, 11/16, and 3/4 inch open end or two adjustab le wrenches Pliers Le v el Electric dr ill Supplies needed Y ou will need a soap and water solution to chec k f or gas leaks. (See Step "Chec k f or gas leaks.") Note - The hardware siz e of nuts, bol[...]

12 Left frame Upright frame Brace panel F rame connector with bushings F rame connector T wo front/back base panels Steam-N-Chips Smoker body Steam-N-Chips Smoker flue Steam-N-Chips Smoker w ater pan W ork table T wo swing tab les Left end panel (#1) P anels and doors are identified with remov able stick ers. Please leav e on dur ing assembly . Thr[...]

13 Right hand slide bar assembly Assembly consists of: Right hand slide bar Suppor t rod Slide Left hand slide bar assembly Assembly consists of: Left hand slide bar Suppor t rod Slide Side burner assembly Bur ner grate Side burner knob T wo side burner locks T wo left/r ight base panels W ar m-Up Basket Five long Fla vorizer Bars Se v en shor t Fl[...]

14 Check contents of hardw are packs Three burner control knobs FlameCheck Button Three tool holders Eight tubing plugs (two are spares) Manif old brac ket F our 10-24 x 1 3/4 inch machine screws (actual size) F our 10-24 he x nuts (actual size) T wo hinge pins (hardware siz e: 1/4 x 1 1/2 inch cle vis pin) (actual size) Five 1/4-20 x 2 inch bolts [...]

15 1/4-20 keps n ut Thir teen 1/4-20 hex nuts (actual size) F or ty two nylon w ashers (actual size) Nine 1/4-20 x 1 1/2 inch bolts (actual size) T wo hair pin cotters (actual size) F our 1/4 inch f ender washers (actual size) Gas line brac ket F our plastic buttons T wo swing tab le end brackets[...]

16 Step 2 Assemble base Y ou will need: left/right base panels, front/back base panels, f our 1/4-20 x 1/2 inch bolts, eight nylon w ashers and f our 1/4-20 he x nuts . P osition a left/right base panel with a front/back base panel (flanges down) with left/right base panel on the outside. Align the bottom holes . Slip a washer on a 1/4-20 x 1/2 inc[...]

17 Step 4 Le vel the base Y ou will need: base assembly , le v el, 5/8 inch and 3/4 inch wrenches. Using the 3/4 inch wrench, loosen the locking n uts (square nuts). Figure 3. Locking n ut Mount plate Figure 3 T ur n the base assembly ov er or r ight side up. (Flanges are now up .) Set the base in position on your dec k, concrete pad, or patio f or[...]

18 Step 5 Assemble the fr ame Y ou 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 - W ork on car peted area (on grass, or on one of the bo x es) to protect the finish during frame assembly . Put the frame pieces so the leg tabs are up . Put the r ight frame to y our right and left f[...]

19 Step 7 Complete frame assemb ly Y ou will need: par tial frame assembly , one frame connector with bushings , one frame connector without bushings , f our 1/4-20 x 2 inch bolts, four n ylon washers and a 7/16 inch wrench. Hold the frame connector with the b ushings between the two upright frames abov e the front panel. T ur n it so the bushings [...]

20 Step 10 Secure frame assemb ly to anchored base Y ou will need: completed frame assemb ly , four 1/4-20 x 1 1/2 inch bolts, eight n ylon washers , f our 1/4-20 he x nuts , f our plastic buttons and a 7/16 inch wrench.  CA UTION: The base must be anchored at all f our anchor points prior to mounting the frame to the base. See base installation[...]

21 Repeat the procedure with the other two bac k panels. When in place they should be flush with each other . Figure 14. Left upright Figure 14 Right upright Step 14 Install side burner locks Y ou will need: frame assemb ly , two side burner locks and a 7/16 inch wrench. Loosen the right rear 1/4 x 20 bolt. Install the side burner lock. The “U”[...]

22 Step 15 Add cooking bo x Y ou will need: frame assemb ly , cooking box assemb ly , 1/4-20 x 2 inch bolt, nylon w asher , 1/4-20 keps nut, pliers and a 7/16 inch wrench. Set the cooking bo x into the frame so the b urner tubes are under the frame brace . Figure 17. Burner tubes Frame brace Figure 17 Y our W eber Gas Barbecue burner assembly has b[...]

23 Step 16 Install side burner Y ou will need: side burner assembly , 5/8 inch, 11/16 inch and 3/4 inch or two adjustab le wrenches.  W ARNING: No sealant is required on the side burner fitting. Do not use pipe dope, tape or an y other type of sealant on the fitting or hose. Use an 11/16 inch wrench to remov e the protective brass cap from the s[...]

24 Figure 23 Step 19 Check that all b ur ner valv es are off Y ou will need: one burner control knob . (V alves are shipped in the OFF position, b ut you should check to be sure .) Put the knob on each v alv e. Chec k by pushing down and turning clockwise. If the y do not tur n they are off , proceed to the next sho w . Figure 23. Step 18 Connect b[...]

25 Step 21 Purge air from gas lines Y ou will need: one burner control knob and FlameCheck button. It is necessar y to bleed the air out of ne wly installed gas lines. T ur n gas supply ON at the source. Put on the FlameCheck b utton and the front bur ner control knob . Push the front burner control knob down and turn to HI. Push FlameCheck b utton[...]

26 Step 22 Check f or gas leaks  W ARNING: Y ou should check f or gas leaks every time you disconnect and reconnect a gas fitting. Note - All f actor y made connections hav e been thoroughly check ed for gas leaks. The b ur ners hav e been flame tested. As a saf ety precaution you should recheck all fittings f or leaks before using y our Weber G[...]

27 Step 23 Install brace panel and right end panel Y ou will need: brace panel, right end panel, 1/4-20 x 1 1/2 inch bolt, 1/4-20 he x nut, 1/4-20 x 1/2 inch bolt, 1/4-20 wing nut, three nylon w ashers, gas line brac ket and a 7/16 inch wrench. P osition the right end panel with the flange at the top f acing aw ay from the barbecue, and the bottom [...]

28 Step 25 Inser t Flav orizer Bars and Steam-N-Chips Smoker Y ou will need: five long Fla vorizer Bars, se ven short Flav or izer Bars, Steam-N-Chips Smok er body and flue. Place the three long Flav or izer Bars in the rear of the cooking bo x. Inser t the remaining two bars through the Steam-N-Chips Smoker flue and set into place in the cooking b[...]

29 Step 27 Install left hand s wing table Y ou will need: s wing table end br ack et, two 10-24 hex nuts, tw o 10-24 x 1 3/4 inch machine screws , left hand slide bar assembly , s wing table , f our nylon w ashers, screwdriv er and pliers. Allow the slide bar to hang do wn. Push the suppor t rod into the lower support brack et. Figure 35 (a). Swing[...]

30 P osition slide bar assembly on the outside of the caster frame. Put a n ylon washer on each 1 3/4 inch screw , inser t screws through frame and slide bar assemb ly and add nylon w ashers and he x nuts . Tighten nuts using a screwdriv er and pliers. Figure 37. Figure 37 View from front of barbecue Notch to the front Slide bar Step 28 Install rig[...]

31 Figure 41 Figure 42 P osition slide bar assembly on the outside of the wheel fram e. Put a nylon w asher on each 1 3/4 inch screw , inser t screws through frame and slide bar assembly and add nylon w ashers and he x nuts . Tighten nuts using a screwdriv er and pliers. Figure 41. T o lower table: Pull support rod up to disengage slide lock and lo[...]

32 Step 30 Install the lid Y ou will need: lid, two hinge pins and two hair pin cotters . Set the lid in place from the rear of the barbecue. Close and align the hinge at the rear . Inser t hinge pins from the outside through the hinge. Insert hair pin cotters into the small holes in the hinge pins. Figure 46. Figure 46 Hair pin cotter Hinge pin St[...]

33 Step 31 Install the control panel, burner control knobs, FlameCheck b utton and tool holders Y ou will need: control panel, three burner control knobs, FlameCheck b utton and three tool holders. Hook the tool holders ov er the frame rail. Figure 47. Set the control panel in place ov er both frame braces. (Hold the Crossov er Ignition button up w[...]

34 (b) Figure 50 (c) (d) (e) (f) Step 33 Install glass doors Y ou will need: one LH glass door assembly and tw o RH glass door assemblies . Star t with the LH door assembly . Inser t the long hinge pin at the top of the door into the plastic bushing in the underside of the left frame. Insert the bottom (shor t) hinge pin into the bushing in the fr [...]

35 Lighting Summar y lighting instructions are on the control panel. Crosso ver Ignition System Note - The Crossov er Ignition System ignites the Front burner with a spark from the igniter electrode inside the Gas Catcher Ignition Chamber . Y ou generate the energy f or the spark by pushing the Crossov er Ignition button until it clicks .  W ARN[...]

36 5) Open the center glass door . Str ike a match and put the flame into the matchlight hole in the front of the cooking bo x. 6) Push down and hold the FlameChec k button do wn. Note - Gas is supplied to the burner only when the FlameCheck b utton is depressed. Observe if front b urner has ignited by looking through matc hlight hole. If the burne[...]

37 Lighting the side b urner The side burner has a separate ignition system from the main cooking bo x. The side burner will onl y operate when the Front burner is lit. 1) Open the side bur ner lid. Figure 3. 2) Push down and tur n the side burner control valv e ON. 3) Push the side bur ner igniter button se veral times so it clicks each time . [...]

38 After a P eriod of Nonuse ■ The W eber Gas Barbecue should be check ed for gas leaks and any obstructions in the burner tubes bef ore using. (See Sections "General and Annual Maintenance.") ■ Check that the areas under the control panel and the bottom tra y are free from debr is that might obstruct the flow of combustion or v entil[...]

39 Using the Steam-N-Chips Smoker The Steam-N-Chips Smoker cooks with both W eber FireSpice W ood Chips and Chunks. F or best results with f aster cooking f oods like steaks , burgers and chops, etc., we recommend using the FireSpice Chips because the y ignite and create smoke f aster . For longer cooking f oods such as roasts, chic k en and turkey[...]

40 Annual Maintenance After a period of nonuse, we recommend that y ou perf orm the following maintenance procedures , f or y our saf ety .  W ARNING: Check gas suppl y line before eac h use of barbecue for nic ks or cracking. If the gas supply line is found to be unserviceable, do not use barbecue. Replace using only W eber authorized replaceme[...]

41 Inspection and Cleaning of the W eber Spider Stopper Guards T o inspect the Spider Stopper Guards, remov e the control panel, and look to see if they ha ve dust or dir t on their outside surf aces. If the y do, brush off the outside surf ace of the Spider Stopper Guards with a soft bristle brush (an old toothbr ush, f or e xample). Check that th[...]

42 e) Unlatch the Spider Stopper Guards and remov e. Figure 13. f) Use an adjustable wrench to remo v e the ther mocouple from the FlameCheck v alve. g) Remov e the manifold brac ket and unscrew the tw o thumb screws that hold the manif old to the cooking bo x. Pull the manif old and v alve assemb ly out of the burners and carefully set it down. Fi[...]

43 ij) T o reinstall burners, re v erse steps c) through i). V entur i fin Check fit around b ur ner Figure 18 Check fit around valv e Crosso ver Ignition System Operations If the Crossov er Ignition System fails to ignite the F ront burner , light the F ront burner with a match. If the F ront burner lights with a match, then check the Crosso v er [...]

44 Prob lem Burners b urn with a yello w 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 th[...]

45 Side Burner Maintenance  W ARNING: All gas controls and suppl y valves should be in the OFF position. Check igniter: Remov e side burner cov er . T o remov e side burner cov er , remov e control knob and screws that hold cov er to bottom. Figure 21. Make sure wire is connected between igniter and electrode. Chec k that igniter lock n ut is ti[...]

46 ® ® ® ® ® ® ® ® 1 2 3 7 8 9 10 11 12 13 14 15 16 19-20 22-24 15 34 26 27 31 32 33 34 23 43 44 47 49 20 23 24 18 71-72 50 69 68 70 65 63 64 62 61 60 59 57 56 55 54 53 2 2 2 3 LH RH RH 21 18 25 29 30 48 58 67 39 73 73 1 66 75 4-6 19 20 39 46 51 45 36 37 38 39 40 41 42 35 76 52 17 17 28[...]

47 1 Lid (assembly) 2 Weber W ar m-Up Basket 3 Warming rack 4 Steam-N-Chips Smoker body 5 Steam-N-Chips Smoker flue 6 Steam-N-Chips Smoker water pan 7 Stainless Steel Shor t Flav or izer Bars (7) 8 Stainless Steel Long Flavorizer Bars (5) 9 Narrow cooking grate 10 Wide cooking grate 11 Ser ving tra y 12 W ork table (Grey) 13 Back panels (3) 14 T ub[...]

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 har d to pr oduce the highest quality pr oducts for your satisfaction. While we give much attention to our pr oducts, an occasional err or may occur . Our knowledgeable Customer Service staf f is pr epared to help you with any pr oblems with par[...]