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Weber 5500 Owner's Manual

Manual is about: Weber Gas Burner Owner's Manual 5500

Summary of 5500

  • Page 1

    Genesis ® 5500 series perma-mount ™ natural gas barbecue serial number please use this number in registering your warranty and any correspondence with the factory. Owner’s manual for your safety do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other a...

  • Page 2: Danger

    2 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 assemb...

  • Page 3: Warranty

    3 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, stainless steel flavorizer bars, 5 years, ...

  • Page 4: Patents and Trademarks

    4 © 1996 weber. Weber, , genesis, flavorizer and crossover are registered u.S. Trademar ks; 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 barbecue...

  • Page 5: Contents

    5 contents warnings ................................................................ 2 warranty & patents .................................................. 3-4 general instructions.................................................... 6 assembly ..........................................................

  • Page 6: General Instructions

    6 general instructions 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 ...

  • Page 7: General Specifications

    7 general specifications for piping american national standards institute (ansi) recommendations for gas supply installations: connections: ■ this barbecue is designed to operate at 7 inches of water column pressure (.2526 psi). ■ a manual shut-off valve must be installed outdoors, immediately ahead...

  • Page 8

    8 typical 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 caution: follow "general specifications for piping" in this manual. We recommend that this installation be done by a professio...

  • Page 9

    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” 4” 40” figure 4 if you use a...

  • Page 10

    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 washer. Figure 8. Note - use a 3/4 inch diameter concrete drill bit for drilling the hole for the screw base. The machine screw anchor requires a setting tool. 3/8-16 x 1 1/2 machine screw 3/8 inch flat...

  • Page 11: Assembly

    11 assembly tools needed screwdrivers, regular and phillips hammer two 7/16 inch, one 5/8, 11/16, and 3/4 inch open end or two adjustable wrenches pliers level electric drill supplies needed you will need a soap and water solution to check for gas leaks. (see step "check for gas leaks.") note - the ...

  • Page 12

    12 left frame upright frame brace panel frame connector with bushings frame connector two front/back base panels steam-n-chips smoker body steam-n-chips smoker flue steam-n-chips smoker water pan work table two swing tables left end panel (#1) panels and doors are identified with removable stickers....

  • Page 13

    13 right hand slide bar assembly assembly consists of: right hand slide bar support rod slide left hand slide bar assembly assembly consists of: left hand slide bar support rod slide side burner assembly burner grate side burner knob two side burner locks two left/right base panels warm-up basket fi...

  • Page 14

    14 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) four 10-24 hex nuts (actual size) two hinge pins (hardware size: 1/4 x 1 1/2 inch clevis pin) ...

  • Page 15

    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

    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. Align the bottom ...

  • Page 17

    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. Locking nut mount plate figure 3 turn the base assembly over or right side up. (flanges are now up.) set the base in position on y...

  • Page 18

    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. Put th...

  • Page 19

    19 step 7 complete frame assembly 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. Hold the frame connector with the bushings between the two upright frames above the...

  • Page 20

    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 ...

  • Page 21

    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 right upright step 14 install side burner locks you will need: frame assembly, two side burner locks and a 7/16 inch wrench. Loosen the right rear 1/4 x 20 bo...

  • Page 22

    22 step 15 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. Set the cooking box into the frame so the burner tubes are under the frame brace. Figure 17. Burner tubes frame brace figure 17 your web...

  • Page 23

    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. Use an 11/16 inch wrench to re...

  • Page 24

    24 figure 23 step 19 check that all burner valves are off 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 ...

  • Page 25

    25 step 21 purge air from gas lines you will need: one burner control knob and flamecheck button. It is necessary to bleed the air out of newly installed gas lines. Turn gas supply on at the source. Put on the flamecheck button and the front burner control knob. Push the front burner control knob do...

  • Page 26

    26 step 22 check for gas leaks warning: you should check for gas leaks every time you disconnect and reconnect a gas fitting. 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...

  • Page 27

    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 fac...

  • Page 28

    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 fl...

  • Page 29

    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 sup...

  • Page 30

    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. Figure 37. Figure 37 view from front of barbecue notch t...

  • Page 31

    31 figure 41 figure 42 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. To lower table: pull suppo...

  • Page 32

    32 step 30 install the lid you 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. Insert hinge pins from the outside through the hinge. Insert hair pin cotters into the small holes in the hinge pins. Fig...

  • Page 33

    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 brac...

  • Page 34

    34 (b) figure 50 (c) (d) (e) (f) step 33 install glass doors you will need: one lh glass door assembly and two rh glass door assemblies. 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 (s...

  • Page 35: Lighting

    35 lighting summary lighting instructions are on the control panel. Crossover ignition system note - the crossover ignition system ignites the front burner with a spark from the igniter electrode inside the gas catcher ignition chamber. You generate the energy for the spark by pushing the crossover ...

  • Page 36: To Extinguish

    36 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. Note - gas is supplied to the burner only when the flamecheck button is depressed. Observe if front burner has ignited by loo...

  • Page 37: Lighting The Side Burner

    37 lighting the side burner the side burner has a separate ignition system from the main cooking box. The side burner will only operate when the front burner is lit. 1) open the side burner lid. Figure 3. 2) push down and turn the side burner control valve on. 3) push the side burner igniter button ...

  • Page 38: After A Period of Nonuse

    38 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...

  • Page 39: Using The Steam-N-Chips

    39 using the steam-n-chips smoker 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 fo...

  • Page 40: Annual Maintenance

    40 annual maintenance after a period of nonuse, we recommend that you perform the following maintenance procedures, for your safety. 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 usi...

  • Page 41: General Maintenance

    41 inspection and cleaning of the weber spider stopper guards to inspect the spider stopper guards, remove the control panel, and look to see if they have dust or dirt on their outside surfaces. If they do, brush off the outside surface of the spider stopper guards with a soft bristle brush (an old ...

  • Page 42

    42 e) unlatch the spider stopper guards and remove. Figure 13. F) use an adjustable wrench to remove the thermocouple from the flamecheck valve. G) remove the manifold bracket and unscrew the two thumb screws that hold the manifold to the cooking box. Pull the manifold and valve assembly out of the ...

  • Page 43

    43 ij) to reinstall burners, reverse steps c) through i). Venturi fin check fit around burner figure 18 check fit around valve crossover ignition system operations if the crossover ignition system fails to ignite the front burner, light the front burner with a match. If the front burner lights with ...

  • Page 44: Troubleshooting

    44 problem burners burn 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: caution: do not line the bottom tray with aluminum foil. Burner flame pattern is erratic. Flame is low when burner is on high....

  • Page 45: Side Burner Maintenance

    45 side burner maintenance warning: all gas controls and supply valves should be in the off position. Check igniter: remove side burner cover. To remove side burner cover, remove control knob and screws that hold cover to bottom. Figure 21. Make sure wire is connected between igniter and electrode. ...

  • Page 46

    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.

  • Page 47: Parts List

    47 1 lid (assembly) 2 weber warm-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 short flavorizer bars (7) 8 stainless steel long flavorizer bars (5) 9 narrow cooking grate 10 wide cooking grate 11 serving tray 12 wo...

  • Page 48

    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 ...