Serial Number Please use this number in registering your warranty and any correspondence with the factory. GENESIS 5000 Series ® Propane Fixed Piping System 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 ■ Improper assembly may be dangerous. Please carefully follow the assembly instructions in this manual. ■ After a period of storage, and/or nonuse, the Weber Gas Barbecue should be checked for gas leaks and burner obstructions before using.
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; Spirit, Perma-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. Spirit 500, 700, and Genesis 1000-5500 Gas Barbecues are covered under one or more of the following patent nos.: U.S.
Contents WARNINGS ................................................................ 2 Warranty & Patents.................................................. 3-4 General Instructions.................................................... 6 Assembly ............................................................... 7-28 Operating Instructions Lighting ....................................................... 29-30 Cooking ............................................................ 31 Storage and/or Nonuse .............
General Instructions Storage Your 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 portable so you can easily change its location in your yard or on your patio. Portability means you can take your Weber Gas Barbecue with you if you move.
Assembly Step 1 Check package contents Tools needed Screwdrivers, regular Cooking box (assembly) and Phillips Hammer 7/16, 5/8, 11/16 and 3/4 inch open-end or two adjustable wrenches Lid (assembly) ® Pliers Hose Block of wood Supplies needed Bottom 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.
Left frame Work table Wheel frame Two swing tables Brace panel 1 Panels and doors are identified with removable stickers. Please leave on during assembly.
Right hand slide bar assembly Right frame Assembly consists of: Right hand slide bar Caster frame Support rod Warming rack Slide Manifold bracket Cooking grate Left hand slide bar assembly Narrow cooking grate Assembly consists of: Seven short Flavorizer Bars Left hand slide bar Catch pan holder Support rod Catch pan Slide Two drip pans Thermometer 9
Two wheel hubcaps (actual size) Side burner assembly Two hinge pins (hardware size: 1/4 x 1 1/2 inch clevis pin) (actual size) Burner grate Side burner knob Five 1/4-20 x 2 inch bolts (actual size) Two side burner locks 1/4-20 x 1 1/2 inch bolt (actual size) Check contents of hardware packs Six 1/4-20 x 1/2 inch bolts (actual size) Four 10-24 x 1 3/4 inch machine screws (actual size) Two 1/4-20 wing nuts (actual size) Twenty three 1/4 inch nylon washers (actual size) 1/4-20 keps nut (actual size)
Step 2 Step 3 Assemble wheels Assemble frame You will need: axle, two wheel hubcaps, two wheels, wheel frame, hammer and a block of wood. 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. Place one end of the axle on the block of wood (or other protected surface). Tap on one hubcap. 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.
Step 4 Step 5 Continue frame assembly Complete frame assembly You will need: frame assembly, wheel frame assembly, front panel, caster frame, four 1/4-20 x 1/2 inch bolts, four nylon washers and a 7/16 inch wrench. 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. Place the caster frame onto the tabs of the left frame with the dimple to the inside. Figure 3.
Step 6 Step 8 Insert casters Install left end panel You will need: frame assembly and two casters. You will need: frame assembly and left end panel. (Number 1) Push the casters firmly into the caster inserts in the ends of the caster legs. Figure 5. Place the bottom of the left end panel on the caster frame lower cross piece. Set the end panel upright in place. Figure 7.
Step 9 Step 10 Install the three back panels Install side burner locks You will need: frame assembly, two plastic buttons and the three back panels. (Number 2) You will need: frame assembly, 2 side burner locks and a 7/16 inch wrench. Place the bottom of one back panel on the back frame connector, notches to the top. Set in place to the far left, butting up against the caster frame. Repeat the procedure with the the other two back panels. Figure 8. Loosen the right rear 1/4 x 20 bolt.
Step 11 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 acorn nut, pliers and a 7/16 inch wrench. a) Do the valves fit into the ends of the burners? Figure 13 (a). Set the cooking box into the frame so the burner tubes are under the frame brace. Figure 11.
Step 12 Typical propane gas supply installation. Figure 14. Install gas supply Gas supply General Specifications for Piping Inside wall Note - Contact your local municipality for building codes regulating outdoor gas 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. Outside wall Some of the following are general requirements taken from ANSI Z223.1, for gas supply installations.
Step 13 Step 15 Check that all burner valves are off Install side burner You will need: one burner control knob. You will need: side burner assembly, burner grate, manifold bracket, 3/4 inch, 5/8 inch and an 11/16 inch or two adjustable wrenches. (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. Figure 15. CAUTION: No sealant is required on the side burner fitting.
Step 16 Step 17 Install manifold bracket Install brace panel You will need: manifold bracket You will need: brace panel. Hook the bracket onto the manifold at the center burner valve. Figure 19. Place your hand underneath the bracket. Lift the bracket, manifold and cooking box slightly as a unit and hook onto the frame brace. Slide the side burner back. Insert the tabs into the slots in the frame brace at the wheel legs. (Make sure the side burner hose is to the front of the barbecue.) Figure 20 (a).
Step 18 Place a nylon washer on the 1/4-20 x 1/2 inch bolt. Insert the bolt through the top of the right end panel and the brace panel. Put on wing nut and tighten. Figure 22. Install right end panel You will need: right end panel (Number 3), 1/4-20 x 1 1/2 inch bolt, 1/4-20 hex nut, two nylon washers, 1/4-20 x 1/2 inch bolt, 1/4-20 wing nut and a 7/16 inch wrench. Set the right end panel over the brace panel. Make sure the gas supply hose is on the outside of the panel.
Step 19 Step 20 Install bottom accessory trays Install igniter You will need: two accessory trays 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. Set the two accessory trays between the two frame connectors. Figure 23. The igniter lock nut is on the igniter. Insert the top of the igniter up through the large part of the keyhole in the frame brace.
Step 21 Insert one end of the hinge rod into the hole in the frame. Figure 26 (a). Install left hand swing table Insert the other end into the hole in the swing table end bracket. Figure 26 (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 26 (c).
Step 22 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 27. 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.
Insert one end of the hinge rod into the hole in the frame. Figure 30 (a). 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 31. Insert the other end into the hole in the swing table end bracket. Figure 30 (b). Hold the end bracket at an angle so the lower tab is inside the frame tube.
Step 23 To perform leak checks: Slide back the collar of the quick disconnect. Push male fitting of the hose into the quick disconnect, and maintain pressure. Figure 34 (a). Slide the collar closed. Figure 34 (b). If it does not engage or lock, repeat procedure. Gas will not flow unless the quick disconnect is properly engaged. Check for gas leaks DANGER 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.
Check: Step 24 a) Hose to manifold connection. Figure 36 (a). Insert Flavorizer Bars and Steam-N-Chips Smoker b) Manifold to side burner hose connection. Figure 36 (b). You will need: five long Flavorizer Bars, seven short Flavorizer Bars, Steam-N-Chips Smoker body and flue. WARNING: If there is a leak at connections a or b, retighten the fitting with a wrench and recheck for leaks with soap and water solution. Place the three long Flavorizer Bars in the rear of the cooking box.
Step 25 Slide the bottom tray onto the mounting rails under the cooking box with finger grip toward you. Figure 42. Install cooking grates CAUTION: Do not line bottom tray with aluminum foil. It can cause grease fires by trapping the grease and not allowing grease to flow into the catch pan. You will need: two cooking grates. 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.
Step 28 Step 29 Install tool holders, control panel, burner control knobs and FlameCheck button Secure 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 45. Caution: Make sure both locks have snapped into place.
Step 30 Step 31 Install glass doors Complete accessory installation 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 (short) hinge pin into the bushing in the frame connector. Repeat the procedure with the RH door assemblies. The glass doors latch on the frame connector. Figure 46.
OPERATING INSTRUCTIONS Lighting Summary lighting instructions are on the control panel. 3) Turn gas supply valve on. 4) Push Front burner control knob down and turn to START/HI. DANGER 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 8) After the FRONT burner is lit you can turn on the other burners. 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 flameup which can cause serious bodily injury or death. Note - The FRONT burner must be on at all times when operating the other burners. The FlameCheck Safety System monitors the Front burner.
Cooking Storage and/or Nonuse The Weber Genesis Gas Barbecue should not be moved when operating or hot. ■ When storing the Weber Gas Barbecue, make sure that the inside shut off valve and/or locking outdoor shut off valve is secured in the OFF postion. When the Weber Gas Barbecue is stored indoors, the gas supply MUST BE DISCONNECTED. ■ After a period of storage and/or nonuse the Weber Gas Grill should be checked for gas leaks and any obstructions in the burner tubes before using.
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 foods such as roasts, chicken and turkeys, etc., we recommend using FireSpice Chunks because they ignite slowly and provide smoke for a longer period of time.
WARNING: If there is a leak at connections a or b, retighten the fitting with a wrench and recheck for leaks with soap and water solution. Annual Maintenance After a period of nonuse we recommend that you perform the following maintenance procedures for your safety. If a leak persists after retightening the fitting, turn OFF the gas. DO NOT OPERATE THE BARBECUE. Contact your dealer. WARNING: Check hose before each use of barbecue for nicks, cracking, abrasions or cuts.
General Maintenance Weber Spider Stopper Guards Main Burner Flame Pattern 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 6. This could result in a fire in and around the air shutters, under the control panel, causing serious damage to your barbecue.
h) Lift and twist the burner assembly slightly, to separate the crossover tube from the burners. Figure 14. Remove the burners from the cooking box. Replacing Main Burners a) Weber Gas Barbecue must be OFF and cool. b) Turn gas OFF at the 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. Lift off the control panel. d) Unlatch the Spider Stopper Guards and remove. Figure 11.
j) FlameCheck Safety System Reinstall the Spider Stopper Guards. Slightly rotate the Spider Stopper Guards so that the seams are in line with the Venturi fins. There should be no gaps in the seams or in the fit around the burners and valves. Figure 16. The correct positioning of the thermocouple probe is shown in Figure 18. The tip of the probe is positioned in the flame. The probe senses the heat from the Front burner, and activates the FlameCheck valve.
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 fuel hose bent or kinked? Straighten fuel hose.
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 48 49 ® ® 50 2 3 4-6 51 52 53 7 8 9 10 54 55 56 11 57 58 12 59 60 13 14 15 2 61 2 16 62 2 17 18 63 19-20 1 64 65 66 67-70 21 22-24 25 26 3 27 28 29 17 18 LH RH 30 RH W 31 E BE R W 71 E BE R 32 33 34 35 36 47 23 37 38 39 40 41 42 43 43 44 45 19 46 24 40
Parts List Contact: All items are single quantities unless otherwise specified. Parts can be ordered directly from Weber-Stephen Products Co. by phone or mail. Weber-Stephen Products Co. Customer Service Center 250 South Hicks Road Palatine, IL 60067-6241 (800) 446-1071 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.
A FINAL WORD OF THANKS you for choosing a Weber Barbecue. TOurhankfamily 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.
