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Weber 3500 manual

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Table of contents for the manual

  • Page 1

    GENESIS ® 3500 Natural Gas Barbecue Serial Number Please use this number in registering your w arranty and any correspondence with the f actory . Owner’ s Manual 98636 10/97 ® 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: These instruc[...]

  • Page 2

    2  D ANGER Failure to f ollo w the Dangers, W arnings and Cautions contained in this Owner’ s Manual may result in serious bodil y injur y 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 dangerous. Plea[...]

  • Page 3

    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 and Fla vorizer Bars, 3 y ears, All Remaining P ar ts, 5 y ears, when assembled and oper ated[...]

  • Page 4

    4 © 1997 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. Genesis Gas Barbecues are cov ered under the follo w[...]

  • Page 5

    5 Contents WARNINGS ................................................................ 2 W arranty & P atents .................................................. 2-3 General Instructions .................................................... 6 Assembly ............................................................. 10-27 Operating Instructions Lightin[...]

  • Page 6

    6 General Instructions Y our W eber Gas Barbecue is a stationary 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" fla v or in the food. The natural gas sup[...]

  • Page 7

    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[...]

  • Page 8

    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 View from behind barbecue Gas Supply Accessible Locking Shut off Indoor Shut off Figure 2 Outside Inside  CA UTION: Follow "General Specifications for Piping" in [...]

  • Page 9

    9 Recommended concrete pad requirements W e recommend a pad a minim um 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 maxi[...]

  • Page 10

    Assembl y T ools needed Regular screwdriv er Phillips screwdriv er Hammer 7/16 inch or an adjustable wrench Pliers T ape Measure P encil Electric dr ill Supplies needed Y ou will need a soap and water solution to chec k f or gas leaks. (See Step "Check f or gas leaks.") Note - The hardware size of n uts, bolts , and screws is giv en. F or[...]

  • Page 11

    11 F ront Panel Cooking grate (2) Catch pan holder Catch P an Drip pans (2) Ther mometer Condiment basket Side burner assembly Bur ner grate Side burner knob Side burner locks (2) Note: The loc ks are taped to the inside of the side burner lid. Left frame Right frame Side frame (2) Accessor y rack W ar m-Up Basket W ar ming Rack Five long Fla voriz[...]

  • Page 12

    12 Check contents of hardw are packs Three burner control knobs Three tool holders Three tubing plugs Manif old brac ket T wo hinge pins (hardware siz e: 1/4 x 1 1/2 inch cle vis pin) (actual size) One 1/4-20 x 2 inch bolts (actual size) Six 1/4-20 x 1/2 inch bolts (actual size) One 1/4-20 keps n ut Se v en nylon w ashers (actual size) T wo hair pi[...]

  • Page 13

    13 Step 2 Assemble the fr ame Y ou will need: left frame, right frame , two nylon w ashers, two 1/4-20 x 1/2 inch bolts and a 7/16 inch wrench. Note - Work 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 right frame to y our right and left fr[...]

  • Page 14

    14 Step 4 Install side burner locks Note: The locks are taped to the inside of the side burner lid. Y ou will need: frame assembly , two side burner locks and a 7/16 inch wrench. T ur n frame assembly right side up . Loosen the right rear 1/4 x 20 bolt. Install the side burner lock. The “U” shape cut out of the lock slips do wn ov er the bolt. [...]

  • Page 15

    15 Figure 6 1 2 3 4 Step 6 T ypical installation of the base f or an existing concrete patio , new pad or wood dec k  CA UTION: Combustible materials should ne ver be within 24 inches of the top, bottom, bac k or sides of the barbecue. Do not locate under overhead combustib le construction. Note - With the lid open the depth of the barbecue is 2[...]

  • Page 16

    16 Method 3 - Concrete 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 9. Note - Use a 3/4 inch diameter concrete drill bit for drilling the hole f or the screw base . The machine scre w anchor requires a setting tool. 3/8-16 x 1 1/2 machine screw 3/8 inch flat washer Mount plate 3/8 inch scre[...]

  • Page 17

    17 Step 7 Tighten all frame bolts Fully tighten the 1/4-20 bolts in the frame assemb ly , that you only started in Step “Continue F rame Assembly” Figure 12. Figure 12 Figure 11 T ypical installation of the base f or an existing concrete patio , new pad or wood dec k (continued) Method 4 - W ood deck After assembling the base according to the a[...]

  • Page 18

    18 Y our Weber Gas Barbecue b ur ner assembly has been f actor y assembled, pressure and flame tested. As a safety precaution we recommend y ou check the b ur ner alignment: a) Are the ends of the burners under the washers at the left rear and left front of the cooking bo x? The screws are only guides. Do not tighten. Figure 15 (a). b) Are the wing[...]

  • Page 19

    Step 10 Connect barbecue gas supply line to the natural gas supply Note - W e 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 suppl y line of y our gas barbecue. The fitting is loosely connected for shipping and should b[...]

  • Page 20

    20 Step 11 Check all v alves are off Y ou will need: one b ur ner 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. Check b y pushing down and turning clockwise. If the y do not tur n they are off . Proceed to the ne xt step. Figure 18. Figure 18 Step 12 Install side burner Y [...]

  • Page 21

    Step 14 Purge air from gas lines Y ou will need: one b ur ner control knob .  D ANGER Be sure there are no sparks or open flames in the area while purging. This can cause fire, explosion or serious bodil y injury . Figure 22 21 Step 13 Install manif old brack et Y ou will need: manif old brack et. Hook the brac ket onto the manif old at the cent[...]

  • Page 22

    22 Step 15 Check f or gas leaks  D ANGER Do not use an open flame to chec k f or gas leaks. Be sure there are no sparks or open flames in the area while y ou chec k for leaks. This will result in a fire or explosion which can cause serious bodil y injury or death and damage to property . Figure 25 Figure 24 Figure 23 (a) Gas supply shut off at t[...]

  • Page 23

    23 Step 16 Add base panel Y ou will need: Base panel. Put the right side in and down, tilt and set the left side in place. Figure 26. Step 17 Install side panels Y ou will need: two side panels, and eight plastic b uttons. F rom the inside of the frame assembly , set the left side panel in place between the side frame legs . Notice that there are t[...]

  • Page 24

    24 Step 19 Install the bottom tra y Y ou will need: bottom tra y , catch pan holder , catch pan and one drip pan. Figure 31 Figure 30 Figure 32 Bottom tra y Finger grip on front edge of bottom tra y Finger grip F ront side of catch pan holder Step 18 Install Flav orizer Bars and Cooking Grates Y ou will need: five long Fla vorizer Bars, eight short[...]

  • Page 25

    25 Step 20 Install Lid Y ou will need: lid, two hinge pins and two hair pin cotters . Set the lid in place. Align the hinges at the rear of the barbecue. Inser t hinge pins from the outside. Inser t hair pin cotters into the small holes in the hinge pins. Figure 33. Hair pin cotter Hinge pin Figure 33 Step 21 Add tool holders, control panel and b u[...]

  • Page 26

    26 Figure 35 View from top View from side Step 23 Install the condiment basket Y ou will need: condiment basket and end brac ket. Inser t one wire end of the condiment basket into the hole in the side frame. Figure 36 (a). Inser t the opposite wire end of the condiment basket into the hole in the end brac ket. Hold the end brac ket at an angle so t[...]

  • Page 27

    Step 25 Complete accessor y installation Y ou will need: W ar m-Up Basket, war ming rack, work tab le, three tubing plugs, thermometer and a hammer . Inser t one end of the W eber W ar m-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 38 (a). Set the warming rack into the slots [...]

  • Page 28

    28 28 Lighting Summar y lighting instructions are on the control panel. 1 6 4 2 7 7 5 Figure 1 Crosso ver Ignition System 1) Open the lid. Figure 1. 2) Make sure all burner control knobs are tur ned OFF . (Push each burner control knob down and turn clockwise .) 3) T ur n gas supply valv e on.  W ARNING: Do not lean over open barbecue. Keep your[...]

  • Page 29

    29 Manual Lighting 1 4, 6 5 2 7 7 Figure 2 Manual Lighting  D ANGER Failure to open lid while igniting the barbecue, or not waiting 5 minutes to allow the gas to c lear if the barbecue does not light, may result in an e xplosive flame-up which can cause serious bodil y injury or death. 1) Open the lid. Figure 2. 2) Make sure all burner control k[...]

  • Page 30

    3 2 1 Lighting the side b urner The side burner has a separate ignition system from the main cooking bo x. 5 2 4 1 Figure 3  D ANGER Failure to open lid while igniting the side burner , or not waiting 5 minutes to allow gas to clear if the side b urner does not light, may result in an e xplosive flame-up which can cause serious bodily injury or [...]

  • Page 31

    31 Cooking Y ou can adjust the FRONT , CENTER and BACK b ur ners as desired. The control settings High (H), Medium (M), Low (L), or Off (O) are described in your W eber cookbook. The cookbook uses these notations to describe the settings of the FRONT , CENTER, and BA CK b ur ners. For e xample, to sear steaks you w ould use (HHH) (all b ur ners at [...]

  • Page 32

    32 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 v e dust or dir t on their outside surf aces. If the y are dirty , brush off the outside surface of the Spider Stopper Guards with a soft bristle br ush (an old toothbrush for e xample). Chec k t[...]

  • Page 33

    33 General Maintenance W eber Spider Stopper Guards Y our W eber Gas Barbecue , as w ell as an y outdoor gas appliance, is a target f or spiders and other insects. They can nest in the venturi section of the b urner tubes. This bloc ks the nor mal gas flow , and can cause the gas to flow back out of the air shutter . Figure 6. This could result in [...]

  • Page 34

    i) T o reinstall the bur ners, re verse steps c) through g).  CA UTION: The burner openings must be positioned properl y over the v alve orifices. Figure 15 (a). Check proper assemb ly before f astening manifold in place. Figure 15 (b). 34 e) Disconnect gas supply line and side burner . f) Remov e the manifold brac ket and unscrew the tw o wing [...]

  • Page 35

    35 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 e r Ignition System. ■ Check that both the white and b lack ignition wires are attached properly . Figure 17. Figure 17 White wire Bl[...]

  • Page 36

    36 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[...]

  • Page 37

    37 Prob lem Side burner does not light. Flame is low in HIGH position. Flame is very yellow in conjunction with the smell of gas, OR Burner makes popping noise in conjunction with the smell of gas. Push button ignition does not w ork. Check Is gas supply off? Is fuel hose bent or kinked? Inspect the W eber Spider Stopper Guard f or possible obstruc[...]

  • Page 38

    38 ® ® ® ® ® ® ® ® 1 2 3 6 7 8 10 9 20 21 14 15,16 45-49 55 9 42 40 39 38 37 36 34 33 32 31 30 29 28 43 44 41 22 35 11 12 13 17 18 19 5 4 24 17 25 26 23 54 53 50-51,49 27 27[...]

  • Page 39

    39 1 Lid (assembly) 2 Lid handle 3 W ar m-Up Basket 4 W ar ming rack 5 Shor t Flav orizer bars (8) 6 Long Flav or izer bars (5) 7 Cooking grates (2) 8 W ork table 9 T ubing plugs (3) 10 1/4-20 x 2 inch bolt 11 End brac ket 12 Left frame 13 F ront panel 14 Condiment bask et 15 1/4-20 x 1/2 inch bolts (6) 16 1/4 inch n ylon washers (7) 17 Side panel [...]

  • Page 40

    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[...]