Weber 55159 User Manual
®®
55159 10/18/01
NOTICE TO INSTALLER: These
instructions must be left with the owner
and the owner should keep them for
future use.
WARNING: Follow all leak-check
procedures carefully in this manual prior
to barbecue operation. Do this even if
barbecue was dealer-assembled.
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.
DANGER
If you smell gas:
1. Shut off gas to the appliance.
2. Extinguish any open flames.
3. Open lid.
4. If odor continues, keep away from the
appliance and immediately call your
gas supplier or your fire department.
Leaking gas may cause a fire or
explosion which can cause serious
bodily injury or death, or damage to
property.
Owners Guide
Natural Gas
Y
OU MUST READ THIS OWNERS GUIDE
BEFORE OPERATING YOUR GAS GRILL
WARNING
Do not store or use gasoline or other
flammable liquids or vapors within 25
feet (8m) of this appliance.
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 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. See instructions in this manual for correct
procedures.
Do not operate the Weber Gas Barbecue if there is a gas leak present.
Do not use a flame to check for gas leaks.
Combustible materials should never be within 24 inches of the top, bottom, back or sides of
your Weber Gas Barbecue.
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. Accessible parts of the barbecue
may be very hot. Keep young children away while it is in use.
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, or moved while in operation.
Should the burners go out while in operation, turn all gas valves off. Open the lid and wait five
minutes before attempting to relight, using the lighting instructions.
Do not use charcoal or lava rock in your Weber Gas Barbecue.
Never lean over open grill or place hands or fingers on the front edge of the cooking box.
Should a grease fire occur, turn off all burners and leave lid closed until fire is out.
Do not enlarge valve orifices or burner ports when cleaning the valves or burners.
The Weber Gas Barbecue should be thoroughly cleaned on a regular basis.
Liquid Propane gas is not natural gas. The conversion or attempted use of natural gas in an
liquid propane unit or liquid propane gas in a natural gas unit is dangerous and will void your
warranty.
Do not attempt to disconnect any gas fitting while your barbecue is in operation.
Use heat-resistant barbecue mitts or gloves when operating barbecue.
Combustion byproducts produced when using this product contain chemicals known to the
state of California to cause cancer, birth defects, or other reproductive harm.
3
Weber-Stephen Products Co. (Weber) hereby
warrants to the ORIGINAL PURCHASER of this
Weber Gas Grill that it will be free of defects in
material and workmanship from the date of purchase
as follows:
Aluminum Castings, lifetime, 1 year paint
Porcelain Hood Section, 25 years
Burners, 10 years
Igniter, 3 years
Cooking Grates, 3 years no rust through
Flavorizer Bars, 1 year no rust through
Thermoplastic/
Thermoset Parts, 10 years excluding fading
All Remaining Parts, 5 years,
when assembled and operated in accordance with the
printed instructions accompanying it.
Weber may require reasonable proof of your date of
purchase. THEREFORE, YOU SHOULD RETAIN
YOUR SALES SLIP OR INVOICE.
This Limited Warranty shall be limited to the repair or
replacement of parts that prove defective under
normal use and service and which on examination
shall indicate, to Weber's satisfaction, they are
defective. Before returning any parts, contact the
Customer Service representative in your region using
the contact infromation sheet provided with your
manual. If Weber confirms the defect and approves
the claim, Weber will elect to replace such parts
without charge. If you are required to return defective
parts, transportation charges must be prepaid. Weber
will return parts to the purchaser, freight or postage
prepaid.
This Limited Warranty does not cover any failures or
operating difficulties due to accident, abuse, misuse,
alteration, misapplication, vandalism, improper
installation or improper maintenance or service, or
failure to perform normal and routine maintenance,
including but not limited to damage caused by insects
within the burner tubes, as set in this owner's manual.
Deterioration or damage due to severe weather
conditions such as hail, hurricanes, earthquakes or
tornadoes, discoloration due to exposure to chemicals
either directly or in the atmosphere, is not covered by
this Limited Warranty.
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. Some states do not allow limitation on how
long an implied warranty lasts, so this limitation may
not apply to you.
Weber is not liable for any special, indirect or
consequential damages. Some regions do not allow
the exclusion or limitation of incidental or
consequential damages, so this limitation or exclusion
may not apply to you.
Weber does not authorize any person or company to
assume for it any other obligation or liability in
connection with the sale, installation, use, removal,
return, or replacement of its equipment; and no such
representations are binding on Weber.
This Warranty applies only to products sold at retail.
WEBER-STEPHEN PRODUCTS CO.
Customer Service Center
1890 Roselle Road, Suite 308
Schaumburg, IL 60195
USA
WARRANTY
4
CONTENTS
Danger & Warnings . . . . . . . . . . . . . . . . . . . . .2
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
General Instructions . . . . . . . . . . . . . . . . . . . .5
Exploded View . . . . . . . . . . . . . . . . . . . . . . . .6
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
General Specifications for Piping . . . . . . . . .11
Assembly Instructions . . . . . . . . . . . . . . . . . .14
Operating . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Manual Lighting . . . . . . . . . . . . . . . . . . . . . . .29
Cooking . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
After a Period of Nonuse . . . . . . . . . . . . . . . .30
Periodic Cleaning . . . . . . . . . . . . . . . . . . . . .30
Annual Maintenance . . . . . . . . . . . . . . . . . . .31
General Maintenance . . . . . . . . . . . . . . . . . .32
Replacing Main Burners . . . . . . . . . . . . . . . .32
Crossover Ignition System Operations . . . . .34
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . .35
55
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 in the food.
The natural gas supply is easy to use and gives you
more cooking control than charcoal fuel.
• These instructions will give you the minimum
requirements for assembling your Weber Gas
Barbecue. Please read the instructions carefully
before using your Weber Gas Barbecue. Improper
assembly can be dangerous.
• Not for use by children.
• If there are local codes that apply to gas grills, you
will have to conform to them. If there are no local
codes, you must conform to the latest edition of
the National Fuel Gas Code: ANSI Z 223.1.
• This Weber Gas Barbecue is designed for natural
(piped in city) gas only. Do not use Liquid Propane
(LP) bottled gas. The valves and orifices are for
natural gas only.
• Do not use with charcoal fuel.
• Check that the area under the control panel and
the bottom tray are free from debris that might
obstruct the flow of combustion or ventilation air.
For Installation in Canada
These instructions, while generally accecptable, do not
necessarily comply with the Canadian Installation
codes, particularly with piping above and below ground.
In Canada the installation of this appliance must comply
with local codes and/or Standards CAN/ CGA-B149.1
(Installation Code for Natural Gas Burning Appliances
and 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.
WARNING: Never use your Weber Gas Barbecue
under an unprotected combustible roof or
overhang.
WARNING: Your Weber Gas Barbecue is not
intended to be installed in or on recreational
vehicles and/or boats.
WARNING: Do not use combustible materials
within 24 inches of the top, bottom, back or sides
of the grill.
WARNING: The entire cooking box gets hot
when in use. Do not leave unattended.
WARNING: Keep any electrical supply cord away
from any heated surface.
WARNING: Keep the cooking area clear of
flammable vapors and liquids, such as gasoline,
alcohol, etc., and combustible materials.
Gas supply testing
• Disconnect your Weber Gas Barbecue when the
gas supply is being tested at high pressures. This
appliance and its individual shutoff valve must be
disconnected from the gas supply piping system
during any pressure testing of that system at test
pressures in excess of 1/2 psig (3.5 kPa).
• Turn off your Weber Gas Barbecue when the gas
supply is being tested at low pressures. This
appliance must be isolated from the gas supply
piping system by closing its individual manual
shutoff valve during any pressure testing of the
gas supply piping system at the pressure equal to
or less than 1/2 psig (3.5 kPa).
6
Genesis Silver-B Permamount NG 051701
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45
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1 Hinge pin
2 Left endcap
3 Shroud
4 Handle
5 Warm-Up basket
6 Warming rack
7 Cooking grate
8 Flavorizer bar
9 Cooking box
10 1/4-20 keps nut
11 Slide out bottom tray
12 Catch pan holder
13 1/4-20 x 2 inch bolt
14 Left trim piece
15 Work surface
16 Left frame
17 Condiment basket
18 1/4-20 x 1/2 inch bolt
19 1/4 inch nylon washer
20 Side panel
21 Side frame
22 Accessory rack
23 Base panel
24 Hair pin cotter
25 Thermometer
26 Right endcap
27 Burner control knob
28 Control panel
29 Igniter button
30 Control panel hardware
31 Crossover tube
32 Front and back burners
33 Center burner
34 Manifold hardware
35 Manifold
36 Manifold support bracket
37 Disposable drip pan
38 Catch pan
39 Igniter
40 Right frame
41 Control panel trim piece
42 Right trim piece
43 Gas supply line
44 Flare fitting
45 Plastic button
8
© 2001 Weber-Stephen Products Co., Weber, the silhouette, and the kettle configuration are registered
trademarks of Weber-Stephen Products Co., 200 East Daniels Road, Palatine, IL, 60067-6266, U.S.A. This
product is covered by one or more United States patents and patents in other nations globally. Printed in the
U.S.A.
®
9
Screwdriver
Phillips screwdriver
Hammer
7/16 open-end wrench or adjustable wrench
Pliers
Block of wood
Tape Measure
Pencil
Electric Drill
Lid - 1
Cooking Box - 1
Cooking grates - 2
Control panel - 1
Left frame - 1
Right frame - 1
Side frame - 2
Left trim piece - 1
Right trim piece - 1
Work surface - 1
Gas supply line
(with the flare fitting
loosely attached
for shipping purposes)
®
®®®®
Warming rack - 1
Warm-up basket - 1
Accessory rack - 1
Flavorizer bars - 5
Side panel - 2
Base panel - 1
Wrap-around trim piece - 1
Bottom tray - 1
Catch pan holder - 1
Catch pan - 1
Disposable drip pans - 2
Thermometer - 1
10
Condiment basket - 1
Manifold support bracket - 1
Burner control knobs - 3
Hinge pins (1/4-20 x 1 1/2 inch clevis pin) - 2
2 inch bolts (1/4-20 x 2 inch bolts) - 1
1/2 inch bolts (1/4-20 x 1/2 inch bolts) - 8
Keps nut (1/4-20 keps nut) - 1
1/4 inch nylon washers - 15
Cotter pin - 2
Control panel hardware
(phillips screws/washers) - 2
Plastic button - 8
1111
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 of any connections
or change in pipe material.
■ An additional manual shut-off valve indoors should
be installed in the branch fuel line in an accessible
location near the supply line.
■ The point of tie into the branch line should be
carefully selected to avoid a drip leg or be
downstream of a valve controlling another
appliance.
■ Pipe compound should be used which is resistant
to action of natural gas when connections are
made.
■ The outdoor connector must be firmly attached to
rigid, permanent construction.
Gas line piping
■ If the length of line required does not exceed 50
feet, use a 5/8" O.D. tube. One size larger should
be used for lengths greater than 50 feet.
■ Indoor and above ground piping can be steel or
copper.
Steel
New standard weight (Schedule 40) steel pipe with
malleable iron fittings.
Copper
New copper tubing type K or L.
Copper tubing must meet requirements of ASTM B88
latest edition.
Use flared fittings. Metallic ball sleeve compression
fittings must not be used.
Copper tube joints may be soldered or brazed with
material having a melting point in excess of 1,000°F.
Outside underground piping
Outside underground piping may be copper tubing,
type K or L (ASTM B88) or polyethylene plastic tube
PE3306 (Minimum wall thickness .062") meeting
ASTM 2513, latest specifications.
Steel pipe is not recommended for underground use
unless it is protected with an approved coating,
insulated from hose piping and cathodically protected.
It is recommended that copper tubing be corrosion
protected with a satisfactory material such as TC
Mastic.
All buried fittings should be corrosion protected with a
satisfactory material such as TC Mastic.
Underground piping must have a minimum of 10"
cover.
Plastic tubing
Plastic tubing is suitable only for outside underground
use.
■ The transition from metallic pipe to plastic pipe
should be made outside and at least 10"
underground.
■ When compression or crimp type mechanical
joints are used with plastic pipe, it is advisable to
use an internal rigid stiffener in conjunction with
the fitting.
■ The stiffener should be assembled flush with the
end of the tube and extend at least to the outside
edge of the compression fitting.
Testing connections
You will need a soap and water solution and a rag or
brush to apply it.
All connections and joints must be thoroughly tested
for leaks after gas has been turned into the line.
Notice Before Installation
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.
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 gas leaks. This will result in
a fire or explosion which can cause
serious bodily injury or death, and
damage to property.
Wet the fitting with a soap and water solution. Any
bubbles that form or grow indicate a leak. If bubbles
occur shut off gas, tighten the fitting, and retest.
WARNING: If a leak persists after tightening the
fitting, turn gas off at the supply. DO NOT
OPERATE YOUR BARBECUE. Contact WeberStephen Customer Service.
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