Weber GENESIS GENESIS 3500 LX User manual

GENESIS®3500 LX
Natural Gas Barbecue
Serial Number
Please use this number in registering your warranty
and any correspondence with the factory.
Owner’s Manual
98649 11/97
®
FOR YOUR SAFETY
Do not store or use gasoline or other
flammable vapors and liquids in the vicinity
of this or any other appliance.
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.
FOR YOUR SAFETY
If you smell gas:
1. Shut off gas to the appliance.
2. Extinguish any open flame.
3. Open lid.
4. If odor continues, immediately call your
gas supplier or your fire department.

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.
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.
Should the burners go out during 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.
LP gas is not natural gas. The conversion or attempted use of natural gas in an LP unit or LP 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.
LP GAS UNITS ONLY:
Use the regulator that is supplied with your Weber Gas Barbecue.
Do not attempt to disconnect the gas regulator or any gas fitting while your barbecue is in operation.
A dented or rusty LP tank may be hazardous and should be checked by your liquid propane supplier.
Do not use an LP tank with a damaged valve.
Although your LP tank may appear to be empty, gas may still be present, and the tank should be
transported and stored accordingly.
If you see, smell or hear the hiss of escaping gas from the LP tank:
1. Get away from LP tank.
2. Do not attempt to correct the problem yourself.
3. Call your fire department.

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,
Recycled Work Surfaces, 10 years,
Cooking Grates and Flavorizer Bars, 3 years,
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 which 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 Weber-Stephen Products Co.
Customer Service Center. 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
out 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 states 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
250 South Hicks Road
Palatine, IL 60067-6241
[phone]
WARRANTY

4
© 1997 Weber. Weber, , Genesis, Flavorizer and Crossover are
registered U.S. trademarks; 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. U.S.A. Genesis Gas Barbecues
are covered under the following patent nos.: U.S.A. #4,677,964;
4,727,853; #4,777,927; #4,829,978; #4,860,724; #4,941,817;
#4,966,125; #5,070,776; #D293,067; #D316,355; Canada: Rd
1987 Reg. #58,034; #1,279,540; #1,283,586; #1,300,994;
#1,300,995. Printed in the U.S.A.
PATENTS AND TRADEMARKS

5
Contents
WARNINGS................................................................ 2
Warranty & Patents.................................................. 2-3
General Instructions.................................................... 6
Assembly............................................................. 10-27
Operating Instructions
Lighting........................................................ 28-30
Cooking............................................................ 31
After a Period of Nonuse ................................. 31
Cleaning........................................................... 31
Troubleshooting & Maintenance
Annual Maintenance......................................... 32
General Maintenance.................................. 33-35
Troubleshooting ...........................................36-37
Parts Listing.............................................................. 39
FEATURES:
a) Convenient side table, condiment basket,
wire accessory rack and warming rack.
b) Heavy gauge porcelain-on-steel lid seals in heat.
c) Rapid read thermometer for precision cooking
measures grill temperature, and can be removed and
inserted into the food.
d) Heavy gauge steel Flavorizer Bars distribute heat
within the grill. Flavorizer Bars heat just the right
amount of drippings for flavoring, letting excess fat
drip past to help prevent flare-ups.
e) Weber Warm-Up Basket for additional cooking or
warming space.
f) Separate burners for temperature control.
g) Crossover Ignition System with Gas Catcher Ignition
Chamber.
h) Catch pan catches excess grease.
i) Side burner for making sauces, gravies, etc., while
main grill is in use.
j) Sleek and sturdy base is an attractive addition to your
patio or deck.
a
a
g
h
b
c
d
f
e
j
i

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 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.
Storage
■The gas must be turned OFF at the natural gas supply
when the Weber Gas Barbecue is not in use.
Operating area
WARNING: Onlyuse this barbecue outdoors in a
well ventilated area. Do not use in a garage, building,
breezeway or any other enclosed area.
■Never use your Weber Gas Barbecue under an
unprotected combustible roof or overhang.
■Your Weber Gas Barbecue is not intended to be
installed in or on recreational vehicles and/or boats.
■Do not use combustible materials within 24 inches of
the top, bottom, back or sides of the grill.
■The entire cooking box gets hot when in use. Do not
leave unattended.
■Keep any electrical supply cord away from any heated
surface.
■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).

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 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 Weber-Stephen Customer
Service.

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
professional.
CAUTION: Combustible materials should never be
within 24 inches of the top, bottom, back or sides of the
barbecue. Do not locate under overhead combustible
construction.
Typical natural gas supply installation to a
wood deck View from behind
barbecue
Gas Supply
Accessible
Locking Shut off
Indoor Shut off
Figure 2
Outside
Inside
CAUTION: Follow "General Specifications for Piping"
in this manual.
We recommend that this installation be done by a
professional.
CAUTION: Combustible materials should never be
within 24 inches of the top, bottom, back or sides of the
barbecue. Do not locate under overhead combustible
construction.
View from behind
barbecue
Outside
Indoor Shut off
Figure 3
Accessible
Locking Shut off
Inside
Gas Supply
Typical natural gas supply installation over
an existing post
WARNING: Turn off the natural gas supply at the
source before working on the post.
Prepare the post so that it will be approximately 2 inches
above the pad or ground. Inspect the gas supply line at
the post for any sign of deterioration or corrosion.
CAUTION: If you are in doubt as to the condition of
an existing natural gas supply line, you should
contact a professional or your local gas utility before
attempting any assembly.
CAUTION: Combustible materials should never be
within 24 inches of the top, bottom, back or sides of the
barbecue. Do not locate under overhead combustible
construction.

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 concrete bag mix, use the mix for maximum
strength. An average 80 pound bag of concrete mix will
make approximately 2/3 of a cubic foot of concrete.
Note - Follow the concrete bag mix, manufacturers
recommendations concerning pad preparation, gravel,
sand, etc. Figure 5.
Concrete Pad
Crushed stone,
sand or gravel
Earth
Figure 5
CAUTION: Allow fresh concrete to cure completely
before attempting to anchor the barbecue to the
concrete.

10
Step 1
Check package contents
Cooking box
(assembly)
Lid
(assembly)
Bottom tray
Control panel
Work table
Spacer bracket
Gas supply line
(with the flare fitting
loosely attached
for shipping purposes)
Assembly
Tools needed
Regular screwdriver
Phillips screwdriver
Hammer
One 7/16 inch or an adjustable wrench
Pliers
Tape Measure
Pencil
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 hardware size of nuts, bolts, and screws is
given. For example "1/4-20 x 2 inch bolt" means a bolt
1/4 inch in diameter with 20 threads to the inch, 2 inches
long. On a small screw for example, "6-32 x 1/2 inch
screw" means a number 6 screw, with 32 threads to the
inch, 1/2 inch long.
While we give much attention to our products,
unfortunately an occasional error may occur.
If a part is missing, do not go back to the store.
Call the Weber Customer Service Center toll free
1-800-446-1071 to receive immediate assistance.
Have your owner’s manual and serial number of the
barbecue available for reference.
®® ®® ®® ®®