Weber Genesis 4000 Series Owner's Manual
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Weber Genesis 4000 Series Owner's Manual

Weber lp gas barbecue owner's manual 4000
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GENESIS
LP Gas Barbecue
Owner's Manual
®
National
PROPANEGAS
Association
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.
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.
4000 Series
®
Serial Number
Please use this number in registering your warranty
and any correspondence with the factory.
FOR YOUR SAFETY
1. Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
2. An LP tank not connected for use
shall not be stored in the vicinity of
this or any other appliance.
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.
8601501
6/96

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Summary of Contents for Weber Genesis 4000 Series

  • Page 1 OUTDOOR USE ONLY. Serial Number Please use this number in registering your warranty and any correspondence with the factory. 4000 Series FOR YOUR SAFETY 1. Do not store or use gasoline or other 2. An LP tank not connected for use...

  • Page 2: Warnings

    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.

  • Page 3: Warranty & Patents

    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,...

  • Page 4: Patents And Trademarks

    U.S. trademarks; 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 Barbecues are covered under the following patent nos.: U.S.A. #4,677,964;...

  • Page 5: Table Of Contents

    Troubleshooting & Maintenance Parts Listing ... 43 IMPORTANT NEW FEATURES: Your Weber Gas Barbecue is equipped with a new and improved LP tank connection, that has additional safety features. They are: 1. The connection of the barbecue to the LP tank can be made without the use of tools.

  • Page 6: General Instructions

    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.

  • Page 7: Assembly

    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.
  • Page 8 Serving tray Control panel Front panel Left frame Wheel frame Two frame connectors Tank panel assembly Five long Flavorizer Bars Seven short Flavorizer Bars Two wheels Axle Right frame Caster frame Two casters Cooking grate Narrow cooking grate Warming rack Warm-Up Basket Thermometer Two aluminum drip pans...
  • Page 9 Right hand slide bar assembly Assembly consists of: Right hand slide bar Support Slide Left hand slide bar assembly Assembly consists of: Left hand slide bar Support Slide Fuel scale assembly Catch pan holder Manifold bracket Side burner assembly Burner grate Side burner knob Two side burner locks Steam-N-Chips Smoker body...
  • Page 10 Check contents of hardware packs Three burner control knobs FlameCheck button Three tool holders Four tubing plugs (two are spares) Two wheel hubcaps (actual size) Two hinge pins (hardware size: 1/4 x 1 1/2 inch clevis pin) (actual size) Five 1/4-20 x 2 inch bolts (actual size) Six 1/4-20 x 1/2 inch bolts (actual size)

  • Page 11: Assemble Wheels

    Place one end of the axle on the block of wood (or other protected surface). Tap on one hubcap. Put one wheel on the axle, WEBER side toward the hubcap. Slide the axle through the frame. Add the other wheel, WEBER side out. Tap on the hubcap. Figure 1.

  • Page 12: Continue Frame Assembly

    Step 4 Continue 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. Place the caster frame onto the tabs of the left frame with the dimple to the inside.
  • Page 13 Figure 8. Add keps nut. Tighten by holding the bolt with pliers while you tighten the nut with the 7/16 inch wrench. Your Weber Gas Barbecue burner assembly has been factory assembled, pressure and flame tested. As a safety precaution we recommend you check the burner...
  • Page 14 Step 9 Install tank panel assembly You will need: tank panel assembly, 1/4-20 x 1 1/4 inch bolt, 1/4-20 hex nut, nylon washer and a 7/16 inch wrench. Insert the tank panel tabs into the slots in the frame brace. Slide up until the notch at the bottom of the tank panel fits over the cross brace.

  • Page 15: Check That All Burner Valves Are Off

    Step 11 Install igniter 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. 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.

  • Page 16: Install Side Burner

    Step 13 Install side burner 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. CAUTION: No sealant is required on the side burner fitting. Do not use pipe dope, tape or any other type of sealant on the fittings or hose.
  • Page 17 Step 15 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 support bracket.
  • Page 18 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.
  • Page 19 Insert one end of the hinge rod into the hole in the frame. Figure 22 (a). Insert the other end into the hole in the swing table end bracket. Figure 22 (b). Hold the end bracket at an angle so the lower tab is inside the frame tube.

  • Page 20: Set Lp Fuel Scale

    If the tank manufacturer has not resolved the issue to your satisfaction, then call Weber-Stephen Products Co., Customer Service Center. To fill, take the LP tank and filler adapter to an RV center or look up gas-propane in the phone book for other sources of LP gas.
  • Page 21 Step 19 Connect LP tank WARNING: Make sure that the LP tank valve is closed. Close by turning clockwise. Hook the LP tank onto the fuel scale. Loosen the tank lock wing nut. Swing the tank lock down. Tighten the wing nut.

  • Page 22: Check For Gas Leaks

    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 leaks before using your Weber Gas Barbecue. Shipping and handling may have loosened or damaged a gas fitting.
  • Page 23 If a leak persists after retightening the fitting, turn OFF the gas. DO NOT OPERATE THE BARBECUE. Contact Weber-Stephen Customer Service. d) Side burner hose to side burner connection. Figure 31 (d). e) Valves to manifold connections. Figure 31 (e).
  • Page 24 Step 22 Install cooking grates 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. Set the cooking grates onto the ledges in the cooking box.
  • Page 25 Step 24 Install the lid You 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. Insert hinge pins from the outside. Insert hair pin cotters into the small holes in the hinge pins. Figure 38.
  • Page 26 Warm-Up Basket, warming rack, thermometer, two tubing plugs and a hammer. Insert one end of the Weber Warm-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 41 (a).

  • Page 27: Operating Instructions

    WARNING: Check hose before each use of barbecue for nicks, cracking, abrasions or cuts. If the hose is found to be damaged in any way, do not use the barbecue. Replace using only Weber authorized replacement manifold assembly. Order from Weber-Stephen Products Co., Customer Service Center or authorized dealer.

  • Page 28: Manual Lighting

    Manual Lighting 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 flame- up which can cause serious bodily injury or death.

  • Page 29: Lighting The Side Burner

    Lighting the side burner The side burner has a separate ignition system from the main cooking box. DANGER Failure to open lid while igniting the side burner, or not waiting 5 minutes to allow gas to clear if the side burner does not light, may result in an explosive flame- up which can cause serious bodily injury or death.

  • Page 30: Cooking

    You can adjust the FRONT, CENTER and BACK burners as desired. The control settings High (H), Medium (M), Low (L), or Off (O) are described in your Weber cookbook. The cookbook uses these notations to describe the settings of the FRONT, CENTER, and BACK burners.

  • Page 31: Using The Steam-N-Chips Smoker

    Steam-N-Chips Smoker. To a lesser degree a "smoke" residue will accumulate on the inside of your Weber Gas Barbecue. This residue need not be removed and will not adversely affect the function of your Weber Gas Barbecue.

  • Page 32: Refilling The Lp Tank

    Refilling the LP tank We recommend that you refill before the scale indicator reaches "E". Note - If you run out of fuel, check the indicator setting and/or adjust the fuel scale indicator setting with the scale setting wing nut, while the tank is empty so you do not run out again.
  • Page 33 Mix soap and water. e) Open the tank valve. Figure 8. Figure 8 If leak does not stop, turn off the gas and contact Weber-Stephen Customer Service. Do not use the barbecue. g) When leak checks are complete, turn gas supply LP Tank The LP tank manufacturer is responsible for the materials, workmanship and performance of the tank.

  • Page 34: Safe Handling Tips For Lp Gas

    This vent should be free of dirt, grease, bugs etc. Liquid Propane (LP) Tank(s) The LP tank and connections supplied with your Weber Gas Barbecue have been designed and tested to meet government, American Gas Association and Underwriters Laboratories requirements.

  • Page 35: Annual Maintenance

    WARNING: Check hose before each use of barbecue for nicks, cracking, abrasions or cuts. If the hose is found to be damaged in any way, do not use the barbecue. Replace using only Weber authorized replacement manifold assembly. Order from Weber-Stephen Products Co., Customer Service Center or authorized dealer.

  • Page 36: General Maintenance

    General Maintenance Weber Spider Stopper Guards 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.
  • Page 37 d) Unlatch the Spider Stopper Guards and remove. Figure 16. Figure 16 e) Use an adjustable wrench to remove the thermocouple from the FlameCheck valve. Remove the manifold bracket and unscrew the two wing nuts that hold the manifold to the cooking box.

  • Page 38: Crossover Ignition System Operations

    Check fit around burner Figure 21 CAUTION: If the Spider Stopper Guards do not fit tightly, contact Weber-Stephen Customer Service. CAUTION: After reinstalling the gas lines, they should be leak checked with a soap and water solution before using the barbecue. (See Step "Check for gas leaks".)
  • Page 39 FlameCheck valve, which stops the gas flow to the burners. If the FlameCheck Safety System should fail to operate, contact Weber-Stephen Customer Service. Center line Thermocouple nuts 1/8 inch...

  • Page 40: Troubleshooting

    (Resembles paint peeling.) Fuel scale shows that there is gas in the LP tank, but tank is empty. If problems cannot be corrected by using these methods, please contact Weber-Stephen Customer Service. Check Inspect Weber Spider Stopper Guards for possible obstructions.

  • Page 41: Side Burner Troubleshooting

    Figure 24 Check Is gas supply off? Is the Front burner on? Is fuel hose bent or kinked? Inspect the Weber Spider Stopper Guard for possible obstructions. (Blockage of holes.) Does burner light with a match? Igniter wire Igniter Cure Turn supply on.
  • Page 42 18-19 21-22 29 30 31 33 34 48-49 57-59 63-66 67-68...

  • Page 43: Parts Listing

    Parts can be ordered directly from Weber-Stephen Products Co. by phone or mail. 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.
  • Page 44 INAL 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 to help you with any problems with parts or assembly.

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