Serial Number Please use this number in registering your warranty and any correspondence with the factory. GENESIS 4000 Series ® 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.
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.
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: Aluminum Castings, 10 years, Cooking Grates, 3 years, Stainless Steel Flavorizer Bars, 5 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.
PATENTS AND TRADEMARKS © 1996 Weber. Weber, , Genesis, Flavorizer and Crossover are registered 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; 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.
Contents Troubleshooting & Maintenance Annual Maintenance ........................................ 35 General Maintenance.................................. 36-39 Troubleshooting .......................................... 40-41 Parts Listing .............................................................. 43 WARNINGS ................................................................ 2 Warranty & Patents.................................................. 3-4 General Instructions...................................
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 Block of wood LP tank Supplies needed Your LP tank is shipped empty for safety. After setting the LP fuel scale you will need to fill it. (See Step "Fill LP tank.") LP tank filler adapter You will need a soap and water solution to check for gas leaks. (See Step "Check for gas leaks.
Right frame Control panel Caster frame Front panel Two casters Left frame Cooking grate Wheel frame Narrow cooking grate Two frame connectors Warming rack Tank panel assembly Warm-Up Basket Five long Flavorizer Bars Thermometer Seven short Flavorizer Bars Two aluminum drip pans WE BE Catch pan R Two wheels WE B E R Serving tray Axle 8
Right hand slide bar assembly Side burner assembly Assembly consists of: Right hand slide bar Burner grate Support Side burner knob Slide Two side burner locks Left hand slide bar assembly Assembly consists of: Steam-N-Chips Smoker body Left hand slide bar Support Steam-N-Chips Smoker flue Slide Steam-N-Chips Smoker water pan Fuel scale assembly Catch pan holder Manifold bracket 9
Check contents of hardware packs Three burner control knobs Four 10-24 x 1 3/4 machine screws (actual size) FlameCheck button Four 10-24 hex nuts (actual size) Three tool holders Twenty two 1/4 inch nylon washers (actual size) 1/4-20 keps nut Four tubing plugs (two are spares) 1/4-20 x 1 1/4 inch bolt (actual size) Two wheel hubcaps (actual size) 1/4-20 hex nut (actual size) Two hinge pins (hardware size: 1/4 x 1 1/2 inch clevis pin) (actual size) Two hair pin cotters Five 1/4-20 x 2 inch bolts (act
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, two frame connectors, 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 7 Slide the cooking box to the left within the frame. Put the washer on the bolt. Insert the bolt through the cooking box and frame with the head of the bolt outside the box. Figure 8. Add keps nut. Tighten by holding the bolt with pliers while you tighten the nut with the 7/16 inch wrench. Install side burner locks You will need: frame assembly, 2 side burner locks and a 7/16 inch wrench. Turn frame assembly right side up. Loosen the right rear 1/4 x 20 bolt. Install the side burner lock.
Step 9 Install tank panel assembly Step 10 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. You will need: fuel scale assembly, two 1/4-20 wing nuts and two nylon washers. 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. Figure 10 (a). Slip the bolts on the back of the fuel scale assembly through the two small holes in the tank panel.
Step 11 Step 12 Install igniter Check that all burner valves are off 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. You will need: one burner control knob. (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. If they do not turn, they are off, proceed to the next step. Figure 13.
Step 13 Step 14 Install side burner Install manifold bracket 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. You will need: manifold bracket Hook the bracket onto the manifold at the center burner valve. Figure 16. Place your hand underneath the bracket. Lift the bracket, manifold and cooking box slightly as a unit and hook onto the frame brace. CAUTION: No sealant is required on the side burner fitting.
Step 15 Insert one end of the hinge rod into the hole in the frame. Figure 18 (a). Install left hand swing table Insert the other end into the hole in the swing table end bracket. Figure 18 (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 18 (c).
Step 16 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 19. 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 22 (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 wheel frame and slide bar assembly and add nylon washers and hex nuts. Tighten nuts using a screwdriver and pliers. Figure 23. 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.
Step 17 Step 18 Set LP fuel scale Fill LP tank You will need: LP tank (empty). Note - The LP tank manufacturer is responsible for the materials, workmanship and performance of the tank. If the tank has a defect, malfunctions, or you have a question regarding the tank, call the tank manufacturer's customer service center. The phone number is on the warning decal which is permanently attached to the tank.
Step 19 Route the hose so it will not interfere with the scale indicator rod. Connect LP tank The hose and regulator are connected in the following manner: WARNING: Make sure that the LP tank valve is closed. Close by turning clockwise. Slide back the collar of the quick disconnect on the tank valve. Push the male fitting of the regulator into the quick disconnect, and maintain pressure. Slide the collar closed. Figure 27 (a).
Step 20 To perform leak checks: open tank valve by turning the tank valve handwheel counterclockwise. Figure 29. 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. This will result in a fire or explosion which can cause serious bodily injury or death and damage to property. E F Figure 29 WARNING: You should check for gas leaks every time you disconnect and reconnect a gas fitting.
Check: Step 21 a) Hose to manifold connection. Figure 31 (a). b) Regulator to tank connection. Figure 31 (b). Insert Flavorizer Bars and Steam-N-Chips Smoker c) Manifold to side burner hose connection. Figure 31 (c). 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 (c), retighten the fitting with a wrench and recheck for leaks with soap and water solution.
Step 22 Step 23 Install the bottom tray Install cooking grates You will need: bottom tray, catch pan holder, catch pan and one drip 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. Set the cooking grates onto the ledges in the cooking box. Figure 34.
Step 24 Step 25 Install the lid Install tool holders, control panel, burner control knobs and FlameCheck button You will need: lid, two hinge pins and two hair pin cotters. You will need: three tool holders, control panel, three burner control knobs and FlameCheck button. 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. Hook the tool holders over the frame rail. Figure 39.
Step 26 Step 27 Secure side burner Complete accessory installation 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 40. Caution: Make sure both locks have snapped into place.
OPERATING INSTRUCTIONS Lighting WARNING: The burner control knobs must be in the OFF position before turning on the LP tank valve. If they are not in the OFF position, when you turn on the LP tank valve, the excess flow control will activate, limiting the flow of gas from the LP tank. If this should occur, turn OFF the LP tank Summary lighting instructions are on the control panel.
Manual Lighting 4) Turn the tank on by turning the tank valve counterclockwise. DANGER 5) Push Front burner control knob down and turn to START/HI. 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. 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.
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 flameup which can cause serious bodily injury or death. The side burner will only operate when the Front burner is lit. 1) Open the side burner lid. Figure 3. 2) Push down and turn the side burner control to HI.
Cooking Storage and/or Nonuse continued The Weber Gas Barbecue should not be moved when operating or hot. 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. For example, to sear steaks you would use (HHH) (all burners at high).
Using the Steam-N-Chips Smoker DANGER Do not use any flammable fluid in the Steam-N-Chips Smoker to ignite the wood. This will cause serious bodily injury. 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.
Refilling the LP tank Connecting the filled LP tank WARNING: Make sure that the LP tank valve is closed. Close by turning clockwise. 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. DANGER Do not use an open flame to check for gas leaks.
c) Connect the hose to the tank. Route the hose so it does not interfere with the scale indicator rod. Slide back the collar of the quick disconnect on the tank valve. Figure 7 (a). Push the male fitting of the regulator into the quick disconnect, and maintain pressure. Slide the collar closed. Figure 7 (b). If it does not engage or lock, repeat procedure. Gas will not flow unless the quick disconnect is properly engaged.
Safe handling tips for LP Gas ■ Liquid Propane (LP) gas is a petroleum product as are gasoline and natural gas. LP gas is a gas at regular temperatures and pressures. Under moderate pressure, inside a tank, LP gas is a liquid. As the pressure is released the liquid readily vaporizes and becomes gas. ■ LP gas has an odor similar to natural gas. You should know this odor. ■ LP gas is heavier than air. Leaking LP gas may collect in low areas that prevent dispersion.
WARNING: If there is a leak at connections (a) or (c), 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 Weber-Stephen Customer Service. WARNING: Check hose before each use of barbecue for nicks, cracking, abrasions or cuts.
General Maintenance Main Burner Flame Pattern Weber Spider Stopper Guards The Weber Gas Barbecue burners have been factory set for the correct air and gas mixture. The correct flame pattern is shown in Figure 13. 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 11.
h) Lift and twist the burner assembly slightly, to separate the crossover tube from the burners. Figure 19. Remove the burners from the cooking box. d) Unlatch the Spider Stopper Guards and remove. Figure 16. Crossover tube Figure 19 i) Figure 16 e) Use an adjustable wrench to remove the thermocouple from the FlameCheck valve. f) To reinstall burners, reverse steps c) through h). CAUTION: The burner openings must be positioned properly over the valve orifices. Figure 20a.
j) Crossover Ignition System Operations 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 21. If the Crossover Ignition System fails to ignite the Front burner, light the Front burner with a match. If the Front burner lights with a match, then check the Crossover Ignition System.
FlameCheck Safety System The correct positioning of the thermocouple probe is shown in Figure 23. The tip of the probe is positioned in the flame. The probe senses the heat from the Front burner, and activates the FlameCheck valve. The valve allows the gas to flow into the Front burner. If the Front burner should go out for any reason, the thermocouple probe will cool off, thereby closing the FlameCheck valve, which stops the gas flow to the burners.
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".) Burners do not light. -orBurners have a small flickering flame in the HIGH position. -orBarbecue temperature only reaches 250˚ to 300˚ degrees in the HIGH position.
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 41 42 ® ® 43 2 3 4-6 44 45 46 7 8 9 47 48-49 10 50 11 51 52 53 54 12 55 13 14 56 15 57-59 16 17 18-19 60 61 62 63-66 20 21-22 67-68 23 15 24 17 25 69 29 30 31 70 W 28 E BE R E BE R 27 W 26 32 33 34 35 36 37 42 37 38 21 39 40
Parts List 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. All items are single quantities unless otherwise specified. Parts can be ordered directly from Weber-Stephen Products Co. by phone or mail.
A FINAL WORD OF THANKS T 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. Call our toll free number 1-800-446-1071. For quicker service, please have your owner’s manual available for reference.
