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Weber Genesis 4000 Series Owner's Manual

Manual is about: Weber LP Gas Barbecue Owner's Manual 4000

Summary of Genesis 4000 Series

  • Page 1

    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 notice to installer: these instructions must be left with the owner and the owner should keep them for future use. Warning: follow all leak ...

  • Page 2: Danger

    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 assemb...

  • Page 3: Warranty

    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, cooking grates, 3 years, stainless steel flavorizer bars, 5 years, ...

  • Page 4: Patents and Trademarks

    © 1996 weber. Weber, , genesis, flavorizer and crossover are registered u.S. Trademar ks; 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 ...

  • Page 5: Contents

    5 contents warnings ................................................................ 2 warranty & patents.................................................. 3-4 general instructions.................................................... 6 assembly ...........................................................

  • Page 6: General Instructions

    6 general instructions 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...

  • Page 7: Assembly

    Step 1 check package contents cooking box (assembly) lid (assembly) lp tank lp tank filler adapter bottom tray work table two accessory trays two swing tables 7 assembly tools needed screwdrivers, regular and phillips hammer 7/16, 5/8, 11/16, and 3/4 inch open-end or two adjustable wrenches pliers b...

  • 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 8 right frame caster frame two casters cooking grate narrow cooking grate warming rack warm-up basket thermometer two aluminum ...

  • Page 9

    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...

  • Page 10

    10 four 10-24 x 1 3/4 machine screws (actual size) four 10-24 hex nuts (actual size) twenty two 1/4 inch nylon washers (actual size) 1/4-20 keps nut 1/4-20 x 1 1/4 inch bolt (actual size) 1/4-20 hex nut (actual size) two hair pin cotters two swing table end brackets check contents of hardware packs ...

  • Page 11

    11 step 2 assemble wheels you will need: axle, two wheel hubcaps, two wheels, wheel frame, hammer and a block of wood. 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 f...

  • Page 12

    12 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. Figure 3. Place the wheel f...

  • Page 13

    13 step 7 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. The “u” shape cut out of the lock slips down over the bolt. Tighten with a wrench. Figu...

  • Page 14

    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. F...

  • Page 15

    15 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...

  • Page 16

    16 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 ...

  • Page 17

    17 slot in frame (view from below) insert one end of the hinge rod into the hole in the frame. Figure 18 (a). 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....

  • Page 18

    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. Figure 19. Figure 19 view from front of barbecue notch t...

  • Page 19

    19 figure 22 view from rear of barbecue hinge rod figure 23 figure 24 to lower table: pull support rod up to disengage slide lock and lower table. To raise table, lift table up and engage slide in locked position. Figure 24. F f notch slide bar unlocked position slide support rod locked position whe...

  • Page 20

    20 step 17 set lp fuel scale you will need: lp tank (empty). Note - for accuracy, the fuel scale must be set with an empty tank. We utilize various lp tank manufacturers. Some of the tanks we receive have differing top collar assemblies. (the top collar is the metal protective ring around the valve....

  • Page 21

    21 route the hose so it will not interfere with the scale indicator rod. The hose and regulator are connected in the following manner: 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 c...

  • Page 22

    To perform leak checks: open tank valve by turning the tank valve handwheel counterclockwise. Figure 29. Put the flamecheck button on the flamecheck valve. When checking for gas leaks, push the flamecheck button down and hold down until leak checking is complete. This will allow gas to fill the hose...

  • Page 23

    23 check: a) hose to manifold connection. Figure 31 (a). B) regulator to tank connection. Figure 31 (b). C) manifold to side burner hose connection. Figure 31 (c). 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 sol...

  • Page 24

    24 step 23 install the bottom tray you will need: bottom tray, catch pan holder, catch pan and one drip pan. Hook the ends of the catch pan holder into the hole in the bottom tray. Figure 36. The front of the catch pan holder must be on the same side as the finger grip of the bottom tray. Slide the ...

  • Page 25

    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. Figure 38 hair pin cotter hinge p...

  • Page 26

    26 step 27 complete accessory installation you will need: work table, two accessory trays, serving tray, 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 t...

  • Page 27: Lighting

    27 27 lighting summary lighting instructions are on the control panel. Crossover ignition system note - the crossover ignition system ignites the front burner with a spark from the igniter electrode inside the gas catcher ignition chamber. You generate the energy for the spark by pushing the crossov...

  • Page 28: To Extinguish

    28 4) turn the tank on by turning the tank valve counterclockwise. 5) push front burner control knob down and turn to start / hi. 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. 6) strike a match and put the...

  • Page 29: Lighting The Side Burner

    29 lighting the side burner the side burner has a separate ignition system from the main cooking box. 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. 3) push the side burner igniter button sev...

  • Page 30: Cooking

    30 cooking 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 o...

  • Page 31: Using The Steam-N-Chips

    31 using the steam-n-chips smoker 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 fo...

  • Page 32: Refilling The Lp Tank

    32 scale setting wing nut tank lock wing nut tank valve collar (a) (b) figure 5 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 ...

  • Page 33

    33 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. F...

  • Page 34

    34 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 g...

  • Page 35: Annual Maintenance

    35 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. 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 h...

  • Page 36: General Maintenance

    36 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 sh...

  • Page 37

    37 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. I) to reinstall burners, reverse steps c) through h). Crossover tube figure 19 d) unlatch the spider stopper guards and remove. Figure 16. E) use an...

  • Page 38

    J) 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. Caution: if the spider stopper guards do not fit tightly, contact weber-...

  • Page 39

    39 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 fr...

  • Page 40: Troubleshooting

    40 40 problem burners burn with a yellow or orange flame, in conjunction with the smell of gas. Burners do not light. -or- burners have a small flickering flame in the high position. -or- barbecue temperature only reaches 250˚ to 300˚ degrees in the high position. Burner does not light, or flame is ...

  • Page 41: Side Burner Troubleshooting

    41 41 problem 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 work. Check is gas supply off? Is the front burner on? Is fuel hose be...

  • Page 42

    42 ® ® ® ® ® ® ® ® w ebe r w e be r 1 2 3 7 8 9 10 11 12 13 14 16 21-22 20 23 27 29 30 31 32 33 34 36 40 17 15 67-68 63-66 62 61 55 53 54 52 48-49 51 47 45 44 43 42 41 17 24 35 46 39 56 4-6 38 25 15 57-59 37 37 26 28 50 60 18-19 21 70 69.

  • Page 43: Parts List

    Parts list all items are single quantities unless otherwise specified. 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 ma...

  • Page 44

    A f inal w ord of t 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 ...