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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
®
NationalPROPANEGAS Association
FOR YOUR SAFETY
WARNING: Follow all leak check
1. Do not store or use gasoline or other
procedures carefully in this manual prior
flammable vapors and liquids in the
to barbecue operation. Do this even if
vicinity of this or any other appliance.
barbecue was dealer assembled.
2. An LP tank not connected
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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 bur
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WARRANTY Weber-Stephen Products Co. (Weber) hereby There are no other express warrants except as warrants to the ORIGINAL PURCHASER of set forth herein and any applicable implied this Weber Gas Barbecue that it will be free of warranties of merchantability and fitness are defects in material and workmanship from the limited in duration to the period of coverage of date of purchase as follows: this express written Limited Warranty. Some states do not allow limitation on how long an Aluminum Casti
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PATENTS AND TRADEMARKS © 1996 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:
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e Contents Troubleshooting & Maintenance WARNINGS................................................................ 2 Annual Maintenance ........................................ 35 Warranty & Patents.................................................. 3-4 General Maintenance.................................. 36-39 General Instructions.................................................... 6 Troubleshooting .......................................... 40-41 Assembly .......................................
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General Instructions Your Weber Gas Barbecue is a portable outdoor Storage cooking appliance. With the Weber Gas Barbecue you The gas must be turned OFF at the LP tank when can grill, barbecue, roast and bake with results that are the Weber Gas Barbecue is not in use. difficult to duplicate with indoor kitchen appliances. The closed lid and Flavorizer Bars produce that "outdoor" When the Weber Gas Barbecue is stored indoors, flavor in the food. the gas supply must be disconnected and the LP
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® ® ® ® ® ® ® ® Step 1 Assembly Check package contents Tools needed Screwdrivers, regular Cooking box and Phillips (assembly) 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 ga
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R R E E B B E E W W Serving tray 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 Two wheels Catch pan Axle 8 R R E E B B E E W W
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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
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Check contents of hardware packs Four 10-24 x 1 3/4 machine screws (actual size) Three burner control knobs Four 10-24 hex nuts (actual size) FlameCheck button Twenty two 1/4 inch nylon washers (actual size) Three tool holders 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
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R E B E W Step 2 Step 3 Assemble wheels Assemble frame You will need: axle, two wheel hubcaps, two wheels, You will need: left frame, right frame, two nylon wheel frame, hammer and a block of wood. 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 one wheel on the axle, WEBER s
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Step 4 Step 5 Continue frame assembly Complete frame assembly You will need: frame assembly, wheel frame assembly, You will need: partial frame assembly, two frame front panel, caster frame, four 1/4-20 x 1/2 inch bolts, connectors, four 1/4-20 x 2 inch bolts, four nylon four nylon washers and a 7/16 inch wrench. washers and a 7/16 inch wrench. Place the caster frame onto the tabs of the left frame Hold one frame connector between the caster and with the dimple to the inside. Figure 3. Place t
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Slide the cooking box to the left within the frame. Put the Step 7 washer on the bolt. Insert the bolt through the cooking Install side burner locks box and frame with the head of the bolt outside the box. You will need: frame assembly, 2 side burner locks and Figure 8. Add keps nut. Tighten by holding the bolt with a 7/16 inch wrench. pliers while you tighten the nut with the 7/16 inch wrench. Turn frame assembly right side up. Loosen the right rear 1/4 x 20 bolt. Install the side burner lock.
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E F Step 9 Step 10 Install tank panel assembly Add fuel scale You will need: tank panel assembly, 1/4-20 x 1 1/4 inch You will need: fuel scale assembly, two 1/4-20 wing nuts bolt, 1/4-20 hex nut, nylon washer and a 7/16 inch and two nylon washers. wrench. Slip the bolts on the back of the fuel scale assembly Insert the tank panel tabs into the slots in the frame through the two small holes in the tank panel. Make sure brace. Slide up until the notch at the bottom of the tank indicator rod of
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Step 11 Step 12 Install igniter Check that all burner valves are off Note - The igniter wires are already attached to the Gas You will need: one burner control knob. Catcher Ignition Chamber and the igniter. This was done (Valves are shipped in the OFF position, but you should to factory test the ignition system. check to be sure.) Put the knob on each valve. Check by The igniter lock nut is on the igniter. pushing down and turning clockwise. If they do not turn, they are off, proceed to the ne
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Step 13 Step 14 Install side burner Install manifold bracket You will need: side burner assembly, burner grate, You will need: manifold bracket manifold bracket, 3/4 inch, 5/8 inch and an 11/16 inch or Hook the bracket onto the manifold at the center burner two adjustable wrenches. valve. Figure 16. Place your hand underneath the bracket. Lift the bracket, manifold and cooking box CAUTION: No sealant is required on the side slightly as a unit and hook onto the frame brace. burner fitting. Do n
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Insert one end of the hinge rod into the hole in the Step 15 frame. Figure 18 (a). Install left hand swing table Insert the other end into the hole in the swing table end You will need: swing table end bracket, two 10-24 hex bracket. Figure 18 (b). Hold the end bracket at an angle so nuts, two 10-24 x 1 3/4 inch machine screws, left hand the lower tab is inside the frame tube. Push the bracket into slide bar assembly, swing table, four nylon washers, the frame. Check to see that the lower tab o
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Position slide bar assembly on the outside of the caster Step 16 frame. Put a nylon washer on each 1 3/4 inch screw, Install right hand swing table insert screws through frame and slide bar assembly and add nylon washers and hex nuts. Tighten nuts using a You will need: swing table end bracket, two 10-24 hex screwdriver and pliers. Figure 19. nuts, two 10-24 x 1 3/4 inch machine screws, right hand slide bar assembly, swing table, four nylon Notch to the front washers, screwdriver and pliers. Al
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F F Insert one end of the hinge rod into the hole in the Position slide bar assembly on the outside of the wheel frame. Figure 22 (a). frame. Put a nylon washer on each 1 3/4 inch screw, insert screws through wheel frame and slide bar Insert the other end into the hole in the swing table end assembly and add nylon washers and hex nuts. Tighten bracket. Figure 22 (b). Hold the end bracket at an angle so nuts using a screwdriver and pliers. Figure 23. the lower tab is inside the frame tube. Push t
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E F E E F F 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 Note - For accuracy, the fuel scale must be set with an the tank has a defect, malfunctions, or you have a empty tank. question regarding the tank, call the tank manufacturer's We utilize various LP tank manufacturers. Some of the customer service center. The phone number is on the tanks we receiv
