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Weber 4000 manual

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Table of contents for the manual

  • 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 NO TICE T O INST ALLER: These instructions must be left with the o wner and the owner should keep them f or future use. W ARNING: Follo w all leak chec k procedures carefull y in this ma[...]

  • Page 2

    2  D ANGER  Failure to f ollow the Dangers, W arnings and Cautions contained in this Owner’ s Manual ma y result in serious bodily injury or death, or in a fire or an explosion causing damage to property .  W ARNINGS  ■ Do not store a spare or disconnected LP tank under or near this barbecue. ■ Improper assemb ly may be danger ous[...]

  • Page 3

    3 W eber-Stephen Products Co . (Weber) hereb y warr ants to the ORIGINAL PURCHASER of this W eber Gas Barbecue that it will be free of def ects in mater ial and workmanship from the date of purchase as f ollows: Aluminum Castings , 10 years, Cooking Grates , 3 years, Stainless Steel Flav orizer Bars, 5 y ears, All Remaining P ar ts, 5 years , when [...]

  • Page 4

    © 1996 W eber . W eber , , Genesis, Fla vorizer and Crosso ver are registered U .S. tr ademar ks; P erma-Mount, Gas Catcher , FlameCheck, Steam-N-Chips , Spider Stopper , and W arm-Up are U .S. tr ademar ks of W eber-Stephen Products Co ., 200 East Daniels Road, P alatine, IL 60067-6266. U .S .A. Genesis Gas Barbecues are cov ered under the f ollo[...]

  • Page 5

    5 Contents WARNINGS ................................................................ 2 Warranty & Patents.................................................. 3-4 General Instructions .................................................... 6 Assembly ............................................................... 7-26 Operating Instructions Lighting [...]

  • Page 6

    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 the food. The Weber Gas Barbecue is por[...]

  • Page 7

    Step 1 Check pac kage contents Cooking bo x (assembly) Lid (assembly) LP tank LP tank filler adapter Bottom tra y W or k table T wo accessor y tra ys T wo swing tab les 7 Assembl y T ools needed Screwdriv ers, regular and Phillips Hammer 7/16, 5/8, 11/16, and 3/4 inch open-end or two adjustable wrenches Pliers Block of w ood Supplies needed Y our L[...]

  • Page 8

    Ser ving tra y Control panel F ront panel Left frame Wheel frame T wo frame connectors T ank panel assembly Five long Fla vorizer Bars Se ven shor t Flav orizer Bars T wo wheels Axle 8 Right frame Caster frame T wo casters Cooking grate Narrow cooking gr ate W ar ming rac k W ar m-Up Basket Ther mometer T wo aluminum drip pans Catch pan W E B E R W[...]

  • Page 9

    9 Right hand slide bar assembly Assembly consists of: Right hand slide bar Suppor t Slide Left hand slide bar assembly Assembly consists of: Left hand slide bar Suppor t Slide Fuel scale assembly Catch pan holder Manif old brack et Side burner assembly Bur ner gr ate Side burner knob T wo side burner locks Steam-N-Chips Smoker body Steam-N-Chips Sm[...]

  • Page 10

    10 F our 10-24 x 1 3/4 machine screws (actual size) F our 10-24 hex nuts (actual size) T wenty two 1/4 inch nylon w ashers (actual size) 1/4-20 keps n ut 1/4-20 x 1 1/4 inch bolt (actual size) 1/4-20 he x nut (actual size) T wo hair pin cotters T wo swing tab le end brack ets Check contents of hardw are packs Three burner control knobs FlameCheck b[...]

  • Page 11

    11 Step 2 Assemble wheels Y ou will need: axle, two wheel hubcaps , two wheels, wheel frame, hammer and a b lock of w ood. Place one end of the axle on the bloc k of wood (or other protected surf ace). T ap on one hubcap . Put one wheel on the axle, WEBER side to ward the hubcap . Slide the axle through the frame. Add the other wheel, WEBER side ou[...]

  • Page 12

    12 Step 4 Continue frame assemb ly Y ou will need: frame assemb ly , wheel frame assemb ly , front panel, caster frame, f our 1/4-20 x 1/2 inch bolts, f our 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 frame onto the tabs of the right frame with[...]

  • Page 13

    13 Step 7 Install side burner locks Y ou will need: frame assemb ly , 2 side burner locks and a 7/16 inch wrench. T ur n 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 loc k slips down ov er the bolt. Tighten with a wrench. Figure 6 (a). Loosen the right front 1/4 x[...]

  • Page 14

    14 Step 9 Install tank panel assembly Y ou will need: tank panel assembly , 1/4-20 x 1 1/4 inch bolt, 1/4-20 he x nut, nylon washer and a 7/16 inch wrench. Inser t the tank panel tabs into the slots in the frame brace. Slide up until the notch at the bottom of the tank panel fits ov er the cross brace. Figure 10 (a). Add the washer to the bolt. Put[...]

  • 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 f actor y test the ignition system. The igniter lock n ut is on the igniter . Inser t the top of the igniter up through the large par t of the ke yhole in the frame brace . Figure 12 (b). Loosen the igniter[...]

  • Page 16

    16 Step 13 Install side burner Y ou will need: side burner assembly , burner grate , manif old brack et, 3/4 inch, 5/8 inch and an 11/16 inch or two adjustab le wrenches.  CA UTION: No sealant is required on the side burner fitting. Do not use pipe dope, tape or an y other type of sealant on the fittings or hose. Use an 11/16 wrench to remov e t[...]

  • Page 17

    17 Slot in frame (view from belo w) Inser t one end of the hinge rod into the hole in the frame. Figure 18 (a). Inser t the other end into the hole in the swing tab le end brac ket. Figure 18 (b). Hold the end brac ket at an angle so the lower tab is inside the fr ame tube. Push the brac ket into the frame. Chec k to see that the lower tab of the b[...]

  • Page 18

    18 P osition slide bar assembly on the outside of the caster frame. Put a n ylon washer on each 1 3/4 inch scre w , inser t screws through frame and slide bar assemb ly and add nylon w ashers and hex nuts . Tighten nuts using a screwdriv er and pliers. Figure 19. Figure 19 View from front of barbecue Notch to the front Slide bar T o lower table: Pu[...]

  • Page 19

    19 Figure 22 View from rear of barbecue Hinge rod Figure 23 Figure 24 T o lower table: Pull support rod up to disengage slide lock and lo wer table . T o raise tab le, lift table up and engage slide in lock ed position. Figure 24. F F Notch Slide bar Unlock ed position Slide Suppor t rod Lock ed position Wheel frame View from front of barbecue Slot[...]

  • Page 20

    20 Step 17 Set LP fuel scale Y ou will need: LP tank (empty). Note - F or accuracy , the fuel scale must be set with an empty tank. W e utilize various LP tank manuf acturers. Some of the tanks we receiv e hav e differing top collar assemblies . (The top collar is the metal protective ring around the valv e.) One series of tanks mounts with the v a[...]

  • Page 21

    21 Route the hose so it will not interf ere with the scale indicator rod. The hose and regulator are connected in the f ollowing manner : Slide back the collar of the quic k disconnect on the tank valv e. Push the male fitting of the regulator into the quic k disconnect, and maintain pressure. Slide the collar closed. Figure 27 (a). Figure 27 (b) s[...]

  • Page 22

    T o perform leak checks: open tank v alve by turning the tank valv e handwheel counterclockwise . Figure 29. Put the FlameCheck b utton on the FlameCheck v alve . When checking f or gas leaks, push the FlameChec k button do wn and hold down until leak checking is complete. This will allo w gas to fill the hoses and manif old. Figure 30. Check f or [...]

  • Page 23

    23 Check: a) Hose to manif old connection. Figure 31 (a). b) Regulator to tank connection. Figure 31 (b). c) Manif old to side burner hose connection. Figure 31 (c).  W ARNING: If there is a leak at connections (a) or (c), retighten the fitting with a wrench and rechec k for leaks with soap and water solution. If a leak persists after retighteni[...]

  • Page 24

    24 Step 23 Install the bottom tra y Y ou will need: bottom tra y , catch pan holder , catch pan and one drip pan. Hook the ends of the catch pan holder into the hole in the bottom tra y . 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 bottom tra y onto the mounting rails under[...]

  • Page 25

    25 Step 24 Install the lid Y ou 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. Inser t 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 pin Step 25 Install tool holders, control panel,[...]

  • Page 26

    26 Step 27 Complete accessor y installation Y ou will need: work table , two accessor y tra ys, ser ving tra y , Warm-Up Basket, w ar ming rack, thermometer , two tubing plugs and a hammer . Inser t one end of the Weber W ar m-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 ([...]

  • Page 27

    27 27 Lighting Summar y lighting instructions are on the control panel. Crosso ver Ignition System Note - The Crossov er Ignition System ignites the F ront burner with a spark from the igniter electrode inside the Gas Catcher Ignition Chamber . Y ou generate the energy f or the spar k by pushing the Crosso ver Ignition Button until it clicks .  [...]

  • Page 28

    28 4) T ur n the tank on by turning the tank valv e counterclockwise . 5) Push F ront burner control knob down and turn to ST ART / HI.  W ARNING: Do not lean over open barbecue. Keep your face and bod y at least one foot a way from the matchlight hole when lighting the barbecue. 6) Strike a match and put the flame into the matchlight hole in th[...]

  • Page 29

    29 Lighting the side b urner The side burner has a separate ignition system from the main cooking bo x. The side burner will onl y operate when the Front burner is lit. 1) Open the side bur ner lid. Figure 3. 2) Push down and tur n the side burner control to HI. 3) Push the side bur ner igniter button se v eral times so it clicks each time .  CA[...]

  • Page 30

    30 Cooking The W eber Gas Barbecue should not be moved when operating or hot. Y ou can adjust the FRONT , CENTER and BACK b ur ners as desired. The control settings High (H), Medium (M), Low (L), or Off (O) are described in your W eber cookbook. The cookbook uses these notations to describe the settings of the FRONT , CENTER, and BA CK burners. For[...]

  • Page 31

    31 Using the Steam-N-Chips Smoker The Steam-N-Chips Smoker cooks with both W eber FireSpice W ood Chips and Chunks. F or best results with f aster cooking foods lik e steaks, burgers and chops , etc., we recommend using the FireSpice Chips because the y ignite and create smoke f aster . F or longer cooking foods such as roasts, chic ken and turke y[...]

  • Page 32

    32 Scale setting wing nut T ank lock wing nut T ank valv e Collar (a) (b) Figure 5 Refilling the LP tank W e recommend that you refill bef ore 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 s[...]

  • Page 33

    33 c) Connect the hose to the tank. Route the hose so it does not interf ere with the scale indicator rod. Slide back the collar of the quic k disconnect on the tank valv e. 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, rep[...]

  • Page 34

    34 Safe handling tips f or 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 [...]

  • Page 35

    35  W ARNING: If there is a leak at connections (a) or (c), retighten the fitting with a wrench and rechec k for leaks with soap and water solution. If a leak persists after retightening the fitting, turn OFF the gas . DO NO T OPERA TE THE B ARBECUE. Contact W eber-Stephen Customer Service. d) Side burner hose to side burner connection. Figure 1[...]

  • Page 36

    36 General Maintenance W eber Spider Stopper Guards Y our W eber Gas Barbecue, as well as any outdoor gas appliance, is a target f or spiders and other insects. The y can nest in the venturi section of the b ur ner tubes. This bloc ks the nor mal gas flow , and can cause the gas to flow bac k out of the air shutter . Figure 11. This could result in[...]

  • Page 37

    37 h) Lift and twist the burner assembly slightly , to separate the crossov er tube from the burners. Figure 19. Remov e the burners from the cooking bo x. i) T o reinstall bur ners, re verse steps c) through h). Crossov er tube Figure 19 d) Unlatch the Spider Stopper Guards and remov e. Figure 16. e) Use an adjustable wrench to remo ve the ther mo[...]

  • Page 38

    j) Reinstall the Spider Stopper Guards. Slightly rotate the Spider Stopper Guards so that the seams are in line with the V enturi fins. There should be no gaps in the seams or in the fit around the burners and valv es. Figure 21.  CA UTION: If the Spider Stopper Guards do not fit tightly , contact Weber -Stephen Customer Service .  CA UTION: [...]

  • Page 39

    39 FlameCheck Saf ety 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 F ront burner , and activates the FlameChec k valv e. The v alve allows the gas to flo w into the F ront bur ner . If the F ront burner should go out for an y reaso[...]

  • Page 40

    40 40 Prob lem Burners b urn with a yellow or orange flame, in conjunction with the smell of gas. Burners do not light. -or - Burners ha ve 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 low in HIGH position. Experiencing flare-ups[...]

  • Page 41

    41 41 Prob lem 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 w ork. Check Is gas supply off? Is the F ront burner on? Is fuel hose bent or kinked? Inspect the W eber Spider Stopper[...]

  • Page 42

    42 ® ® ® ® ® ® ® ® W E B E R W E B E 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

    P ar ts List All items are single quantities unless otherwise specified. P ar ts can be ordered directly from Weber-Stephen Products Co . by phone or mail. Note - Do not retur n par ts to W eber-Stephen Products Co . without first contacting the Customer Ser vice Center by phone or mail. Returning the par t may not be necessar y . 43 While we giv e[...]

  • Page 44

    A F INAL W ORD OF T HANKS hank you for choosing a W eber Barbecue. Our family her e at W eber has worked har d to pr oduce the highest quality products for your satisfaction. While we give much attention to our pr oducts, an occasional err or may occur . Our knowledgeable Customer Service staf f is prepar ed to help you with any pr oblems with part[...]