Weber Genesis 4000 LP Owner's Manual

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 check
procedures carefully in this manual prior
to barbecue operation. Do this even if
barbecue was dealer assembled.

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.

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.

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.

8601501 6/96

National

Association

PROPANE

GAS

®

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 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 burner obstructions before using. See instructions in this manual for correct
procedures.

■ Do not operate the Weber Gas Barbecue if there is a gas leak present.

■ Do not use a flame to check for gas leaks.

■ Combustible materials should never be within 24 inches of the top, bottom, back or sides of your

Weber Gas Barbecue.

■ 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.

■ Should the burners go out during operation, turn all gas valves off. Open the lid and wait five minutes

before attempting to relight, using the lighting instructions.

■ Do not use charcoal or lava rock in your Weber Gas Barbecue.

■ Never lean over open grill or place hands or fingers on the front edge of the cooking box.

■ Should a grease fire occur, turn off all burners and leave lid closed until fire is out.

■ Do not enlarge valve orifices or burner ports when cleaning the valves or burners.

■ The Weber Gas Barbecue should be thoroughly cleaned on a regular basis.

■ LP gas is not natural gas. The conversion or attempted use of natural gas in an LP unit or LP gas in a

natural gas unit is dangerous and will void your warranty.

■ Do not attempt to disconnect any gas fitting while your barbecue is in operation.

■ Use heat-resistant barbecue mitts or gloves when operating barbecue.

LP GAS UNITS ONLY:

■ Use the regulator that is supplied with your Weber Gas Barbecue.

■ Do not attempt to disconnect the gas regulator or any gas fitting while your barbecue is in operation.

■ A dented or rusty LP tank may be hazardous and should be checked by your liquid propane supplier.

Do not use an LP tank with a damaged valve.

■ Although your LP tank may appear to be empty, gas may still be present, and the tank should be

transported and stored accordingly.

■ If you see, smell or hear the hiss of escaping gas from the LP tank:

1. Get away from LP tank.

2. Do not attempt to correct the problem yourself.

3. Call your fire department.

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,
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. THEREFORE, YOU
SHOULD RETAIN YOUR SALES SLIP OR
INVOICE.

This Limited Warranty shall be limited to the
repair or replacement of parts which prove
defective under normal use and service and
which on examination shall indicate, to
Weber's satisfaction, they are defective. Before
returning any parts, contact Weber-Stephen
Products Co. Customer Service Center. If
Weber confirms the defect and approves the
claim, Weber will elect to replace such parts
without charge. If you are required to return
defective parts, transportation charges must be
prepaid. Weber will return parts to the
purchaser, freight or postage prepaid.

This Limited Warranty does not cover any
failures or operating difficulties due to accident,
abuse, misuse, alteration, misapplication,
vandalism, improper installation or improper
maintenance or service, or failure to perform
normal and routine maintenance, including but
not limited to damage caused by insects within
the burner tubes, as set out in this owner's
manual.

Deterioration or damage due to severe
weather conditions such as hail, hurricanes,
earthquakes or tornadoes, discoloration due to
exposure to chemicals either directly or in the
atmosphere, is not covered by this Limited
Warranty.

There are no other express warrants except as
set forth herein and any applicable implied
warranties of merchantability and fitness are
limited in duration to the period of coverage of
this express written Limited Warranty. Some
states do not allow limitation on how long an
implied warranty lasts, so this limitation may
not apply to you.

Weber is not liable for any special, indirect or
consequential damages. Some states do not
allow the exclusion or limitation of incidental or
consequential damages, so this limitation or
exclusion may not apply to you.

Weber does not authorize any person or
company to assume for it any other obligation
or liability in connection with the sale,
installation, use, removal, return, or
replacement of its equipment; and no such
representations are binding on Weber.

This Warranty applies only to products sold at
retail.

WEBER-STEPHEN PRODUCTS CO.
Customer Service Center
250 South Hicks Road
Palatine, IL 60067-6241
[phone]

LP Tank

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. If the tank manufacturer has not resolved
the issue to your satisfaction, then call Weber­Stephen Products Co., Customer Service Center.

WARRANTY

© 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: Rd
1987 Reg. #58,034; #1,279,540; #1,283,586; #1,300,994;
#1,300,995. Printed in the U.S.A.

PATENTS AND TRADEMARKS

4

5

Contents

WARNINGS................................................................ 2

Warranty & Patents.................................................. 3-4

General Instructions.................................................... 6

Assembly ............................................................... 7-26

Operating Instructions

Lighting ....................................................... 27-29

Cooking ............................................................ 30

Storage and/or Nonuse .................................... 30

Cleaning ........................................................... 30

Steam-N-Chips Smoker ................................... 31

LP Tank Information.................................... 32-34

Troubleshooting & Maintenance

Annual Maintenance ........................................ 35

General Maintenance.................................. 36-39

Troubleshooting .......................................... 40-41

Parts Listing .............................................................. 43

FEATURES:

a) Convenient tables and racks.

b) Heavy gauge porcelain-on-steel lid seals in heat.

c) Rapid read thermometer for precision cooking.

d) Stainless Steel Flavorizer Bars vaporize just the

right amount of drippings for flavoring.

e) Separate burners for temperature control.

f) Crossover Ignition System with Gas Catcher Ignition

Chamber.

g) Fuel scale indicates LP gas supply.

h) Weber Warm-Up Basket for additional cooking or

warming space.

i) Locking casters for additional portability.

j) FlameCheck Safety System automatically shuts off

gas to the burners if the flame goes out.

k) Steam-N-Chips Smoker lets you add genuine

smoke flavor to any food prepared on this grill.

l) Side burner for making sauces, gravies, etc.,while

main grill is in use.

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.

2. The new connection will not permit the flow of gas
until a positive gas connection is made.

3. If an accidental fire occurs at the LP tank
connection, the flow of gas is stopped by a
temperature activated shutoff.

4. If the LP supply hose becomes damaged, cut,
punctured, or accidentally fire damaged, the
barbecue connection is equipped with an excess
flow control that will limit the flow of gas if leakage or
a fire occurs.

a

b

c

d

e

l

g

a

h

i

f

j

k

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 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.

Liquid Propane (LP) gas supply is easy to use and gives
you more cooking control than charcoal fuel.

■ These instructions will give you the minimum

requirements for assembling your Weber Gas
Barbecue. Please read the instructions carefully
before using your Weber Gas Barbecue. Improper
assembly can be dangerous.

■ Not for use by children.

■ If there are local codes that apply to portable gas

grills, you will have to conform to them. If there are
no local codes, you must conform to the latest
edition of the National Fuel Gas Code: ANSI Z

223.1.

■ The pressure regulator supplied with the Weber Gas

Barbecue must be used. This regulator is set for

10.5 inches of water column (pressure).

■ This Weber Gas Barbecue is designed for use with

liquid propane (LP) gas only. Do not use with
natural (piped in city) gas. The valves, orifices, hose
and regulator are for LP gas only.

■ Do not use with charcoal fuel.

■ Check that the area under the control panel and the

bottom tray are free from debris that might obstruct
the flow of combustion or ventilation air.

■ The area around the LP tank must be free and clear

from debris.

For Installation in Canada

These instructions, while generally acceptable, do not
necessarily comply with the Canadian Installation
codes, particularly with piping above and below ground.
In Canada the installation of this appliance must comply
with local codes and/or Standard CAN/CGA-B149.2
(Installation Code for Propane Burning Appliances and
Equipment).

Storage

■ The gas must be turned OFF at the LP tank when

the Weber Gas Barbecue is not in use.

■ When the Weber Gas Barbecue is stored indoors,

the gas supply must be disconnected and the LP
tank stored outdoors in a well-ventilated space.

■ LP tanks must be stored outdoors in a well-

ventilated area out of the reach of children.
Disconnected LP tanks must not be stored in a
building, garage or any other enclosed area.

■ When the LP tank is not disconnected from the

Weber Gas Barbecue, the appliance and LP tank
must be kept outdoors in a well-ventilated space.

Operating area

WARNING: Only use this barbecue outdoors in a
well ventilated area. Do not use in a garage,
building, breezeway or any other enclosed area.

■ Never use your Weber Gas Barbecue under an

unprotected combustible roof or overhang.

■ Your Weber Gas Barbecue is not intended to be

installed in or on recreational vehicles and/or boats.

■ Do not use combustible materials within 24 inches

of the top, bottom, back or sides of the grill.

■ The entire cooking box gets hot when in use. Do not

leave unattended.

■ Keep any electrical supply cord and the fuel supply

hose away from any heated surface.

■ Keep the cooking area clear of flammable vapors

and liquids, such as gasoline, alcohol, etc., and
combustible materials.

■ Never store an extra (spare) LP tank under or near

the Weber Gas Barbecue.

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

Block of wood

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.")

You will need a soap and water solution to check for gas
leaks. (See Step "Check for gas leaks.")

Note - The hardware size of nuts, bolts and screws is
given. For example "1/4-20 x 2 inch bolt" means a bolt
1/4 inch in diameter with 20 threads to the inch, 2 inches
long. On a small screw for example, "6-32 x 1/2 inch
screw" means a number 6 screw, with 32 threads to the
inch, 1/2 inch long.

®®®®®®®

®

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.

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 drip pans

Catch pan

W

E

B

E

R

W

E

B

E

R

W

E

B

E

R

W

E

B

E

R

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

Steam-N-Chips Smoker flue

Steam-N-Chips Smoker
water pan

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

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)

Two 1/4-20 wing nuts

(actual size)

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 frame. Add the other
wheel, WEBER side out. Tap on the hubcap. Figure 1.

W

E

B

E

R

W

E

B

E

R

Figure 1

Step 3

Assemble frame

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.

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. Put the right
frame to your right and left frame to your left. Figure 2.

Slip the two frame halves together with the tabs inside

,
until the tabs of the right frame are inside the left frame
and the holes align. Figure 2 (a).

Slip washers over bolts; insert and tighten bolts. (If you
try to insert a bolt and there are no holes, you have the
left frame turned the wrong way. Turn the left frame
around.) Figure 2 (b).

Left frame

Leg tabs

Frame tabs

Figure 2

(a)

(b)

Right frame

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
frame onto the tabs of the right frame with the dimple to
the inside. The fuel scale decal should face away as
shown. Figure 3.

The leg tabs must be on the inside of the frames.

Add front panel with the hole down and to your right.
Add the washers to the bolts, insert in the holes as
shown. Only start the bolts at the wheel frame, figure
3 (a) & (b), and tighten the bolts at the caster frame.

Note - Fuel scale decal on wheel frame must be on the
same side as the front panel.

Dimples to
the inside

Fuel scale
decal

Only start
this bolt

Figure 3

Step 5

Complete frame assembly

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.

Hold one frame connector between the caster and
wheel frame. Add nylon washers to the bolts. Put the
bolts through the frame and screw into frame connector.
Tighten.

Repeat procedure with the other frame connector.
Figure 4.

Figure 4

Step 6

Insert casters

You will need: frame assembly and two casters.

Push the casters firmly into the inserts in the ends of the
caster legs. Figure 5.

Figure 5

(a)

(b)

Wheel
frame

Caster
frame

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. Figure 6 (a).

Loosen the right front 1/4 x 20 bolt. The side burner lock
fits between the front panel and the frame.
The “U” shape cut out slips up over the bolt.
Tighten with a wrench.

Burner tubes

Figure 7

Frame brace

Step 8

Add cooking box

You will need: frame assembly, cooking box assembly,
1/4-20 x 2 inch bolt, nylon washer, 1/4-20 keps nut,
pliers and a 7/16 inch wrench.

Uncoil the hose.

Set the cooking box into the frame so the burner tubes
are under the frame brace. Figure 7.

Figure 6

(a)

(b)

Your Weber Gas Barbecue burner assembly has been
factory assembled, pressure and flame tested. As a
safety precaution we recommend you check the burner
alignment:

a) Do the valves fit into the ends of the burners?

Figure 9 (a).

b) Are the ends of the burners under the washers at

the left rear and left front of the cooking box? The
screws are only guides. Do not tighten. Figure 9 (b).

c) Are the wing nuts under the burner assembly

hand tight? Do not tighten with pliers. Figure 9 (c).

If you answered YES to a, b and c, the burners are
correctly aligned. If you answered NO, the burners are
misaligned. Contact Weber-Stephen Customer Service.
Do not use your barbecue.

Guide screw

Figure 9

(a)

(b)

(c)

Wing nuts

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.

Figure 8

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. Figure 10 (a).

Add the washer to the bolt. Put the bolt through panel
and frame brace, add hex nut and tighten with the 7/16
inch wrench. Figure 10 (b).

Figure 10

(a)

(b)

Tabs on tank panel

Slot in frame brace

Frame brace

Cross brace

Step 10

Add fuel scale

You will need: fuel scale assembly, two 1/4-20 wing nuts
and two nylon washers.

Slip the bolts on the back of the fuel scale assembly
through the two small holes in the tank panel. Make sure
indicator rod of fuel scale is on the left side of the wheel
frame.

Add washers, then wing nuts and tighten. Figure 11.

F

E

F

E

Figure 11

View from front left View from front right

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 brace. Figure 12 (b). Loosen the
igniter lock nut and slide the igniter into the small part of
the keyhole. Figure (c). Tighten the igniter lock nut.
Figure 12.

Note - If the igniter works loose, carefully tighten the
igniter lock nut with an adjustable wrench or pliers.

Figure 12

Igniter lock nut

Keyhole in
frame brace

Step 12

Check that all burner valves are off

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.

Figure 13

Small part of
keyhole in
frame brace

Frame brace

Frame brace

(a)

(b)

(c)

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 hose.

Use an 11/16 wrench to remove the protective brass cap
from the side burner fitting on the manifold. Figure 14.

CAUTION: When removing the cap use a 5/8 inch
wrench to "hold" the side burner fitting to keep it
from becoming loose. If the side burner fitting
should loosen, tighten before attaching side burner
hose.

Slide the side burner assembly into the open end of the
right frame. Route the side burner hose so that it
parallels the front of the barbecue. Loop the hose so
that it reaches the side burner fitting. Attach hose and
tighten with a 3/4 inch wrench. Figure 15. Install burner
grate. Check to be sure the side burner valve is OFF.
Push side burner control knob down and turn clockwise.

Figure 14

Figure 15

Step 14

Install manifold bracket

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.

Figure 16

Frame brace

Cap

Side burner fitting

Manifold bracket

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. Check to see that the lower tab of the bracket is
hooked in the slot in the frame. Figure 18 (c).

To fully seat the bracket, you may have to tap it lightly with a
hammer.

WARNING: If swing table end bracket is in any
way cracked or damaged, do not use swing table.
Call our Customer Service Center to order a new
part.

WARNING: The load limit for the swing table is
30 pounds.

Figure 18

(c)

View from rear

of barbecue

Hinge rod

(b)

(a)

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. Figure 17 (a). Swing the
rod up so you can slide the rod all the way inside the
locking tab. Figure 17 (b). The rod should swing freely
inside the locking tab. Figure 17 (c).

Figure 17

(a)

(b)

(c)

Support rod

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 to the front

Slide bar

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 20.

View from rear
of barbecue

Support rod

Locked position

Unlocked position

Figure 20

Slide

Step 16

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.

Allow the slide bar to hang down. Push the support rod
into the lower support bracket. Figure 21 (a). Swing the
rod up so you can slide the rod all the way inside the
locking tab. Figure 21 (b). The rod should swing freely
inside the locking tab. Figure 21 (c).

Figure 21

(a)

(b) (c)

View from rear

Support rod

Slide bar
assembly

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

Notch

Slide bar

Unlocked position

Slide

Support rod

Locked position

Wheel frame

View from front
of barbecue

Slot in frame
(view from below)

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. 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 22 (c).

To fully seat the bracket, you may have to tap it lightly with a
hammer.

WARNING: If swing table end bracket is in any
way cracked or damaged, do not use swing table.
Call our Customer Service Center to order a new
part.

WARNING: The load limit for the swing table is
30 pounds.

(b)

(c)

(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.

F

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.) One series of tanks mounts with the valve facing
the front. The other tanks mount with the valve facing
away from the fuel scale. These types of tanks are
illustrated in Figure 25.

Loosen the tank lock wing nut. Tighten so the lock is
held up out of the way. Figure 25 (a). Lift and hook the
tank onto the fuel scale. With an empty LP tank, adjust
the fuel scale setting to E by turning the scale setting
(top) wing nut. Figure 25 (b).

CAUTION: Do not remove adjustment wing nut
from tank scale.

After adjusting tank scale, push tank down a couple of
times to check that the tank scale is set on “E”.

FEF

E

F

E

Figure 25

Tank lock
wing nut

(a) (b)

Scale setting
wing nut

Step 18

Fill LP tank

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. 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.

WARNING: We recommend that your LP tank be
filled at an authorized LP gas dealer by a qualified
attendant, who fills the tank by weight.

IMPROPER FILLING IS DANGEROUS.

Tell your LP dealer that this is a new LP tank. The air
must be removed from a new LP tank before the initial
filling. Your LP tank dealer is equipped to do this.

CAUTION: If you exchange your LP tank, make
sure you get a similar tank in return. Your LP tank is
equipped with a quick-disconnect valve. Other LP
tanks are not compatible with your barbecue
connection.

The LP tank must be installed, transported and stored in
an upright position. LP tank should not be dropped or
handled roughly.

Never store or transport the LP tank where
temperatures can reach 125° Fahrenheit (too hot to hold
by hand – for example: do not leave the LP tank in a car
on a hot day).

For full instructions on safe handling of LP tanks, see
section "Operating Instructions".

Note - remove LP tank filler adapter before connecting
the regulator to the tank.

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 collar
closed. Figure 27 (a). Figure 27 (b) shows the quick
disconnect engaged and various components of the tank
and regulator. Regulator vent hole should be at 3, 6, or 9
o'clock. It should not be pointed up. Figure 27 (c).

Figure 27

Turn so regulator vent
does not collect water

Hose

Tank lock
wing nut

Quick disconnect
engaged

Valve handwheel
close clockwise

Tank valve

Collar

Male
fitting

Pressure
relief valve

Tank

Regulator

Regulator
vent

(a)

(b)

(c)

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. Figure 26.

Figure 26

F

E

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 hoses and
manifold. Figure 30.

Check for leaks by wetting the connections with the
soap and water solution and watching for bubbles. If
bubbles form or if a bubble grows there is a leak.

Note - Since some leak test solutions, including soap
and water, may be slightly corrosive, all connections
should be rinsed with water after checking for leaks.

WARNING: Do

not ignite burners while leak

checking.

22

Step 20

Check for gas leaks

WARNING: You should check for gas leaks every
time you disconnect and reconnect a gas fitting.

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.

WARNING: Perform these leak checks even if
your barbecue was dealer or store assembled.

You will need: FlameCheck button, a soap and water
solution and a rag or brush to apply it.

Make sure side burner is OFF. Remove valve control
knob and screws. Remove porcelain top. Figure 28.

Figure 28

 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.

Figure 29

Figure 30

E

FEF

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 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 hose to side burner connection.

Figure 31 (d).

e) Valves to manifold connections. Figure 31 (e).

f) Hose to regulator connection. Figure 31 (f).

WARNING: If there is a leak at connections (d), (e)
or (f), turn OFF the gas. DO NO

T OPERATE THE
BARBECUE. Contact Weber-Stephen Customer
Service.

When leak checks are complete, turn gas supply OFF at
the source and rinse connections with water.

Figure 31

(a) (b)

(c)

(d)

(f)

(e)

Place the short Flavorizer Bars in place in the upper
positions in the cooking box. Set the Steam-N-Chips
Smoker body on the flue and across the long Flavorizer
bars. Figure 33.

Step 21

Insert Flavorizer Bars and
Steam-N-Chips Smoker

You will need: five long Flavorizer Bars, seven short
Flavorizer Bars, Steam-N-Chips Smoker body and flue.

Place the three long Flavorizer bars in the rear of the
cooking box. Insert the remaining two bars through the
Steam-N-Chips Smoker flue and set into place in the
cooking box. Figure 32.

Figure 32

Figure 33

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 bottom tray onto the mounting rails under the
cooking box with finger grip toward you. Figure 37.

CAUTION: Do not line bottom tray with aluminum
foil. It can cause grease fires by trapping the grease
and not allowing grease to flow into the catch pan.

Put the foil drip pan into the catch pan.

Slide the catch pan into the catch pan holder with its
finger grip towards you.

Figure 36

Figure 35

Figure 37

Bottom tray

Finger grip on front
edge of bottom tray

Finger grip

Front side of catch
pan holder

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. Figure 34.

Figure 34

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 pin

Step 25

Install tool holders, control panel, burner control
knobs and FlameCheck button

You will need: three tool holders, control panel, three
burner control knobs and FlameCheck button.

Hook the tool holders over the frame rail. Figure 39.

Set the control panel in place over both frame braces.
(Hold the Crossover Ignition button up while setting the
control panel in place.) Place your thumbs over the
control panel push-in buttons and push them into the
frame brace until they snap into place. Figure 39 (a).

Push on the burner control knobs and FlameCheck
button. Figure 39 (b).

Figure 39

Hole in frame brace

Tool holders

(a)

(b)

Control panel
push-in buttons

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 the left end of the lid. Figure 41 (a).

Set the work table onto the left side rails. Figure 41 (b).

Place porcelain serving tray on the work table.
Figure 41 (c).

Set the accessory trays between the two frame
connectors. Figure 41 (d).

Set the warming rack into the slots at the rear of the
cooking box. Figure 41 (e).

Insert the thermometer into its holder. Figure 41 (f).

Insert tubing plugs into the ends of the frame. To fully seat
the plugs, you may have to tap them lightly with a
hammer. Figure 41 (g).

Figure 41

(a)

(e)

(f)

(g)

(b)

(d)

(c)

Step 26

Secure side burner

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.

Figure 40

View from top

Side view

Caution: To keep the barbecue stationary, the tabs
on the locking casters should be in the down
position.

2727

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 Crossover Ignition Button
until it clicks.

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.

Figure 1

Crossover Ignition System

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

valve and burner control knobs and start over.

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) Push down the FlameCheck button and hold down.

Note - Gas is supplied to the burner only when the
FlameCheck button is depressed.

7) Push the Crossover Ignition button several times, so
that it clicks each time.

8) Check that the burner is lit by looking through the
matchlight hole on the front of the cooking box.

If the burner is lit, continue to hold the FlameCheck
button down for about 8 seconds. When the button is
released the burner will stay lit.

WARNING: If the burner does not light, turn the
Front burner control knob to OFF and wait 5
minutes to let the gas clear before you try again or
try to light with a match.

9) After the FRONT burner is lit you can turn on the
other burners.

Note - The FRONT burner must be on at all times when
operating the other burners. The FlameCheck Safety
System monitors the Front burner. For your safety, the
FlameCheck valve will shut off the gas to the burners if the
front burner should inadvertently go out during cooking.

To Extinguish

Turn gas supply OFF at the source, then push down
and turn each burner control knob clockwise to

OPERATING INSTRUCTIONS

 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 flame­up which can cause serious bodily injury
or death.

1) Open the lid. Figure 1.

2) Check that the fuel scale reads more than “E”.

Note - E = empty; F = full.

3) Make sure all burner control knobs are turned OFF.
(Push each burner control knob down and turn
clockwise.)



DANGER



When the excess flow control is
activated, a small amount of gas is still
flowing to the burners. After turning OFF
the tank and burner control knobs, wait at
least 5 minutes for the gas to clear before
attempting to light the barbecue. Failure
to do so may result in an explosive flame­up which can cause serious bodily injury
or death.

1

3

9

4

8

5

6

7

2

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 flame into the matchlight
hole in the front of the cooking box.

7) Push down and hold the FlameCheck button down.

Note - Gas is supplied to the burner only when the
FlameCheck button is depressed.

8) Check that the burner is lit by looking through the
matchlight hole on the front of the cooking box.

If the burner is lit, continue to hold the FlameCheck
button down for about 8 seconds. When the button
is released the burner will stay lit.

WARNING: If the burner does not light, turn the
Front burner control knob to OFF and wait 5 minutes
to let the gas clear before you try again or try to light
with a match.

9) After the FRONT burner is lit you can turn on the
other burners.

Note - The FRONT burner must be on at all times when
operating the other burners. The FlameCheck Safety
System monitors the Front burner. For your safety, the
FlameCheck valve will shut off the gas to the burners if
the front burner should inadvertently go out during
cooking.

To Extinguish

Turn gas supply OFF at the source, then push down
and turn each burner control knob clockwise to OFF.

Manual Lighting

1) Open the lid. Figure 2.

2) Check that fuel scale reads more than “E”.

Note - E = empty; F = full.

3) Make sure all burner control knobs are turned OFF.
(Push each knob down and turn clockwise.)

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 valve
and burner control knobs and start over.

2

1

6

3

4

5

7

9

8

Figure 2

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 flame­up which can cause serious bodily injury
or death.



DANGER



When the excess flow control is
activated, a small amount of gas is still
flowing to the burners. After turning OFF
the tank and burner control knobs, wait at
least 5 minutes for the gas to clear before
attempting to light the barbecue. Failure
to do so may result in an explosive flame­up which can cause serious bodily injury
or death.

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 several times so
it clicks each time.

CAUTION: Side burner flame may be difficult to
see on a bright sunny day.

WARNING: If the side burner does not light:

a) Turn OFF the side burner control valve.

b) Wait 5 minutes to let the gas clear before you try

again or try to light with a match.

3

2

1

Figure 3

 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.

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 of the FRONT, CENTER, and
BACK burners. For example, to sear steaks you would
use (HHH) (all burners at high). Then to complete
cooking you would use (MOM) (FRONT at medium,
CENTER off, and BACK at medium). See your Weber
cookbook for detailed cooking instructions.

Note: The temperatures inside your cooking box, for the
first few uses, while surfaces are still very reflective,
may be hotter than those shown in your cookbook.
Cooking conditions may require the adjustment of the
burner controls to attain the correct cooking
temperatures.

CAUTION: Replace thermometer in lid when not in
use. Do not leave thermometer in food while
cooking.

If burners go out during cooking, open lid, turn off
all burners and wait 5 minutes before relighting.

Preheating

Your Weber Genesis Gas Barbecue is an energy
efficient appliance. It operates at a low B.T.U. rate for
economy. To preheat, after lighting, close lid and turn all
burners to high (HHH). Preheating to between 500° and
550° F (260° and 290° C) will take 10 to 15 minutes
depending on conditions such as air temperature and
wind.

Drippings and grease

The Flavorizer Bars are designed to "smoke" the right
amount of drippings for flavorful cooking. Excess
drippings and grease accumulate in the catch pan under
the bottom tray. Disposable foil liners are available that
fit the catch pan.

CAUTION: Check the bottom tray for grease build­up before each use. Remove excess grease to avoid
a grease fire in the bottom tray.

Storage and/or Nonuse

■ The gas must be turned off at the LP tank when the

Weber Gas Barbecue is not in use.

■ When the Weber Gas Barbecue is stored indoors,

the gas supply must be DISCONNECTED and the
LP tank stored outdoors in a well-ventilated space.

Storage and/or Nonuse continued

■ LP tanks must be stored outdoors in a well-

ventilated area out of reach of children.
Disconnected LP tanks must not be stored in a
building, garage or any other enclosed area.

■ When the LP tank is not disconnected from the

Weber Gas Barbecue, the appliance and LP tank
must be kept outdoors in a well-ventilated space.

■ The Weber Gas Barbecue should be checked for

gas leaks and any obstructions in the burner tubes
before using. (See Sections "General and Annual
Maintenance.")

■ Check that the areas under the control panel and

the bottom tray are free from debris that might
obstruct the flow of combustion or ventilation air.

■ The Spider Stopper Guards should also be checked

for any obstructions. (See Section "Annual
Maintenance.")

Periodic Cleaning

CAUTION: Turn your Weber Gas Barbecue OFF
and wait for it to cool before cleaning.

CAUTION: Do not clean your Flavorizer Bars or
cooking grates in a self-cleaning oven. Replacement
cooking grates and Flavorizer Bars are available
through your retailer or the Weber-Stephen Customer
Service Center.

Outside surfaces - Use a warm soapy water solution.

CAUTION: Do not use oven cleaner, abrasive
cleansers (kitchen cleansers) cleaners that contain
citrus products or abrasive cleaning pads on
barbecue or cart surfaces.

Bottom tray - Remove excess grease and then wash

with warm soapy water.

Flavorizer Bars and Cooking Grates- Clean with a
suitable brass bristle brush. As needed, remove from grill
and wash with warm soapy water.

Catch pan - Disposable foil trays are available, or you can
line the catch pan with aluminum foil. To clean the catch
pan, wash with warm soapy water.

Thermometer - Wipe with warm soapy water, clean with
plastic scrub ball. Do not put in dishwasher or submerge
in water.

Inside cooking box - Brush any debris off of burners
tubes. DO NOT ENLARGE BURNER PORTS
(OPENINGS). Wash inside of cooking box with warm
soapy water.

Inside Lid - While lid is warm, wipe inside with paper
towel to prevent flaking due to grease build-up.

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 foods
such as roasts, chicken and turkeys, etc., we recommend
using FireSpice Chunks because they ignite slowly and
provide smoke for a longer period of time. As you gain
experience in using your Steam-N-Chips Smoker, we
encourage you to experiment with different combinations
of FireSpice Chips and Chunks to find the smoke flavor
that best suits your taste.

To use the Steam-N-Chips Smoker

As a starting point, place a handful of FireSpice Chips or
a few FireSpice Chunks in the bottom of the smoker body.
Figure 4. Since the chunks vary in size, place as many as
you can in the smoker allowing room for the water pan.
As you gain experience in smoking, increase or decrease
the amount of wood to suit your taste. Fill water pan,
place it in the smoker and close the smoker lid.

Light the barbecue and preheat with all burners on HIGH,
lid down, for 10 minutes or until thermometer registers
500°F - 550°F. Adjust the burners for cooking; MOM or
LOL will be your best settings for long duration smoking.
Smoke will start in approximately 10 minutes and last as
long as 45 minutes. If you require more smoke flavor, refill
the smoker with FireSpice Chips and/or Chunks and refill
the water pan with water. The Steam-N-Chips Smoker
may be used to enhance any of the meat, poultry and fish
recipes in the gas barbecue cookbook. Cook with the lid
down according to the times indicated in charts or
recipes.

Note - After refilling smoker, smoke will take about 10 to
15 minutes to start again.

Cutaway view

Cleaning the Steam-N-Chips Smoker

Before each use, empty the Steam-N-Chips Smoker of
ash to allow proper air flow. Accomplish this by lightly
tapping the sides of the smoker and stirring the ashes so
that they sift through the bottom and fall into the bottom
tray of your barbecue. Remove bottom tray and empty.

Note - Smoking will leave a "smoke" residue on the
surface of the smoker. This residue cannot be removed
and will not affect the function of the 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.

 DANGER 

Do not use any flammable fluid in the
Steam-N-Chips Smoker to ignite the wood.
This will cause serious bodily injury.

Place wood in here

Steam-N-Chips Flue

Figure 4

Water Pan

Steam-N-Chips Body

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 wing nut, while the tank is empty so you do
not run out again.

Removal of the LP tank

1) Close tank valve (turn clockwise). Figure 5 (a).

2) Slide the collar back on the quick disconnect to
disengage the fitting. Figure 5 (b).

3) Loosen tank lock wing nut and turn tank lock up out
of the way.

4) Lift tank off.

To refill take LP tank and tank filler adapter to a "Gas
Propane" dealer.

WARNING: We recommend that your LP tank be
filled at an authorized LP gas dealer, by a qualified
attendant, who fills the tank by weight. IMPROPER
FILLING IS DANGEROUS.

CAUTION: If you exchange your LP tank, make
sure you get a similar tank in return. Your LP tank is
equipped with a quick-disconnect valve. Other LP
tanks are not compatible with your barbecue
connection.

Connecting the filled LP tank

WARNING: Make sure that the LP tank valve is
closed. Close by turning clockwise.

You will need: LP tank, a soap and water solution and a
rag or brush to apply it.

Note - Since some leak test solutions, including soap
and water, may be slightly corrosive, all connections
should be rinsed with water after checking for leaks

a) Lift and hook the tank onto the fuel scale.

b) Loosen the tank lock wing nut. Swing the tank lock

down. Tighten the wing nut. Figure 6.

Figure 6

 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.

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. Figure 7 (b). If it
does not engage or lock, repeat procedure. Gas will
not flow unless the quick disconnect is properly
engaged.

d) Mix soap and water.

e) Open the tank valve. Figure 8.

f) Check for leaks by wetting the fitting with the soap

and water solution and watching for bubbles. If
bubbles form or if a bubble grows there is a leak.

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

OFF and rinse connections with water.

LP Tank

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. If the tank manufacturer has not resolved the issue
to your satisfaction, then call Weber-Stephen Products
Co., Customer Service Center.

Figure 8

Male fitting

Regulator

Collar

Quick disconnect
engaged

Figure 7

(a)

(b)

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 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.

■ To fill, take the LP tank and the filler adapter to an

RV center, or look up gas-propane in the phone
book for other sources of LP gas.

WARNING: We recommend that your LP tank be
filled at an authorized LP gas dealer, by a qualified
attendant, who fills the tank by weight. IMPROPER
FILLING IS DANGEROUS.

CAUTION: If you exchange your LP tank, make
sure you get a similar tank in return. Your LP tank is
equipped with a quick-disconnect valve. Other LP
tanks are not compatible with your barbecue
connection.

■ Air must be removed from a new LP tank before the

initial filling. Your LP dealer is equipped to do this.

■ The LP tank must be installed, transported and

stored in an upright position. LP tanks should not be
dropped or handled roughly.

■ Never store or transport the LP tank where

temperatures can reach 125° F (too hot to hold by
hand - for example: do not leave the LP tank in a car
on a hot day).

Note - A refill will last about 20 hours of cooking time at
normal use. The fuel scale will indicate the propane
supply so you can refill before running out. You do not
have to run out before you refill.

■ Treat "empty" LP tanks with the same care as when

full. Even when the LP tank is empty of liquid there
still may be gas pressure in the tank. Always close

the tank valve before disconnecting.

■ Do not use a damaged LP tank. Dented or rusty LP

tanks or LP tanks with a damaged valve may be
hazardous and should be replaced with a new one
immediately. See "LP tank requirements".

■ The joint where the hose connects to the LP tank

must be leak tested each time the LP tank is
reconnected. For example, test each time the LP
tank is refilled.

■ Be sure the regulator is mounted with the small vent

hole pointed downward so it will not collect water.
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.

■ Replacement LP tanks supplied by Weber satisfy

the requirements. Check to be sure the tank has a
D.O.T. certification, and has been tested within five
years. Your LP gas supplier can do this for you.
Figure 9.

If you have questions about spare LP tanks, please
call Weber-Stephen Customer Service.

DOT 4BA240

1/97

Date Tested

20 lb LP tank

D.O.T. Certification (example)

■ All LP tank supply systems must include a collar to

protect the tank valve.

■ The LP tank must be a 20 lb size (18 1/4 inches

high, 12 1/4 inches in diameter).

■ The LP tank must be constructed and marked in

accordance with the specifications for LP gas
cylinders of the U.S. Department of Transportation
(D.O.T.).

Figure 9

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 NO

T OPERATE THE BARBECUE.

Contact Weber-Stephen Customer Service.

d) Side burner hose to side burner connection.

Figure 10 (d).

e) Valves to manifold connections. Figure 10 (e).

f) Hose to regulator connection. Figure 10 (f).

WARNING: If there is a leak at connections (b),
(d), (e) or (f), turn OFF the gas. DO NO

T OPERATE
THE BARBECUE. Contact Weber-Stephen Customer
Service.

When leak checks are complete, turn gas supply OFF at
the source and rinse connections with water.

Annual Maintenance

After a period of nonuse we recommend that you
perform the following maintenance procedures f

or your

safety.

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.

■ Inspect the burners for correct flame pattern. Clean

if necessary, following the procedures outlined in
the "General Maintenance" section of this manual.

■ Check all gas fittings for leaks.

WARNING: You should check for gas leaks every
time you disconnect and reconnect a gas fitting.

You will need: a soap and water solution and a rag or
brush to apply it.

Make sure main burners are in the OFF position.

Make sure side burner is OFF. Remove valve control
knob and screws. Remove enamel top.

Put the FlameCheck button on the FlameCheck valve.

To perform leak checks: open tank valve by turning the
tank valve handwheel counterclockwise. Push the
FlameCheck button down and hold down until leak
checking is complete. This will allow gas to fill the hose
and manifold.

WARNING: Do

not ignite burners while leak

checking.

Check for leaks by wetting the connections with the
soap and water solution and watching for bubbles. If
bubbles form or if a bubble grows there is a leak.

Note - Since some leak test solutions, including soap
and water, may be slightly corrosive, all connections
should be rinsed with water after checking for leaks.

Check:

a) Hose to manifold connection. Figure 10 (a).

b) Regulator to tank connection. Figure 10 (b).

c) Manifold to side burner hose connection.

Figure 10 (c).

 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.

Figure 10

(a) (b)

(c)

(d)

(f)

(e)

Inspection and Cleaning of the Weber
Spider Stopper Guards

To inspect the Spider Stopper Guards, remove the
control panel and look to see if they have dust or dirt on
their outside surfaces. If they do, brush off the outside
surface of the Spider Stopper Guards with a soft bristle
brush (an old toothbrush for example). Check that there
are no gaps in the Spider Stopper Guards’ seams or in
the fit around the burners or valves. (See Section
"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 shutter. Figure 11. This could
result in a fire in and around the air shutters, under the
control panel, causing serious damage to your
barbecue.

The Weber Spider Stopper Guard is factory installed. It
fits tightly around the air shutter section of the burner
tube and the valve, thereby preventing spiders and other
insects access to the burner tubes through the air
shutter openings. Figure 12.

We recommend that you inspect the Weber Spider
Stopper Guards at least once a year. (See section
“Annual Maintenance”.) Also inspect and clean the
Spider Stopper Guards if any of the following
symptoms should ever occur.

1. The smell of gas in conjunction with the burner
flames appearing yellow and lazy.

2. Barbecue does not reach temperature.

3. Barbecue heats unevenly.

4. One or more of the burners do not ignite.

Figure 11

Figure 12

Venturi

Air shutter

Venturi fin

Weber Spider
Stopper Guard

 DANGER 

Failure to correct these symptoms
may result in a fire which can cause
serious bodily injury or death and cause
damage to property.

Main Burner Flame Pattern

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.

If the flames do not appear to be uniform the length of the
burner tube, follow the burner cleaning procedures.

Main Burner Cleaning Procedure

Turn off the gas supply. Remove the manifold.

(See Section “Replacing the main burners”.)

Look inside each burner with a flashlight. Figure 14.

Clean the inside of the burners with a wire
(a straightened out coat hanger will work). Figure 15.
Check and clean the air shutter opening at the ends of
the burners. Check and clean the valve orifices at the
base of the valves. Use a brass bristle brush to clean
outside of burners. This is to make sure all the burner
ports are fully open.

CAUTION: Do not enlarge the burner ports when
cleaning.

Replacing Main Burners

a) Your Weber Gas Barbecue must be OFF and cool.

b) Turn gas OFF at source.

c) Remove control panel: take off the burner control

knobs. Put your fingers under the edge of the
control panel at the control panel push-in buttons
and pull toward you. Lift off the control panel.

Figure 13

Burner inside
cooking box

Flames

Tips occasionally yellowish

Light blue

Dark blue

Figure 14

Figure 15

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 adjustable wrench to remove the

thermocouple from the FlameCheck valve.

f) Remove the manifold bracket and unscrew the two

wing nuts that hold the manifold to the cooking
box. Pull the manifold and valve assembly out of the
burners and carefully set it down. Figure 17.

g) Slide the burner assembly out from under the guide

screw and washer in the corners of the cooking box.
Figure 18.

Figure 16

View from behind
cooking box

Wing nuts

Figure 17

Guide screw

Figure 18

 CAUTION: The burner openings must be
positioned properly over the valve orifices.
Figure 20a.

Check proper assembly before fastening manifold in
place. Figure 20b.

Figure 20

Valve

Burner

(a)

(b)

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-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".)

38

Crossover Ignition System Operations

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.

■ Check that both the white and black ignition wires

are attached properly. Figure 22.

■ Check that the Crossover Ignition button pushes the

igniter (button) down, and returns to the up position.

■ Check to see if the igniter is loose in the frame.

Tighten if necessary; see Step “Install igniter” for
correct procedure.

If the Crossover Ignition System still fails to light, contact
Weber-Stephen Customer Service.

Figure 22

White wire

Black wire

Venturi fin

Check fit around burner

Figure 21

Check fit around
valve

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 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.

If the FlameCheck Safety System should fail to operate,
contact Weber-Stephen Customer Service.

Center line

Thermocouple nuts

Figure 23

1/8 inch

Ignition holes

Wall of cooking box

4040

Problem

Burners burn with a yellow or orange
flame, in conjunction with the smell of gas.

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.

Burner does not light, or flame is low in
HIGH position.

Experiencing flare-ups:

CAUTION: Do not line the bottom tray
with aluminum foil.

Burner flame pattern is erratic. Flame is low
when burner is on HIGH. Flames do not run
the whole length of the burner tube.

Inside of lid appears to be “peeling.”
(Resembles paint peeling.)

Fuel scale shows that there is gas in the LP
tank, but tank is empty.

Check

Inspect Weber Spider Stopper
Guards for possible obstructions.
(Blockage of holes.)

The excess flow safety device,
which is part of the barbecue to tank
connection, may have activated.

Is LP fuel low or empty?

Is fuel hose bent or kinked?

Does the Front burner light with a
match?

Are you preheating barbecue in the
prescribed manner?

Are the cooking grates and
Flavorizer Bars heavily coated with
burned-on grease?

Is the bottom tray "dirty" and not
allowing grease to flow into catch
pan?

Are burners clean?

The lid is porcelain-on-steel, not
paint. It cannot “peel.” What you are
seeing is baked on grease that has
turned to carbon and is flaking off.

THIS IS NOT A DEFECT.

Check adjustment of fuel scale.

Cure

Clean Weber Spider Stopper
Guards. (See Section "Annual
Maintenance".)

To reset the excess flow safety
device turn all burner control
knobs and the tank valve OFF.
Disconnect the regulator from the
tank. Turn burner control knobs
to HIGH. Wait at least 1 minute.
Turn burner control knobs OFF.
Reconnect the regulator to the
tank. Turn tank valve on slowly.
Refer to “Lighting Instructions”.

Refill LP tank.

Straighten fuel hose.

If you can light the Front burner
with a match, then check the
Crossover Ignition System.

All burners on high for 10 to 15
minutes for preheating.

Clean thoroughly. (See Section
"Periodic Cleaning".)

Clean bottom tray.

Clean burners. (See Section
"General Maintenance".)

Clean thoroughly. (See Section
"Periodic Cleaning".)

Fuel scale must be adjusted with
an empty tank.

TROUBLESHOOTING

If problems cannot be corrected by using these methods, please contact Weber-Stephen Customer Service.

4141

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 bent or kinked?

Inspect the Weber Spider Stopper
Guard for possible obstructions.
(Blockage of holes.)

Does burner light with a match?

Cure

Turn supply on. Light front
burner.

Straighten hose.

Clean Weber Spider Stopper
Guard. (See Section "Annual
Maintenance.")

If match lights burner, check
igniter (see below).

Side Burner Troubleshooting

WARNING: Before attempting any troubleshooting
steps, all gas controls and supply valves should be
in the OFF position.

Side Burner Maintenance

WARNING: All gas controls and supply valves
should be in the OFF position.

Check igniter: Remove side burner cover. To remove
side burner cover, remove control knob and screws that
hold cover to bottom. Figure 24. Make sure wire is
connected between igniter and electrode. Check that
igniter lock nut is tight. Figure 25

Note - If the igniter works loose, carefully tighten the
igniter lock nut with an adjustable wrench or pliers.

Adjust igniter electrode. Gap should be 1/8 to 3/16 inch
from tip of electrode to burner. Figure 26. Spark should
be a white/blue color, not yellow.

Figure 24

1/8 to 3/16 inch gap

Figure 25

Figure 26

Venturi/Burner

Electrode

Igniter wire

Igniter

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

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 may not be
necessary.

43

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.

Weber-Stephen Products Company
Customer Service Center
250 South Hicks Road
Palatine, IL 60067-6241
[phone]

1 Lid (assembly)
2 Weber Warm-Up Basket
3 Warming rack
4 Steam-N-Chips Smoker body
5 Steam-N-Chips Smoker flue
6 Steam-N-Chips Smoker water pan
7 Short Stainless Steel Flavorizer Bars (7)
8 Long Stainless Steel Flavorizer Bars (5)

9 Narrow cooking grate
10 Wide cooking grate
11 Serving tray
12 Work table
13 Tubing plugs (4)
14 1/4-20 x 2 inch bolts (5)
15 Swing table end brackets (2)
16 Left frame
17 Swing table assemblies (2)
18 1/4-20 x 1/2 inch bolts (6)
19 Nylon washers (22)
20 Left hand slide bar assembly
21 10-24 x 1 3/4 inch machine screws (4)
22 10-24 hex nuts (4)
23 Caster frame
24 Bottom tray
25 Casters (2)
26 Catch pan holder
27 Catch pan
28 Drip pans (2)
29 Accessory trays (2)
30 Wheel hub caps (2)
31 Wheels (2)
32 Axle
33 Front panel
34 Frame connectors (2)
35 Wheel frame
36 1/4-20 hex nut
37 Side burner locks (2)
38 Tank panel assembly
39 1/4-20 x 1 1/4 inch bolt
40 Right hand slide bar assembly

41 Hair pin cotters (2)
42 Hinge pins (2)
43 Thermometer
44 1/4-20 keps nut
45 Cooking box
46 Burner control knobs (3)
47 FlameCheck button
48 Control panel
49 Igniter button
50 Control panel push-in buttons (2)
51 Crossover tube
52 Front or Back burner
53 Center burner
54 1/4-20 stainless steel wing nuts (2)
55 Manifold assembly
56 Manifold bracket
57 Side burner assembly
58 Burner grate
59 Side burner knob
60 Thermocouple
61 Tool holders (3)
62 Right frame
63 Igniter
64 Igniter lock nut
65 Igniter wire (black)
66 Igniter wire (white)
67 Fuel scale
68 1/4-20 wing nuts (2)
69 LP tank w/quick disconnect
70 Filler adapter

WARNING:
Use only Weber factory authorized parts.
The use of any part that is not factory
authorized can be dangerous. This will also
void your warranty.

A FINAL WORD

OF

THANKS

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. We also welcome any comments

or suggestions you might have regarding our products.

We wish your family the

best in outdoor cooking enjoyment.

Weber-Stephen Products Company

Customer Service Center

200 East Daniels Road

Palatine, Illinois 60067-6266

T