Weber SKYLINETM 520 manual

W E B E R W E B E R SKYLINE ™ 520 LP Gas Barbecue Owner’ s Manual W ARNING: Do not try to light this appliance without reading "Lighting" instructions section of this manual. THIS GAS APPLIANCE IS DESIGNED FOR OUTDOOR USE ONL Y . NO TICE TO INST ALLER: These instructions must be left with the o wner and the owner should keep them for [...]

 D ANGER Failure to f ollow the Danger s, W arnings and Cautions contained in this Owner’ s Manual may result in serious bodil y injury or death, or in a fire or an explosion causing dama g e to property .  W ARNINGS  Do not store a spare or disconnected LP tank under or near this barbecue .  Improper assemb ly ma y be dang er ous. Pl[...]

3 Weber-Stephen Products Co. (W eber) 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, Recycled Work Surfaces, 10 years Cooking Grates and Flavorizer Bars, 3 years, All Remaining Parts, 5 years, when ass[...]

© 1997 Weber . Weber , , Flavorizer and Crossover are registered U.S. trademarks; Spirit, Gas Catcher , FlameCheck, and Spider Stopper are U.S. trademarks of Weber-Stephen Products Co., 200 East Daniels Road, Palatine, IL 60067-6266. U.S.A. Spirit is covered under the following patent nos.: U.S.A. #4,677,964; 4,727,853; #4,829,978; #4,941,817; and[...]

5 Contents WARNINGS ................................................................ 2 W arranty & Patents .................................................. 3-4 General Instructions .................................................... 6 Assembly ............................................................... 7-20 Operating Instructions Lightin[...]

6 General Instructions Y our 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 po[...]

7 Step 1 Check package contents Cooking box (assembly) Lid (assembly) LP tank Bottom tray T wo cooking grates LP tank filler adapter Control panel Assembl y T ools needed Hammer 7/16 open-end or an adjustable wrench Pliers Block of wood Phillips screwdriver Supplies needed Y our LP tank is shipped empty for safety . After setting the LP fuel scale [...]

Left frame Right frame Wheel frame Leg frame Frame connector Work table Accessory rack W arming rack Five Flavorizer Bars T ank panel assembly Front panel Catch pan holder Catch pan T wo drip pans Manifold bracket Thermometer T wo wheels Fuel scale assembly Spacer bracket 8 W E B E R W E B E R W E B E R W E B E R[...]

T wo plastic buttons (actual size) T wo 1/4-20 wing nuts (actual size) Eleven 1/4 inch nylon washers T wo hair pin cotters T wo wheel hubcaps 1/4-20 keps nut T wo phillips screws/washers Check contents of hardware packs T wo burner control knobs T wo tool holders Eight tubing plugs (two are spares) T wo hinge pins (hardware size: 1/4 x 1 1/2 inch c[...]

10 Figure 1 W E B E R W E B E R Figure 2 Leg tabs Frame tabs (a) (b) Right frame Left frame Step 2 Assemble wheel frame Y ou will need: wheel frame, two wheels, two wheel hubcaps, hammer and a block of wood. Set one end of wheel frame on the block of wood (or other hard, protected surface). Put one wheel on axle, WEBER side facing up, and tap on on[...]

11 Figure 3 Figure 4 Figure 5 View from rear of barbecue Dimples to the inside Fuel scale decal Plastic buttons Step 5 Install tubing plugs Y ou will need: two tubing plugs and a hammer . Insert tubing plugs into the ends of the leg frame.Figure 4. T o fully seat the plugs, you may have to tap them lightly with a hammer . Step 4 Continue frame asse[...]

Guide screw (a) (b) (c) Wing Nuts View from behind cooking box Figure 8 12 Figure 6 Burner tubes Frame brace (a) (b) Spacer bracket Keps nut Ta b Frame cross piece Nylon washer Bolt Slide the cooking box to the left within the frame. Put the washer on the bolt. T ake the spacer bracket and hold it up to the frame making sure both tabs fit underneat[...]

Frame brace Manifold bracket 13 Figure 9 Figure 10 Figure 11 Frame connector Cross brace T ank panel tabs Slots in frame brace Frame brace Step 8 Install manifold bracket Y ou will need: manifold bracket Hook the bracket onto the manifold at approximately the center of the length of the manifold. Place your hand underneath the bracket. Lift the man[...]

14 Figure 12 View from front right View from front left F E F E Figure 13 Igniter lock nut Small part of keyhole in frame brace Frame brace Frame brace Keyhole in frame brace (a) (b) (c) Step 10 Add fuel scale assembly Y ou 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 asse[...]

15 F E F E F E Figure 14 T ank lock wing nut (a) (b) Scale setting wing nut Step 12 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. We utilize various LP tank manufacturers. Some of the tanks we receive have differing top collar assemblies. (The top collar is the metal protect[...]

16 Figure 17 T urn so regulator vent does not collect water Hose T ank lock wing nut Quick disconnect engaged V alve handwheel close clockwise T ank valve Collar Male fitting Pressure relief valve T ank Regulator Regulator vent (a) (b) (c) Figure 16 Figure 15 F E Step 15 Connect LP tank  W ARNING: Make sure that the LP tank valve is closed. Clos[...]

17 Figure 18 (a) Figure 19 (c) (d) (b)  W ARNING: Y ou should check f or gas leaks every time you disconnect and reconnect a gas fitting. Note - All f actor y made connections hav e been thoroughly check ed f or gas leaks. The burners hav e been flame tested. As a saf ety precaution you should rechec k all fittings f or leaks before using y our [...]

18 Figure 20 Figure 21 Figure 23 Figure 22 Figure 24 Bottom tray Finger grip on front edge of bottom tray Finger grip Front side of catch pan holder Step 17 Install Flavorizer Bars and Cooking Grates Y ou will need: five Flavorizer Bars and two cooking grates. Set the Flavorizer Bars side to side in the cooking box. Figure 20. Set the cooking grate[...]

19 Hair pin cotter Hinge pin Figure 25 Figure 26 T ool holders Insert in frame brace Control panel Phillips screws/ washers (a) (b) Step 19 Install 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. Insert hinge pins from the outside. Insert hair pin cotters into the[...]

20 Step 21 Complete accessory installation Y ou will need: work table, accessory rack, warming rack, four tubing plugs and thermometer . Set the accessory rack across the bottom braces in front of the frame connector . Figure 27 (a). Open the lid and set the warming rack into the slots at the rear of the cooking box. Figure 27 (b). Set the work tab[...]

21 1 3 2 4 7 6 8 5 Figure 1 Crosso ver Ignition System OPERA TING INSTR UCTIONS Lighting Summary lighting instructions are on the control panel.  D ANGER Failure to open lid while igniting the barbecue, or not waiting 5 minutes to allow the gas to c lear if the barbecue does not light, may result in an e xplosive flame-up which can cause serious[...]

22 1 3 2 4 5 8 6 7 Figure 2 Manual Lighting Manual Lighting 4) Turn the tank on by turning the tank valve counterclockwise. 5) Strike a match and put the flame into the matchlight hole in the front of the cooking box.  W ARNING: Do not lean o ver open barbecue. Keep your face and bod y at least one foot a way fr om the matchlight hole when light[...]

23 Cooking  W ARNING: Do not move the W eber Gas Barbecue when operating or hot. Y ou can adjust the FRONT and BACK burners as desired. The control settings High (H), Medium (M), Low (L), or Of f (O) are described in your W eber cookbook. The cookbook uses these notations to describe the settings of the FRONT and BACK burners. For example, to se[...]

24 Scale setting wing nut T ank lock wing nut T ank valve Collar (a) (b) Figure 3 Figure 4 Refilling the LP tank We recommend that you refill before the scale indicator reaches "E". Note - If you run out of fuel, chec k the indicator setting and/or adjust the fuel scale indicator setting with the scale setting wing nut, while the tank is [...]

25 Figure 6 Male fitting Regulator Collar Quick disconnect engaged Figure 5 (a) (b) 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 5 (a). Push the male fitting of the regulator into the quick disconnect, and maintain press[...]

26 26 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 cylinder , LP gas is a liquid. As the pressure is released the liquid readily vaporizes and becomes gas. ■ LP gas has an odor similar to n[...]

Annual Maintenance After a period of nonuse we recommend that you perform the following maintenance procedures f or y our saf ety .  W ARNING: Check hose bef ore each use of barbecue for nic ks, cracking, abrasions or cuts. If the hose is found to be dama ged in an y wa y , d o not use the barbecue. Replace using only W eber authorized replaceme[...]

28 Burner inside cooking box Figure 11 Dark blue Light blue T ips occasionally yellowish Figure 9 V enturi Air shutter V enturi fin Weber Spider Stopper Guard Figure 10 Flames Figure 12 Figure 13 General Maintenance W eber Spider Stopper Guards Y our Weber Gas Barbecue, as well as any outdoor gas appliance, is a target for spiders and other insects[...]

29 e) 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 15. View from behind cooking box Wing nuts Figure 15 Guide screw Figure 16 Crossover tube Figure 17 Figure 14 d) Unlatch the Spider Stopper Guards and re[...]

30 30 Figure 20 White wire Black wire  CA UTION: If th e Sp i der Stopper Guards do not fit tightly , contact Weber -Stephen Customer Service .  W ARNING: A fter reinstalling the gas lines, they should be leak chec ked with a soap and water solution before using the barbecue. See Step“Check for gas leaks”. ■ Check that the Crossover Ign[...]

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: [...]

32 W E B E R W E B E R 4 3 2 1 5 6 7 9 8 12-13 15 16 18 19 20 21 23 24 25 26 50 51 46 47 45 43 41 40 39 38 36 35 34 48-49 44 42 22 17 13 27 37 11 10 14 33 31 32 30 29 28 ® ® ® ® ® ® ® ®[...]

33 1 Left endcap 2 Shroud assembly 3 Lid handle 4 W arming rack 5 Flavorizer bars (5) 6 Cooking grates (2) 7 Work table 8 T ubing plugs (8) 9 1/4-20 x 2 inch bolt 10 Spacer bracket 1 1 Left frame 12 1/4-20 x 1/2 inch bolts (6) 13 1/4 inch nylon washers (1 1) 14 Leg frame 15 Bottom tray 16 Catch pan holder 17 Catch pan kit 18 Accessory rack 19 Frame[...]

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A F INAL W ORD OF T HANKS hank you for choosing a W eber Barbecue. Our family here at W eber 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 prepar ed to help you with any problems with parts or as[...]