Serial Number Please use this number in registering your warranty and any correspondence with the factory. SKYLINE 520 ™ Natural Gas Barbecue WEB WEB E R Owner’s Manual E R ® WARNING: Follow all leak check procedures carefully in this manual prior to barbecue operation. Do this even if barbecue was dealer assembled. NOTICE TO INSTALLER: These instructions must be left with the owner and the owner should keep them for future use.
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.
WARRANTY 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: 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.
PATENTS AND TRADEMARKS © 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 #4,966,125; Canada: #1,279,540; #1,300,994; and #1,300,995. Printed in the U.S.A.
Contents WARNINGS ................................................................ 2 Warranty & Patents.................................................. 3-4 General Instructions.................................................... 6 Assembly ............................................................... 7-18 Operating Instructions Lighting........................................................ 19-20 Cooking ............................................................ 21 Storage and/or Nonuse .............
Storage 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.
Step 1 Assembly Check package contents Tools needed Hammer Cooking box (assembly) 7/16 and 3/4 inch open-end or an adjustable wrench Pliers Lid (assembly) Block of wood Phillips screwdriver Bottom tray Supplies needed 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.
Check contents of hardware packs Left frame Two burner control knobs Right frame Two tool holders Wheel frame Eight tubing plugs (two are spares) Leg frame Two hinge pins (hardware size: 1/4 x 1 1/2 inch clevis pin) (actual size) 1/4-20 x 2 inch bolt (actual size) Frame connector Two 1/4-20 x 1 3/4 inch bolts (actual size) Accessory rack Six 1/4-20 x 1/2 inch bolts (actual size) Front panel Two plastic buttons (actual size) Catch pan holder Nine 1/4 inch nylon washers Catch pan Two hair pin c
Step 2 Step 3 Assemble wheel frame Assemble top frame You will need: wheel frame, two wheels, two wheel hubcaps, hammer and a block of wood. You will need: left frame, right frame, two 1/4-20 x 1/2 inch bolts, two nylon washers and a 7/16 inch wrench. 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 one hubcap.Figure 1.
Step 4 Step 6 Continue frame assembly Add front panel You will need: leg frame, wheel frame, four 1/4-20 x 1/2 inch bolts, four nylon washers and a 7/16 inch wrench. You will need: front panel and two plastic buttons. Place the leg 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. Figure 3.
Step 7 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: Add cooking box You will need: frame assembly, cooking box assembly, work table spacer, 1/4-20 keps nut, 1/4-20 x 2 inch bolt, pliers and a 7/16 inch wrench. a) Do the valves fit into the ends of the burners? Figure 8 (a).
Step 8 Step 10 Install manifold bracket Install gas supply You will need: manifold bracket General Specifications for Piping Hook the bracket onto the manifold at approximately the center of the length of the manifold. Place your hand underneath the bracket. Lift the manifold, bracket and cooking box slightly and hook the tab of the bracket onto the frame brace. Figure 9. Note - Contact your local municipality for building codes regulating outdoor gas barbecue installations.
Typical natural gas supply installation. Figure 11. Test connections All connections and joints must be thoroughly tested for leaks in accordance with local codes and all listed procedures in the latest edition of ANSI Z223.1. Gas supply Inside wall DANGER Outside wall 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 gas leaks.
Step 11 Step 12 Install igniter Check that all burner valves are off 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. 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.
Step 13 WARNING: Do not ignite burners while leak checking. Check for gas leaks 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. DANGER 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. Do not use an open flame to check for gas leaks.
Step 14 Step 15 Install the bottom tray Install Flavorizer Bars and Cooking Grates You will need: bottom tray, catch pan holder, catch pan and one drip pan. You will need: five Flavorizer Bars and two cooking grates. Set the Flavorizer Bars side to side in the cooking box. Figure 16. Finger grip on front edge of bottom tray Front side of catch pan holder Figure 18 Hook the ends of the catch pan holder into the hole in the bottom tray. Figure 19.
Step 16 Step 17 Install Lid You will need: lid, two hinge pins and two hair pin cotters. Add tool holders, control panel and burner control knobs 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 21. You will need: two tool holders, control panel, two Phillips screws/washers, a Phillips screwdriver, and two burner control knobs. Hook the tool holders over the frame rail.
Step 18 Complete accessory installation You 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 23 (a). Open the lid and set the warming rack into the slots at the rear of the cooking box. Figure 23 (b). Set the work table onto the left side rails. Figure 23 (c). Insert the thermometer into its holder. Figure 23 (d). Insert the tubing plugs into the ends of the frame.
OPERATING INSTRUCTIONS Lighting 1) Open the lid. Figure 1. Summary lighting instructions are on the control panel. 2) Make sure all burner control knobs are turned OFF. (Push each burner control knob down and turn clockwise.) DANGER 3) Turn the gas supply valve on. 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.
Manual Lighting 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. 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. 7) After the FRONT burner is lit you can turn on the other burner.
Cooking Storage and/or Nonuse WARNING: Do not move the Weber Gas Barbecue when operating or hot. ■ When storing the Weber Gas Barbecue, make sure that the inside shut off valve and/or locking outdoor shut off valve is secured in the OFF position. When the Weber Gas Barbecue is stored indoors, the gas supply MUST BE DISCONNECTED. ■ After a period of storage and/or nonuse the Weber Gas Grill should be checked for gas leaks and any obstructions in the burner tubes before using.
Annual Maintenance Check: a) Hose to manifold connection. Figure 3 (a). After a period of nonuse we recommend that you perform the following maintenance procedures for your safety. WARNING: If there is a leak at the hose to manifold connection, Figure 3 (a), retighten the hose fitting with a wrench and recheck for leaks with soap and water solution. WARNING: Check hose before each use of barbecue for nicks, cracking, abrasions or cuts.
General Maintenance Main Burner Flame Pattern Weber Spider Stopper Guards The Weber Gas Barbecue burners have been factory set for the correct air and gas mixture. The correct flame pattern is shown in Figure 6. 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 4.
d) Unlatch the Spider Stopper Guards and remove. Figure 9. g) Lift and twist the burner assembly slightly, to separate the crossover tube from the burners. Figure 12. Remove the burners from the cooking box. Crossover tube Figure 9 Figure 12 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 10. h) To reinstall the burners, reverse steps c) through g).
i) Crossover Ignition System Operations 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 14. 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.
TROUBLESHOOTING Problem Check Cure Burners burn with a yellow or orange flame, in conjunction with the smell of gas. Inspect Weber Spider Stopper Guards for possible obstructions. (Blockage of holes.) Clean Weber Spider Stopper Guards. (See Section "Annual Maintenance".) Burner does not light, or flame is low in HIGH position. Is fuel hose bent or kinked? Straighten fuel hose.
1 27 2 28 ® ® 29 3 30 4 31 5 6 32 33 34 35 36 37 7 38 39 8 9 10 40 41 42 43 11 12-13 14 44 45 46 15 47 16 W 17 E BE R W E BE R 18 19 20 21 22 23 24 25 28 12 26
Parts List 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. All items are single quantities unless otherwise specified. Parts can be ordered directly from Weber-Stephen Products Company by phone or mail.
A FINAL WORD OF THANKS Thank 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.