Weber SKYLINE 520 User Manual
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SKYLINE
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520
Natural Gas Barbecue
Serial Number
Please use this number in registering your warranty and
any correspondence with the factory.
Owner’s Manual
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.
NOTICE TO INSTALLER: These instructions
must be left with the owner and the owner
should keep them for future use.
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 you fire department.
W ARNING: Follow all leak check procedures
carefully in this manual prior to barbecue
operation. Do this even if barbecue was
dealer assembled.
FOR YOUR SAFETY
Do not store or use gasoline or other
flammable vapors and liquids in the vicinity
of this or any other appliance.
98693 12/97
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DANGER
Failure to follow the Dangers, Warnings and Cautions contained in this Owner’s Manual
may result in serious bodily injury or death, or in a fire or an explosion causing damage
to property.
WARNINGS
Do not store a spare or disconnected LP tank under or near this barbecue.
Improper assembly may be danger ous. Please carefully follo w the assembly instructions in this manual.
After a period of storage, and/or nonuse, the Weber Gas Barbecue should be chec ked for gas leaks
and burner obstructions before using. See instructions in this man ual 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 inc hes 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 v alves off . Open the lid and wait five minutes
before attempting to relight, using the lighting instructions.
Do not use charcoal or lav a 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 thor oughl y cleaned on a regular basis.
LP gas is not natural gas. The conver sion 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 W eber 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 c hec ked 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 y our self .
3. Call your fire department.
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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 and Flavorizer Bars, 3 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
(800) 446-1071
WARRANTY
© 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.
PATENTS AND TRADEMARKS
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Contents
WARNINGS................................................................ 2
Warranty & Patents.................................................. 3-4
General Instructions.................................................... 6
Assembly............................................................... 7-18
Operating Instructions
Lighting........................................................ 19-20
Cooking............................................................ 21
Storage and/or Nonuse.................................... 21
Cleaning .......................................................... 21
Troubleshooting & Maintenance
Annual Maintenance......................................... 22
General Maintenance.................................. 23-24
Troubleshooting................................................ 26
Parts Listing.............................................................. 29
FEATURES:
a) Convenient tables and racks.
b) Heavy gauge porcelain-on-steel lid seals in heat.
c) Rapid read thermometer for precision cooking.
d) Heavy gauge steel Flavorizer Bars distribute heat
within the grill. Flavorizer Bars heat just the right
amount of drippings for flavoring, letting excess fat
drip past to help prevent flare-ups.
e) Separate burners for temperature control.
f) Crossover Ignition System with Gas Catcher Ignition
Chamber.
g) Catch pan catches excess grease.
a
b
c
d
e
f
a
g
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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.
The natural 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.
■ This Weber Gas Barbecue is designed for natural
(piped in city) gas only. Do not use Liquid Propane
(LP) bottled gas.The valves, orifices and hose are for
natural 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.
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-B149.1 (Installation
Code for Natural Gas Burning Appliances and Equipment).
Storage
■ The gas must be turned OFF at the natural gas supply
when the Weber Gas Barbecue is not in use.
■ When the Weber Gas Barbecue is stored indoors, the
gas supply must be disconnected.
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.
Gas supply testing
■ Disconnect your Weber Gas Barbecue when the gas
supply is being tested at high pressures. This appliance
and its individual shutoff valve must be disconnected
from the gas supply piping system during any pressure
testing of that system at test pressures in excess of
1/2 psig (3.5 kPa).
■ Turn off your Weber Gas Barbecue when the gas
supply is being tested at low pressures. This appliance
must be isolated from the gas supply piping system by
closing its individual manual shutoff valve during any
pressure testing of the gas supply piping system at
the pressure equal to or less than 1/2 psig (3.5 kPa).
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Step 1
Check package contents
Cooking box
(assembly)
Lid
(assembly)
Bottom tray
Two cooking grates
Control panel
Work table
Five Flavorizer Bars
Assembly
Tools needed
Hammer
7/16 and 3/4 inch open-end or an adjustable wrench
Pliers
Block of wood
Phillips screwdriver
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. 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.
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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.
Left frame
Right frame
Wheel frame
Leg frame
Frame connector
Accessory rack
Warming rack
Front panel
Catch pan holder
Catch pan
Two drip pans
Thermometer
Two wheels
Spacer bracket
Check contents of hardware packs
Two burner control knobs
Two tool holders
Eight tubing plugs
(two are spares)
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)
Two 1/4-20 x 1 3/4 inch bolts
(actual size)
Six 1/4-20 x 1/2 inch bolts
(actual size)
Two plastic buttons
(actual size)
Nine 1/4 inch nylon washers
Two hair pin cotters
Two wheel hubcaps
Manifold bracket
1/4-20 keps nut
Two Phillips Screws/Washers
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Figure 1
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Figure 2
Leg tabs
Frame tabs
(a)
(b)
Right frame
Left frame
Step 2
Assemble wheel frame
You 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 one hubcap.Figure 1.
Repeat with other wheel and hubcap.
Step 3
Assemble top frame
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.
Note - Work on carpeted area (on grass or one of the
boxes) to protect the finish during frame assembly.
Lay the leg pieces as shown so the leg tabs point up.
Figure 2.
Slip the two frame pieces together with the tabs inside.
Figure 2 (a). Slip washers on bolts, insert bolts as shown
and tighten. Figure 2 (b). (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.)
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Figure 3
Figure 4
Figure 5
View from rear
of barbecue
Dimples to
the inside
Plastic buttons
Step 4
Continue frame assembly
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.
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.
The leg tabs must be on the inside of the frames.
Add the washers to the bolts, insert in the holes as shown
and tighten with the wrench. Figure 3.
Step 5
Install tubing plugs
You will need: two tubing plugs and a hammer.
Insert tubing plugs into the ends of the leg frame. Figure 4.
To fully seat the plugs, you may have to tap them lightly
with a hammer.
Step 6
Add front panel
You will need: front panel and two plastic buttons.
Turn frame assembly right side up.
Align the panel with the holes in the frame and insert the
plastic buttons through the front panel and frame. Figure 5.
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