Weber 520 manual

W E B E R W E B E R SKYLINE ™ 520 Natural Gas Barbecue Serial Number Please use this number in registering your warranty and any correspondence with the factory . 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 O[...]

2  D ANGER Failure to f ollow the Dangers, 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 damage 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. Ple[...]

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, Cooking Grates and Flavorizer Bars, 3 years, All Remaining Parts, 5 years, when assembled and operated in accordance[...]

© 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 ............................................................... 7-18 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) Bottom tray T wo cooking grates Control panel Work table Five Flavorizer Bars Assembl y T ools needed Hammer 7/16 and 3/4 inch open-end or an adjustable wrench Pliers Block of wood Phillips screwdriver Supplies needed Y ou will need a soap and water solution to check for gas leak[...]

Left frame Right frame Wheel frame Leg frame Frame connector Accessory rack W arming rack Front panel Catch pan holder Catch pan T wo drip pans Thermometer T wo wheels Spacer bracket 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 clevi[...]

9 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 one[...]

10 Figure 3 Figure 4 Figure 5 View from rear of barbecue Dimples to the inside Plastic buttons Step 4 Continue frame assembly Y ou 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 fr[...]

11 Guide screw (a) (b) (c) Wing nuts View from behind cooking box Figure 8 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[...]

12 Frame brace Manifold bracket Figure 9 Figure 10 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 manifold, bracket and cooking box slightly and hook the tab of the bracket onto the frame b[...]

13 T ypical natural gas supply installation. Figure 11. T est 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.  D ANGER Do not use an open flame to chec k for gas leaks. Be sure there are no sparks or open flames in the area w[...]

14 Figure 13 Figure 12 Igniter lock nut Keyhole in frame brace Small part of keyhole in frame brace Frame brace (c) (b) (a) Step 11 Install igniter Note - The igniter wires are already attached to the Gas Catcher Ignition Chamber and the igniter . This was done to f actory test the ignition system. The igniter lock nut is on the igniter . Insert th[...]

15 (a) Figure 15 Figure 14 (c) (b) Male fitting T o barbecue Quick disconnect engaged Collar Outside house wall Locking shut off (a) (b) Step 13 Check for gas leaks  D ANGER Do not use an open flame to chec k for gas leaks. Be sure there are no sparks or open flames in the area while y ou check for leaks. This will result in a fire or explosion [...]

16 Figure 16 Figure 17 Figure 19 Figure 18 Figure 20 Bottom tray Finger grip on front edge of bottom tray Finger grip Front side of catch pan holder Step 14 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 16. Set the cooking grate[...]

17 Hair pin cotter Hinge pin Figure 21 Figure 22 T ool holders Insert in frame brace Control panel Phillips screws/ washers (a) (b) Step 16 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[...]

(a) (c) (d) (b) 18 Step 18 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 23 (a). Open the lid and set the warming rack into the slots at the rear of the cooking box. Figure 23 (b). [...]

19 1 2 3 6 5 7 4 Figure 1 Crosso ver Ignition System Lighting Summary lighting instructions are on the control panel. 1) Open the lid. Figure 1. 2) Make sure all burner control knobs are turned OFF . (Push each burner control knob down and turn clockwise.) 3) Turn the gas supply valve on.  W ARNING: Do not lean o ver open barbecue . K eep your f[...]

20 1 2 3 4 7 5 6 Figure 2 Manual Lighting Manual Lighting  W ARNING: I f t h e b urner does not light, turn the Front burner contr ol knob to OFF and wait 5 minutes to let the gas clear bef ore you try again or try to light with a match. 7) After the FRONT burner is lit you can turn on the other burner . Note - Alwa ys light the FRONT b ur ner f[...]

21 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 Off (O) are described in your Weber cookbook. The cookbook uses these notations to describe the settings of the FRONT and BACK burners. For example, to sear[...]

22 Annual Maintenance After a period of nonuse we recommend that you perform the following maintenance procedures f or y our saf ety .  W ARNING: Chec k 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 , do not use the barbecue. Replace using only W eber authorized replac[...]

23 23 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. 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. This could result in a fir[...]

24 View from behind cooking box Wing nuts Figure 10 Guide screw Figure 11 Crossover tube Figure 12 Figure 9 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. f) Slide the burner assembly out [...]

25 25 i) Reinstall the Spider Stopper Guards. Slightly rotate the Spider Stopper Guards so that the seams are in line with the V enturi fins. There should be no gaps in the seams or in the fit around the burners and valves. Figure 14. V enturi fin Figure 14 Check fit around valve Check fit around burner Figure 15 White wire Black wire  CA UTION:[...]

26 Prob lem Burners b urn with a yellow or orange flame, in conjunction with the smell of gas. Burner does not light, or flame is low in HIGH position. Experiencing flare-ups:  CA UTION: Do not line the bottom tray with aluminum f oil. Burner flame pattern is erratic. Flame is low when burner is on HIGH. Flames do not run the whole length of the[...]

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29 29 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 (9) 14 Leg frame 15 Bottom tray 16 Catch pan holder 17 Catch pan kit 18 Accessory rack 19 Fram[...]

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A F INAL W ORD OF T HANKS hank you for choosing a W eber Barbecue. Our family her e at W eber has worked har d to produce the highest quality products for your satisfaction. While we giv e much attention to our products, an occasional error may occur . Our knowledgeable C ustomer Service staff is pr epared to help you with any problems with parts o[...]