Weber Summit Cookbox Guide

COOKBOX ASSEMBLY
REPLACEMENT INSTRUCTIONS
SEE STEP #5:
COOKBOX ASSEMBLY
REPLACEMENT
NOTE: The grills illustrated may have slight differences than the model purchased.
 WARNING: BEFORE PERFORMING ANY WORK MAKE SURE THE GAS SUPPLY IS TURNED OFF AT THE SOURCE.
DISCONNECT AND REMOVE GAS SUPPLY AT SOURCE, BEFORE ATTEMPTING ANY STEPS ON THIS SHEET.
FAILURE TO FOLLOW DANGERS, WARNINGS AND CAUTIONS CONTAINED IN THIS CONVERSION SHEET MAY CAUSE A
FIRE OR AN EXPLOSION RESULTING IN SERIOUS PERSONAL INJURY OR DEATH AND DAMAGE TO PROPERTY.
THIS PROCEDURE MUST BE PERFORMED BY AN AUTHORIZED
WEBER-STEPHEN PRODUCTS CO. SERVICE TECHNICIAN.
(ANY UNAUTHORIZED REPAIRS WILL VOID WARRANTY PROTECTION).
56312 2/22/08 DZ
1CONTROL PANEL REMOVAL 1
1
2
3
MAKE SURE ALL CONTROL KNOBS ARE SET TO THE
“OFF” POSITION BEFORE STARTING TO REMOVE
THE CONTROL PANEL.
 CAUTION: Disconnect the battery pack located in the cabinet
of the grill before removing the control panel.
Control Panel Removal:
A) Remove ALL of the control knobs.
B) Open both doors: Remove the two (2) screws from the underside of
control panel with a Phillips head screwdriver. (Disconnect Battery Pack)
C) Gently pull the bottom of the control panel forward (1) at the same time tilt
(2) and lift (3) the control panel off the hanger brackets and away from the
grill. This will allow the control panel to clear the manifold valve assemblies.
D) Slide the control panel out slightly to get to the lighted control knob plug.
Disconnect the leads from the light switch assembly (4).
TOOLS NEEDED: - PHILLIPS
 WARNING: Make sure that all control knobs are turned to
the OFF position before reconnecting the gas supply and
operating the grill.
4
IMPORTANT: To do a proper leak check the control panel
must be removed. After checking for leaks replace the
control panel and control knobs.
BEFORE STARTING: Make sure the casters
are locked to prevent the grill from moving
while removing the cookbox assembly.

TOOLS NEEDED: - PHILLIPS
Left Side Table Removal:
A) Remove the two (2) screws and washers from the underside of the left
side table and remove left side table assembly, using a Phillips head
screwdriver.
B) If your grill doesn't have a right side burner assembly: Remove the two
(2) screws and washers from the underside of the right side table and
remove right side table assembly.
Main Gas Line Removal:
A) Remove the main gas line
from the manifold assembly
(1) using a 7/8" wrench.
B) Let the main gas line to rest
on the cabinet of the grill.
Cookbox Assembly Removal:
A) Remove the two (2) cookbox bolts, nuts and washers from both sides
of the frame, using a 7/16" wrench. The cookbox nut is located inside of
cookbox (not pictured).
B) Lift out the whole cookbox assembly from the frame.
Make sure the manifold does not catch on the frame when
removing the cookbox assembly.
1SIDE TABLES REMOVAL
3
1MAIN GAS LINE REMOVAL
5
1COOKBOX REMOVAL
6
Right Side Burner Assembly Removal (470 & 670 MODELS):
A) Lift the side burner lid. Remove side burner components from the top of
the side burner assembly.
B) Remove quick-disconnect gas line from the side burner control valve
assembly.
C) Remove the two (2) screws and washers from the underside
of the right side burner table. Remove side burner table
assembly.
1
Shroud Assembly Removal:
A) Lift the shroud to the open position, remove the cotter pins out of the clevis
pins (1). Close the shroud, remove the clevis pins.
B) Lift and remove the shroud.
1SHROUD REMOVAL
2
1
TOOLS NEEDED: - 7/8"
TOOLS NEEDED: - 7/16"
Grates and Flavorizer® Bars Removal:
A) Remove the cooking grates & Flavorizer®bars (not pictured).
B) 470 AND 670 MODELS: Remove the smoker box, rotisserie motor and
bracket (not pictured).
1COOKBOX COMPONENTS REMOVAL
4

• PLACE THE ENTIRE COOKBOX ASSEMBLY
ON A SURFACE WHERE YOU CAN ACCESS ALL
OF THE COMPONENTS EASILY.
FOLLOWING STEPS ARE FOR REMOVING THE
REST OF THE COOKBOX COMPONENTS
Infrared Burner Cover Removal:
A) Remove the four (4) screws from the inside of the cookbox, using a
Phillips head screwdriver.
B) Lift and remove the
IR burner cover.
1IR BURNER COVER REMOVAL
7
1IR BURNER ASSEMBLY REMOVAL
8
1
2
3
4
5
6
10
89
7
A) Disconnect the two (2) hose and wire retaining clips (1) from the left side
of the cookbox holding on the IR burner igniter, thermocouple and IR
burner gas line to the cookbox assembly (Use a 3/8" wrench).
B) Disconnect the IR burner igniter wire from the electrode (2) on the IR
burner unit located on the backside of the cookbox assembly.
C) Disconnect the IR burner thermocouple from the IR burner box by
removing the thermocouple nut (3) from the inside of the cookbox,
(using a 10 mm wrench).
D) Remove the thermocouple wire from the back of IR burner box (4). Slide
the thermocouple out from the backside of the cookbox assembly.
E) Remove the two (2) nuts and washers from the IR burner box (5) using a
3/8" wrench. Slide out the entire IR burner box out from the inside of the
cookbox assembly (6).
F) Remove the IR gas line from the back of IR burner (7). Use two wrenches
one to hold the IR orifice in place and a 9/16" wrench to release the IR gas
line from the IR burner.
G) Remove the bolts (8) and nuts (9) from both ends of the IR burner using a
5/16" wrench, holding the IR burner to the cookbox assembly.
H) Slide the infrared burner out from the
inside of the cookbox assembly (10).
1IR BURNER COMPONENTS REMOVAL
9
1
2
3
Infrared Burner Valve Assembly Removal:
A) To gain access to the IR burner valve assembly, loosen the manifold bolts
slightly (using a 3/8" wrench).
(DO NOT remove the screws completely at this point)
B) Disconnect the IR burner igniter wire (1), thermocouple (using an 8 mm
wrench) (2) and the IR burner gas line (using a 9/16" wrench) (3) from the
IR burner valve assembly located at far left of manifold assembly.
C) Let the IR burner igniter wire, thermocouple and the IR burner gas line
rest on the cookbox.
 Do not bend Thermocouple (2) line. This could cause
it to break.
 Wipe the end of Thermocouple (2) with a clean, soft
cloth before re-connecting.
TOOLS NEEDED: - PHILLIPS
TOOLS NEEDED: - 3/8", 9/16",
8 mm
TOOLS NEEDED: - 3/8", 5/16",
9/16", 10 mm

1
2
COOKBOX INSTALLATION
1HEAT SHIELD INSTALLATION
1
Make sure the slotted
end of the burner tubes
(1) properly aligns
into the slots on the
backside of the cookbox.
1
HEAT SHIELD & BAFFLE REMOVAL
11
Heat Shield and Baffle Removal:
A) Remove two (2) bolts from the inside of the cookbox frame (using a 5/16"
wrench with a ratchet extender) to release the heat shield and baffle form
the cookbox assembly.
B) Slide out and remove the heat shield and baffle from the cookbox
assembly.
Heat Shield and Baffle Installation:
A) Slide in the heat shield and baffle into the cookbox assembly.
B) Install two (2) bolts into the inside of the cookbox frame (using a 5/16"
wrench with a ratchet extender).
NOTE:The grills illustrated may have slight differences than the model purchased.
MANIFOLD ASSEMBLY REMOVAL
10
BURNER TUBES INSTALLATION
2
Manifold Assembly Removal:
A) Remove bolts (1) from both sides of the cookbox frame (using a 3/8"
wrench or socket) to release the manifold from the cookbox assembly.
B) Slide the manifold out and slightly down (2) to remove the manifold from
the cookbox assembly.
C) Slide ALL of the burner tubes out of the cookbox assembly.
Manifold Assembly Installation:
A) Slide ALL of the burner tubes into the cookbox assembly.
 FOLLOW INSTALLATION STEPS FOR INSTALLING THE
NEW COOKBOX ASSEMBLY, AND GRILL RE-ASSEMBLY.
TOOLS NEEDED:TOOLS NEEDED: - 5/16"- 3/8"
TOOLS NEEDED: - 5/16"

MANIFOLD ASSEMBLY INSTALLATION
3
CAUTION: When installing new manifold assembly, the burner
tube openings (a) must be positioned properly over the valve
orifices (b).
b
a
Manifold Assembly Installation:
A) Slide the manifold valve assemblies into the burner tube openings (b).
B) Install the two (2) bolts (1) on both sides of the frame (using just your
fingers) to secure the manifold to the cookbox assembly.
Do not fully tighten the two (2) bolts at this time. Tighten just enough
so the burner tubes do not slip out of either the back slots in the
cookbox or the manifold valve stems.
Infrared Burner Assembly Installation:
A) Connect the IR burner igniter wire (3), thermocouple (using an 8 mm
wrench) (4) and the IR burner gas line (using a 9/16" wrench) (5) to the IR
burner valve assembly located at the far left of manifold.
B) Fully tighten all of the connections to the IR burner assembly.
3
4
5
1
Manifold Assembly Completion:
 VISUAL CHECK: Make sure that all of the manifold valves are
positioned into all of the burner tubes.
 VISUAL CHECK: Make sure the slotted end of the burner
tubes are properly aligned into the slots on the backside of
the cookbox.
A) Fully tighten the two (2) bolts on both sides of the cookbox frame (using a
3/8" wrench) to secure the manifold to the cookbox assembly.
9
8
7
6
5
10
2
4
1
3
A) Slide the infrared burner unit into the opening in the cookbox assembly (1).
B) Install the bolts (2) and nuts (3) into both ends and of the IR burner using
a 5/16" wrench, to secure the IR burner to the cookbox assembly.
C) Connect the IR burner gas line to the back of IR burner (4). Use two
wrenches; one to hold the IR orifice in place, and a 9/16" wrench to
connect the IR burner gas line to the IR burner.
D) Slide in the IR burner box into the inside of the cookbox assembly (5).
Connect the two (2) nuts and washers onto the IR burner box (6) to secure
the IR box to the cookbox assembly.
E) Slide the thermocouple back into the IR burner box (7) from the rear of the
cookbox assembly. Connect the IR burner thermocouple to the IR burner
box by installing the thermocouple nut (8) from the inside of the cookbox,
(using a 10 mm wrench).
F) Connect the IR burner igniter wire to the electrode (9) on the IR burner box
located on the backside of the cookbox assembly.
G) Connect the two (2) hose and wire retaining clips (10) to the left side of the
cookbox to secure the IR burner igniter, thermocouple and IR burner hose
to the cookbox assembly (Use a 3/8" wrench).
1IR BURNER COMPONENTS INSTALLATION
4
TOOLS NEEDED: - 3/8", 5/16",
9/16", 10 mm
TOOLS NEEDED: - 3/8", 9/16",
8 mm

Grates and Flavorizer® Bars Installation:
A) Install the cooking grates & Flavorizer®bars (not pictured).
B) 470 AND 670 MODELS: Install the smoker box, rotisserie motor and
bracket (not pictured).
1COOKBOX COMPONENTS INSTALLATION
7
Infrared Burner Cover Installation:
A) Slide the IR burner cover over the IR burner unit, IR gas line,
thermocouple and igniter wire. Install the four (4) screws in the inside of
the cookbox to secure the
IR cover to the cookbox assembly
using a Phillips head screwdriver.
1IR BURNER COVER INSTALLATION
5
TOOLS NEEDED: - PHILLIPS
1
Cookbox Assembly Installation:
A) Lift the whole cookbox assembly onto the frame assembly.
Make sure the manifold does not catch on the frame when installing
the cookbox unit.
B) Install the two (2) cookbox bolts, nuts and washers into both sides of
the frame, using a 7/16" wrench. The cookbox nut is located inside of
cookbox (not pictured).
1COOKBOX INSTALLATION
6
TOOLS NEEDED: - 7/16", 7/8"
TOOLS NEEDED: - PHILLIPS
Left Side Table Installation:
A) Install the two (2) screws and washers into the underside of the left side
table assembly and secure the left side table to the grill assembly, using
a Phillips head screwdriver.
B) If your grill doesn't have a right side burner assembly: Install the two (2)
screws and washers into the underside of the right side table assembly
and secure the right side table to the grill assembly.
1SIDE TABLES INSTALLATION
8
Right Side Burner Assembly Installation (470 & 670 MODELS):
A) Install the two (2) screws and washers into the underside
of the right side burner table assembly and secure the right side burner
table to the grill assembly.
B) Reconnect the quick-disconnect gas line to the side burner control valve
assembly.
C) Lift the side burner lid. Replace the side burner components
on the top of the burner assembly.
1
Shroud Assembly Installation:
A) Lift and place the shroud on the cookbox.
B) Slide in the clevis pins into the shroud assembly.
Lift the shroud to the open position,
install the cotter pins into the
clevis pins (1). Close the shroud.
1SHROUD INSTALLATION
9
Main Gas Line Installation:
A) Connect the main gas line (1) to the manifold assembly (using a 7/8"
wrench).
B) Fully tighten the main gas line connection.
 FOLLOW LEAK CHECK STEP BEFORE INSTALLING THE
CONTROL PANEL ASSEMBLY, AND FINISHING THE GRILL
RE-ASSEMBLY.

6 7
NGLP
Gas Sources:
4
2
3
5
1
1CHECK FOR GAS LEAKS
10
 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. Sparks or open flames will result in a fire or
explosion, which can cause serious bodily injury or death
and damage to property.
You will need: a soap and water solution and a rag or brush to apply it.
A) Mix soap and water.
B) Turn on the cylinder valve.
C) 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.
D) When leak checking is complete, turn gas supply off at the source and
rinse connections with water.
Check:
A) Main gas line to manifold connection (1).
B) IR burner gas line to orifice assembly (2).
C) IR burner valve to gas line (3).
 DANGER: If there is a leak at connection (1, 2 or 3), retighten
the fitting with a wrench and recheck for leaks with soap and
water solution. If a leak persists, turn OFF the gas. DO NOT
OPERATE THE GRILL. Failure to follow dangers, warnings and
cautions contained in this Instruction sheet may cause a fire
or an explosion resulting in serious personal injury or death
as well as damage to property. Contact the Customer Service
Representative in your area using the contact information on
our web site. Log onto www.weber.com®.
D) Quick-disconnect gas line connection (4).
E) Valve to manifold connection (5).
F) LP: Regulator connection (6).
G) NG: Hose to quick-disconnect gas line connection (7).
 DANGER: If there is a leak at connection (4, 5, 6 or 7), turn
off the gas. DO NOT OPERATE THE GRILL. Failure to follow
dangers, warnings and cautions contained in this Instruction
sheet may cause a fire or an explosion resulting in serious
personal injury or death as well as damage to property.
Contact the Customer Service Representative in your area
using the contact information on our web site.
Log onto www.weber.com®.
When leak checks are complete, turn gas supply OFF at the source and rinse
connections with water.
IMPORTANT: To do a proper leak check the control panel must be
removed. After checking for leaks replace the control panel and
control knobs.
CONTROL PANEL INSTALLATION
11
Control Panel Installation:
A) Open both doors: Connect the leads from the light switch assembly (1) to
the lighted control knob plug.
Connect the battery pack and check to see if the lights on the control
panel work, then disconnect the battery pack before continuing.
B) Slide the control panel onto the hanger brackets (3) on the front of the
grill assembly. Gently slide the bottom portion of the control panel over the
valve assemblies of the manifold (4).
C) Install the two (2) screws into the underside of control panel with a
Phillips head screwdriver.
(Connect the Battery Pack)
D) Close both doors: Install ALL of the control knobs.
 WARNING: Make sure that all control knobs are turned to
the OFF position before reconnecting the gas supply and
operating the grill.
1
2
4
3

WEBER-STEPHEN PRODUCTS CO.
Customer Service Center
1890 Roselle Road, Suite 308
Schaumburg, IL 60195
1-800-446-1071 (USA ONLY)
www.weber.com®
 WARNING: All repairs to gas carrying, gas burning, igniter components or structural components must be
performed by an authorized Weber-Stephen Products Co. service technician.
These parts may be gas carrying, gas burning components, igniter components or structural components. Please contact Weber-Stephen
Products Co., Customer Service Department for Genuine Weber-Stephen Products Co. replacement part(s) information.
 WARNING: Do not attempt to make any repair to gas carrying, gas burning, igniter components or structural
components without contacting Weber-Stephen Products Co., Customer Service Department. Your actions, if you
fail to follow this Product Warning, may cause a fire, an explosion, or structural failure resulting in serious personal
injury or death as well as damage to property.
 PROPOSITION 65 WARNING: HANDLING THE BRASS MATERIAL ON THIS PRODUCT EXPOSES YOU TO LEAD, A CHEMICAL
KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM.
(WASH HANDS AFTER HANDLING THIS PRODUCT.)