Weber Summit Series Guide

MANIFOLD repLAceMeNt

INstructIONs

NOTE: The grills illustrated or photographed may have slight differences than the model purchased.

THIS PROCEDURE MUST BE PERFORMED BY AN AUTHORIZED

WEBER-STEPHEN PRODUCTS CO. SERVICE TECHNICIAN.

(ANY UNAUTHORIZED REPAIRS WILL VOID WARRANTY PROTECTION).



DANGER: BEFORE PERFORMING ANY WORK MAKE SURE THE GAS SUPPLY IS TURNED OFF AT THE SOURCE.

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.

WARNING: GENUINE WEBER-STEPHEN REPLACEMENT PARTS MUST BE USED FOR ANY REPAIR OR REPLACEMENT.

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.

(WILL VOID ALL WARRANTY PROTECTION.)

MANIFOLD

REPLACEMENT

56413 08/06/09

1CONTROL PANEL REMOVAL

TOOLS NEEDED: - PHILLIPS

BEFORE STARTING: Make sure the lid is down and the casters

are locked to prevent the grill from moving.

A) Remove all of the burner control knobs by pulling up.

A B

A - Part# 41788 B - Part# 41787

B) Remove the black phillips head screw and nylon washer on the left and

right side of the control panel.

Part # 42536

Part # 42537

1CONTROL PANEL REMOVAL (cont.)

C) Put your fingers under the front edge of the control panel and lift up

slightly(1).

Move the control panel out from under the fire box end cap control panel

brackets and lift panel up and out from the unit. Set aside so it will not get

scratched.

2FRONT PANEL REMOVAL

A) Remove the stainless steel front panel by lifting the panel up and out of the

fire box end cap locating slots.

3BATTERY CASE REMOVAL

A) Unscrew the battery cap with red button from the battery case. The case

is upside down Remove the spring and battery from the case by pulling in

a downward motion. If the battery does not come out easily, wait until

you remove the battery case from the heat shield and igniter mounting

bracket to remove the spring and battery.

Part# 42053

B) Using an adjustable wrench loosen the nut that holds the battery case to the

heat shield and igniter mounting bracket (1).

TOOLS NEEDED: - PHILLIPS

3BATTERY CASE REMOVAL (cont.)

C)Hold the battery case and manually finish removing the nut by hand, and

then lift up on the battery case to remove from brackets. Remove the top

positive (+) and bottom negative (–) wires from the case after it is removed.

4IGNITION MODULE REMOVAL

A)Cut and remove the two nylon wire ties from the ignition module (1).

B)Using a phillips screwdriver remove the two mounting screws from the left

and right of the ignition module. This allows the module to swing down freely.

C)The module can be allowed to hang in place with all the wires still attached,

as shown (2).

TOOLS NEEDED: - PHILLIPS

4IGNITION MODULE REMOVAL (cont.)

5DISCONNECT THE I.R. CONNECTIONS

(Silver D and Gold D only)

A)Using an 8mm open end wrench, loosen nut on thermocouple and unscrew

fitting by hand (1). Once disconnected move thermocouple down and out of

the way. Do not bend the thermocouple capillary (2).

B)Using a 9/16" open end wrench, loosen and remove the ss I.R. Corrugated

gas line from the I.R. valve (3).

6DISCONNECT THE MAIN GAS LINE

A)Using a 7/8" open end wrench, loosen the main ss corrugated gas line from

the manifold (1). I f there is a copper 45° degree washer, inside of the brass

connection on the end of the tube (2), it will be loose and can fall out.

Do not reuse the copper gasket. When reassembled check for leaks.

7MANIFOLD REMOVAL

A)Using a phillips head screwdriver, locate the screws on both sides of the

manifold frame(1) and remove the screws from the frame.

Part #42541

8-32 x ½"

Phil Pan HD Blk

TOOLS NEEDED: - PHILLIPS

TOOLS NEEDED: TOOLS NEEDED: - 7/8"

- 9/16", 8mm

B)The manifold is now ready to be removed from the burner tubes. Pull the

manifold away from the burner tubes (3). The burner tubes may move with

the manifold as it is removed and dislodge from the mounting slot in the rear

channel. They must be assembled back into the slot before the manifold is

reassembled.

7MANIFOLD REMOVAL (cont.)

8INSTALL NEW MANIFOLD

Please note:The difference between the Original Manifold and the New

Replacement manifold is how the right side mounts into the “C” channel

manifold slide. The left side remains unchanged It is the same for both the

SUMMIT SILVER & GOLD 4 AND 6 BURNER MODELS.

A)The new replacement Manifold comes with it own separate Mounting

Bracket, which fits both the Silver and Gold SUM 28” / 36” New Replacement

Manifolds.

The original manifold has both the right and left side mounting

brackets (1).

The new replacement manifold does not have the right side mounting

bracket (2).

The new replacement manifold comes with it own separate mounting bracket,

which fits both the Silver and Gold SUM 28” / 36” new Replacement Manifolds.

B) Install bracket onto the right side of the manifold only (3).

C).Before reinstalling the manifold make sure that the burner tubes are properly

installed into the mounting slots of the rear channel on the

cookbox (4).

8INSTALL NEW MANIFOLD (cont.)

D)Position the new manifold in front of the burner tubes for reassembly.

E)Install manifold paying attention to the position of the right side mounting

bracket. Make sure that the mounting bracket (5) slides over the outside

edge of the C channel (6).

BEFORE PROCEEDING MAKE SURE THAT THE BURNER TUBES ARE

PROPERLY LINED UP WITH THE VALVES ON THE MANIFOLD.

F)Install mounting hardware. The new mounting bracket comes with a clevis

pin and hair pin cotter. Line up the Mounting bracket hole with the mounting

hole in the “C” Channel Manifold slide (7).

G)insert the clevis pin down through the mounting holes (7) and insert the

cotter pin through the clevis pin mounting hole locking it in place (8).

G).line up the left side of the manifold with the bracket and reassemble the

mounting screw (9).

9REINSTALL MAIN GAS LINE

A)Using a 7/8" open end wrench, reinstall the main ss corrugated gas line to

the manifold.You must replace the copper 45° degree washer inside of the

brass connection on the end of the tube (1). Do not reuse the old copper

gasket. When reassembled check for leaks (See proper instructions for

leak checks later in this instruction manual).

TOOLS NEEDED: - 7/8"

8INSTALL NEW MANIFOLD (cont.)

11 CHECK FOR GAS LEAKS

10 REINSTALL I.R. GAS LINE

(Silver D and Gold D only)

A)Using a 9/16" open end wrench, reinstall the ss I.R. Corrugated gas line to

the I.R. valve (1).

B)Reinstall the thermocouple capillary line. Start the threads by hand and

using an 8mm open end wrench tighten connection (2). Do not bend the

thermocouple capillary (3). When reassembled check for leaks

 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.

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) Gas supply to IR burner valve assembly (1) on models SilverD and

Gold D only.

B) Gas supply to manifold connection (2).

 DANGER: If there is a leak at connection (1 or 2), 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®.

C) Valve to manifold connection (3).

D) LP: Regulator connection (4).

E) NG: Hose to quick disconnect gas line connection (5).

 DANGER: If there is a leak at connection (3, 4, or 5), 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.

Gas Sources:

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 gas supply at the source.

TOOLS NEEDED: - 9/16", 8mm

12 REPLACE IGNITION MODULE

A)Make sure that all wires remain connected to the ignition module.

B)Replace ignition module back into mounting position. Using a phillips

screwdriver secure the two mounting screws on the left and right of the

ignition module (1).

C)Replace the two nylon wire ties to the ignition module (2).

13 REPLACE BATTERY CASE

A) Replace battery case to heat shield. Using an adjustable wrench tighten

the nut that holds the battery case to the heat shield and igniter mounting

bracket (1).

B) Replace the Spring and battery back into the battery case. Replace and

screw the battery cap with red button back onto the battery case.

1 4 REPLACE FRONT PANEL

A) Replace the stainless steel front panel. Slide the panel down and back into

the fire box end caps locating slots.

TOOLS NEEDED:

15 REPLACE CONTROL PANEL

A) Slide the back edge of the control panel in and under the fire box end cap

control panel brackets. Push the control panel all the way in and down over

valves.

TOOLS NEEDED: - PHILLIPS

A B

A - Part# 41788 B - Part# 41787

Part # 42536

Part # 42537

B) Replace the black phillips head screw and nylon washer on the left and

right side of the control panel.

A) Replace all of the burner control knobs.

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