Hopper-Burner Assembly Replacement Instructions for Non-WiFi Grills

What is a Hopper-Burner Assembly (HBA) and how to install and remove it on your AC grill. 

What is a Hopper-Burner Assembly (HBA)?

A hopper-burner assembly, HBA for short, is a combination your grill's hopper (the black box on the left side of your grill that holds your pellets) and all the major components of your grill: the controller, auger, auger motor, hot rod, and firepot.

Removing your grill's HBA is sometimes necessary in order to access certain internal components, resolve mechanical issues, and replace some parts.

To learn more about this part, see Hopper Burner Assemblies & Hopper Assemblies.

HBAs on Portable Grills

Hopper-Burner Assemblies are not available for the PTG, Scout, Trailhead or Ranger. These require a full grill replacement.

Replacement Instructions for Non-WiFIRE Grills

Remove the HBA

1. With the grill turned off and unplugged, open the grill lid.
2. Remove all internal items, such as grill grates, heat baffles, and drain pans.
3. Remove the controller from the front of the hopper.
4. With the controller removed, take a small flathead screwdriver and disconnect the RTD probe from the controller.
5. With the RTD probe disconnected, go inside the grill body and remove the RTD screws, slowly pulling the RTD out of the grill until it is completely removed.
6. With the RTD removed, find the 4 screws on the inside of the grill (some models have 6 screws), located on the hopper side of the grill, and remove them. In this case, it would be on the left. 
7. With the 4 screws removed, the hopper is now loose. Remove the 4 wing nuts holding the firepot in place.
8. With the wing nuts removed, the hopper burner should slide out. 

Install the new HBA

1. On the new hopper burner, remove the firepot wing nuts.
2. Install the new RTD into the grill body and feed the wire through the hole in the grill body.
3. Remove the controller from the new hopper burner and feed the RTD wires into it.
4. Connect the RTD wires to the controller on the new HBA and then reinstall the controller onto the new HBA.
5. With the RTD connected to the new HBA and the wing nuts removed from the new HBA, slide the new HBA into the grill body.
6. Reinstall the 4 screws holding the HBA to the grill.
7. Reinstall the 4 wingnut screws into the firepot.
8. Reinsert the heat baffle, drain pan, and grill grate.