Hopper Burner Assembly Replacement Instructions for D2 Grills

The following article will cover what a Hopper Burner Assembly is and how to install and remove it on your D2 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 right 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.

Removing & Installing an HBA

Removing and installing an HBA varies slightly depending on which grill model you have, but they follow the same general instructions. To help guide you through the process, we've outlined these steps for each WiFIRE-enabled grill model.

• Pro 575, Pro 780, Silverton 620, & Silverton 810
• Ironwood 650, Ironwood 885, & Century 885
• Timberline 850 & Timberline 1300

Replacing an HBA on a Pro 575 & 780 and a Silverton 620 & 810

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. Once all internals are removed, locate the lower metal grill insulation on the hopper side of the grill.
4. Remove the lower metal insulation panel from the grill by removing 6 small screws.
5. Remove the controller from the front of the hopper.
6. With the controller off, disconnect the thermocouple from the back of the controller.
7. With the thermocouple disconnected, go inside the grill body, remove the thermocouple screws, and slowly pull the thermocouple out of the grill until it is completely removed.
8. With the thermocouple removed, locate the 6 screws inside the grill, located on the hopper side, and remove them. In this case, it would be on the right. 
9. With the 6 screws removed, the hopper is now loose. Remove the 4 wing nuts holding the firepot in place.
10. 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 thermocouple 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 thermocouple wires into it.
4. Connect the thermocouple wires to the controller on the new HBA and then reinstall the controller onto the HBA.
5. With the thermocouple 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 6 screws holding the HBA to the grill.
7. Reinstall the 4 wing nut screws into the firepot.
8. Reinstall the lower insulation panel using the 6 small screws.
9. Reinsert the heat baffle, drain pan, and grill grates.
   
   

Replacing an HBA on an Ironwood 650 & Ironwood 885 and a Century 885

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. Once all internals are removed, locate the metal grill insulation on the hopper side of the grill.
4. Remove the upper and lower metal insulation panel from the grill by removing 6 small screws from each panel.
5. Remove the controller from the front of the hopper.
6. With the controller off, disconnect the thermocouple from the back of the controller.
7. With the thermocouple disconnected, go inside the grill body, remove the thermocouple screws, and slowly pull the thermocouple out of the grill until it is completely removed.
8. With the thermocouple removed, locate the 6 screws on the inside of the grill located on the hopper side of the grill and remove them. In this case, it would be on the right. 
9. With the 6 screws removed, the hopper is now loose. Remove the 4 wing nuts holding the firepot in place.
10. 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 thermocouple 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 thermocouple wires into it.
4. Connect the thermocouple wires to the controller on the new HBA and then reinstall the controller onto the HBA.
5. With the thermocouple 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 6 screws holding the HBA to the grill.
7. Reinstall the 4 wing nut screws into the firepot.
8. Reinstall the lower insulation panel using the 6 small screws.
9. Reinsert the heat baffle, drain pan, and grill grates.
   
   

Replacing an HBA on a Timberline 850 & 1300

Remove the HBA

1. With the grill unplugged and turned off, begin by removing the front stainless-steel shelf by removing 4 screws (2 from the left and 2 from the right), securing it in place. 
2. Open the grill lid.
3. Remove all internal items, such as grill grates, heat baffles, and drain pans.
4. Once all internals are removed, locate the upper and lower metal grill insulation on the hopper side of the grill and remove the metal insulation panels from the grill by removing 6 small screws.
5. Once the upper insulation panel is removed, pinch the thermocouple clip to release it from the insulation panel.
6. Find the 6 screws on the inside of the grill located on the hopper side of the grill and remove them. In this case, it would be on the right. 
7. With the 6 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.  Carefully slide it out and pull the thermocouple out simultaneously (since the thermocouple will still be connected to the controller).

Install the new HBA

1. On the new hopper burner, remove the firepot wing nuts.
2. Lift and slide the HBA into the body and while sliding it in, feed the thermocouple wire into the hole on the grill.
3. Reinstall the 6 screws holding the HBA to the grill.
4. Feed the thermocouple into the clip and then place the clip into the upper insulation panel.
5. With the thermocouple clipped into the upper insulation panel, reinstall the insulation panels by installing the 6 screws into the grill body.
6. Reinstall the 4 wing nut screws into the firepot.
7. Reinstall the lower insulation panel using the 6 small screws.
8. Reinsert the heat baffle, drain pan, and grill grates.
9. Reinstall the front shelf.