Hopper Burner Assembly Replacement Instructions for WiFIRE Grills

What's in This Article?

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

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

 

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 & Silverton XL
  • Ironwood 650, Ironwood 885, Redland, Redland XL & Century 885
  • Timberline 850 & Timberline 1300 D2 & AC

 

Replacement Instructions for Pro 575 & 780; Silverton 620, 810 & Silverton XL

 

Removing the HBA

Follow the next steps to help remove the HBA on a Pro 575 & 780; Silverton 620, 810 & Silverton XL.

Removing the HBA

1. With the grill turned off and unplugged, open the grill lid.

Grill plugged in.png

2. Remove access panel from bottom of hopper (2 screws).

access panel removal D2.png

3. Cut zip ties that restrict cables.

 

D2 Wire bundle.png

4. Remove the 4 screws that hold the controller in place.Remove D2 controller screws.png

5. Remove the controller from the front of the hopper.

 

Remove controller D2.png

6. Unplug all plastic connectors from controller. Including the thermocouple.

 

d2 wiring.png

7. Remove 4 Phillips screws that secure the hopper (2 in the front. 2 in the back).

Removing D2 hopper screws.png

8. Remove all internal items: grill grates, heat baffles, and drain pans.

 

Internals removed D2.png

9. Once all internals are removed, locate the lower metal grill insulation on the hopper side of the grill. 10. Remove the lower metal insulation panel from the grill by removing 2 small screws. heat shield screws.png

11. Remove the screws on either side of the thermocouple.

 

 

TC for Pros.png

12. Slowly pull the thermocouple out of the grill until it is completely removed.

 

Remove TC D2.png

13. Locate the screws inside the grill, located on the hopper side, and remove them. In this case, it would be on the right.barrel to hopper screws.png

14. With the screws removed, the hopper is now loose. Remove the 4 wing nuts holding the firepot in place.Wing Nuts.png

 

15. With the wing nuts removed, the hopper burner should slide out. Once removed. Move to the HBA installation instructions below.

 

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 2 small screws.
  9. Reinsert the heat baffle, drain pan, and grill grates.

Replacement Instructions for Ironwood 650 & 885; Redland & Redland XL; Century 885

 

Removing the HBA

Follow the next steps to help remove the HBA on an Ironwood 650 & 885; Redland & Redland XL; Century 885.

Removing the HBA

1. With the grill turned off and unplugged, open the grill lid.

Grill plugged in.png

2. Remove access panel from bottom of hopper (2 screws).

access panel removal D2.png

3. Cut zip ties that restrict cables.

 

D2 Wire bundle.png

4. Remove the 4 screws that hold the controller in place.Remove D2 controller screws.png

5. Remove the controller from the front of the hopper.

 

Remove controller D2.png

6. Unplug all plastic connectors from controller. Including the thermocouple.

 

d2 wiring.png

7. Remove 4 Phillips screws that secure the hopper (2 in the front. 2 in the back).

Removing D2 hopper screws.png

8. Remove all internal items, such as grill grates, heat baffles, and drain pans.

Ironwood no internals.png

9. Once all internals are removed, locate the metal grill insulation on the hopper side of the grill.

10. Remove the screws on either side of the TC. Slowly pull the thermocouple out of the grill until it is completely removed.

TC screws Ironwood 650885.pngRemove TC D2.png

11. Remove the upper and lower metal insulation panel from the grill by removing 8 small screws: 6 on the top panel and 2 on the lower panel.

 

Top insulation panel Ironwood 650885.pngBottom insulation panel Ironwood 650885.png

12. With the insulation panel and 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.

 

 

hopper to grill screws 2 Ironwood 650885.png

13. With the 6 screws removed, the hopper is now loose. Remove the 4 wing nuts holding the firepot in place. Wing Nuts.png 14. With the wing nuts removed, the hopper burner should slide out.  Once removed. Move to the HBA installation instructions below.  

 

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.

Replacement Instructions for Timberline 850 & 1300

Follow the next steps to help remove the HBA on a Timberline 850 & 1300 whether D2 or AC WiFIRE.

 

D2 Timberline 850 & 1300

Removing 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. 

Shelf removal.png

2. Open the grill lid. Remove all internal items, such as grill grates, heat baffles, and drain pans.

 

 

Tim no internals.png

3. Once all internals are removed, locate the metal grill insulation on the hopper side of the grill and remove the metal insulation panels from the grill by removing 6 small screws.

insulation panel Timberline 8501300.png

4. Once the insulation panel is removed, pinch the thermocouple clip to release it from the insulation panel. TC Timberline 850pulling TC through - Tim.png
5. 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. panel behind insulation.png

6. With the 6 screws removed, the hopper is now loose. Remove the 4 wing nuts holding the firepot in place.

Wing Nuts.png

7. 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).  8. Once removed. Move to the HBA installation instructions below.

 

 

 

 

 

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.

 

AC Timberline 850 & 1300

Remove the HBA

Removing 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. 

Shelf removal.png

2. Open the grill lid. Remove all internal items, such as grill grates, heat baffles, and drain pans.

 

 

 

Tim no internals.png

3. Once all internals are removed, locate the panel on the hopper side of the grill and remove the 5 screws holding the right-side panel.Right Panel Tim AC.png

4. Once the panel is removed, pinch the thermocouple clip to release it from the  panel.

 

TC Tim AC.png

5. Find the 6 screws on the inside of the grill located on the hopper side of the grill and remove them. Do not remove the safety screw yet.AC Tim barrel to hopper panel.png

6. With the 6 screws removed, the hopper is now loose. Remove the 4 wing nuts holding the firepot in place.

 

 

Wing Nuts.png

7. Now Remove the safety screw holding the hopper burner. Pull the TC wire free and remove the hopper burner should slide out.  8. Once removed. Move to the HBA installation instructions below.

 

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, including the safety screw.
  4. Feed the thermocouple into the clip and then place the clip into the right panel.
  5. With the thermocouple clipped into the panel, reinstall the panels by installing the 5 screws into the grill body.
  6. Reinstall the 4 wing nut screws into the firepot.
  7. Reinsert the heat baffle, drain pan, and grill grates.
  8. Reinstall the front shelf.
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