RTD Replacement Instructions

This first set of replacement instructions applies to most AC grills. Variants of these steps for specific models are provided after these initial instructions:

Supplies Needed:

• Phillips screwdriver (#2 size)

• Flathead screwdriver (1/8” or 3mm)

• Optional:

  • Cutting pliers or scissors

  • Zip ties, 8” (1-3)

Replacement Instructions:

1. Turn off and unplug your grill.
2. Unscrew the screws securing your controller to your hopper and pull the controller away from the grill to expose the wiring and connection points.
3. Locate the green box in the upper corner of the control panel that secure the RTD wires in place. Loosen the two screws holding the RTD sensor wires just enough to be able to remove the RTD wires.
4. Open your grill and locate the RTD temperature probe on the left side of your barrel and unscrew the two Phillips screws holding it in place.
   • Depending on your grill, the RTD may be 2" or 7".
5. Pull the RTD probe and its wires completely out of the grill.
6. Insert the new RTD probe wires through the same channel you pulled the old RTD out of so that the end of the wires are near the controller.
7. Screw the new RTD probe in place with the two Phillips screws.
8. Insert the new RTD probe wires into the green RTD connection box and gently tighten the screws to secure the wires in place.
9. Make sure no wires are touching the fan blades. If you have zip ties on hand, zip tie the wires together to keep them bundles.
10. Reinstall the controller to the front of the hopper.

Tools Needed

• Phillips screwdriver (#2 size)

• Flathead screwdriver (1/8” or 3mm)

• Optional:

  • Thin wire or string, about 2 ft/60cm

  • Grill cleaner

  • Paper towels or rags

  • Gloves

  • Cutting pliers or scissors

  • Zip ties, 8” (1-3)

1. Turn off and unplug the grill.
2. Remove the grease bucket, grill grate and drip tray.
3. Empty the hopper and remove any remaining pellets from the firepot.
4. Clean the grill thoroughly.
5. Remove the five Phillips screws that secure the hopper, RTD, and grill cavity in place.
   
6. Lift the hopper-burner assembly (HBA) out of the grill using the handle labeled, Caution Hot.
   
   • If the HBA doesn't have a handle, pull it from the hopper and auger tube/firepot (older Ranger and Scout models do not have this handle).
7. Cut the zip ties that bundle the wires together, careful not to cut any wires.
   
8. Rangers & Trailheads only: Find the back of the power switch and disconnect the two black wires from the power switch on the back of the grill body.
   
9. Unscrew the two Phillips screws holding the controller in place and pull the controller away from the grill to expose the back of the controller.
   
10. Locate the green box in the upper corner of the control panel that secure the RTD wires in place. Loosen the two screws holding the RTD sensor wires just enough to be able to remove the RTD wires.
    
11. Tie a string to the RTD wires. You will use this string to help guide the new RTD back through the grill.
    
12. Gently pull the RTD up and away from the grill, stopping when the leads that connect to the controller are out of the grill and the string is just exposed.
13. Untie the string from the old RTD and tie it to the new RTD. Pull the string and the new RTD wires through the grill so you can attach the new RTD to the controller.
    
14. Remove the wire/string from the RTD connectors and connect the RTD contacts to the controller, tightening the slotted screws just tight enough to keep the RTD wires secure.
    
15. Re-install the controller to the grill body using your Phillips screwdriver.
16. Bundle the wires together and secure them with at least one 8” zip tie, making sure the wires do not contact any moving parts.
    
     
17. Ranger & Trailhead Only: Re-connect the main power switch wires on or inside the rear of the grill body.
18. Lower the HBA back into the grill body.
19. Reinstall the five screws, noting the difference between the machine thread and self-tapping screws.
    • Machine thread: 3 total, secure HBA to grill body
    • Self-tapping: 2 total, secure RTD to HBA
20. Reinstall the drip tray, grill grate, and grease bucket.

Supplies Needed

• Phillips screwdriver (#2 size)

• Slotted screwdriver (1/8” or 3mm)

• Wrench

• Optional:

  • Grill cleaner

  • Paper towels or rags

  • Gloves

1. Turn off and unplug the grill.
2. Remove the grill grates, drip tray and heat baffle. Clean the grill thoroughly.
3. First-Time Replacing an RTD: Because Juniors and Tailgaters are shipped with the HBA inside the barrel, the RTD comes in two pieces that connect together when assembling the grill. 
     
   The replacement RTD is one piece instead of two. Assure that the single RTD is the correct replacement part even though they look different.
4. Find the RTD probe on the left side of the grill. Use a Phillips screwdriver to unscrew the 2 screws securing the RTD to the grill.
   
    
5. Use a Phillips screwdriver to unscrew the controller from the front of the hopper.
   
    
6. Find the green RTD connection box. Use a small flathead screwdriver to loosen the two screws on the top of the box. This will allow you to then remove the RTD probe wires.
   
    
7. Use a wrench to unscrew the bolts holding the hopper-burner assembly to the grill.
   
    
8. Pull the hopper away from the grill so you can see the entry points for the RTD wires.
   Junior/Tailgater: the hopper does not need to be removed during replacement.
    
    
9. Pull the RTD out of the grill.
   
    
10. Feed the new RTD wires through the grill and through the entry points between the grill barrel and the hopper-burner assembly until you are able to grab the ends of the wires near the controller.
11. Reattach the hopper-burner assembly to the grill.
12. Screw the new RTD in place.
13. Insert the RTD wires into the green RTD connection box and gently tighten the screws to secure the wires in place.
14. Make sure no wires are touching fan blades. If possible, use a zip tie to secure wires together.
15. Using a Phillips screwdriver, re-screw the controller to the grill.

Replacement Steps

1. Turn off and unplug the grill.

2. Remove the 6 Phillips head screws holding the upper panel assembly together on the back of the grill.

3. Locate the RTD wire running through the back of the grill and into the hopper assembly

4. Remove the 2 screws holding the RTD in place.                                                             
5. With a small screwdriver, loosen the brackets holding the RTD wires.       

6. Remove the screws holding the RTD in place and pull it through the grill (cut any zip ties holding the wires together).

7. Feed the new RTD through the hole in the middle of the barrel.                         

8. Run the wire through the back of the grill to the small hole leading into the hopper assembly.

9. Once through, replace the upper panel.                                                 

10. From underneath, string the RTD wires through the hopper and out the controller cutout.

11. With a screwdriver, reinsert the RTD wires back into the housing box on the back of the controller.

12. Screw the controller back in place.

13. Tighten the RTD probe back into place and install the RTD guard.
     

Tools Needed:

• Phillips screwdriver
• Small flathead screwdriver
• Zip ties
• Tape and string (optional for wire routing)

Replacement Steps

1. Power Off the Grill
   • Turn off and unplug the grill to ensure safety.
2. Remove the RTD Probe
   • Inside the barrel, locate the RTD probe (usually on the left side).
   • Unscrew the 2 screws and nuts holding the RTD in place.
3. Access the Controller
   • Unscrew the controller from the front of the hopper using a Phillips screwdriver.
   • On the back of the controller, locate the green terminal block.
     
   • Use a small screwdriver to loosen the screws and disconnect the RTD wires.
4. Free the Wiring
   • Cut any zip ties securing the RTD wires inside the hopper.
   • If needed, use tape and string to pull the old RTD wire out and guide the new one through the same path.
      
5. Install the New RTD Probe
   • Feed the new RTD wire through the placement hole on the side of the barrel.
   • Protect the probe tips with plastic and tape during installation to avoid damage.
   • Screw the new RTD securely into place.
6. Reconnect the Wiring
   • Attach the new RTD wires to the green terminal block on the controller.
   • Tighten the screws to secure the connection.
7. Secure and Reassemble
   • Use zip ties to tidy up and secure the wiring away from heat sources or moving parts.
   • Reattach the controller to the hopper using a Phillips screwdriver.
   • Reinstall any panels or covers removed during the process.
8. Test the Grill
   • Plug the grill back in and power it on.
   • Set a temperature and verify that the RTD is reading accurately.