Thermocouple Replacement - Touchscreen Grills

How to replace a thermocouple on a Timberline grill.

PART NUMBER: KIT0659

IMPORTANT: Before proceeding

To continue you'll need to remove your hopper service panel. To remove this panel for the first time, you'll want to use an impact driver to remove the screws behind the P.A.L rail on your hopper service panel. 

1. If this is your first time removing the hopper service panel and you don't have an impact driver of your own. Contact our customer support team and we'll send you a complimentary manual impact driver.
   • If you already have a manual impact driver, proceed to removing the hopper service panel.
   • If you have already removed the service panel screws, you can disregard the impact driver and use a regular Phillips screwdriver.
2. Once you've removed the screws using the impact driver, continue with the next steps outlined here in this article.
    

Timberlines

1. Remove all pellets from the grill.
2. Remove side service panel.
3. Remove the lid of the grill, by removing the top half of the hinges.
4. Locate the Thermocouple wire cover, in between the hoper and the grill lid.
   
   • Remove this by removing one Phillips head screw.
5. Remove the Thermocouple window on the back of the grill by removing 2 Phillips head screws.
6. Locate the stainless steel clip holding the thermocouple wire in place.
7. Remove the thermocouple by loosening the thermocouple bracket clamp screw.
8. Inside the hopper locate the bright yellow thermocouple wire and gently pull old thermocouple out now that all fasteners are removed.
9. Take new thermocouple wire and feed it into the opening of the back of the hopper.
10. Feed the wire though the window on the back of the grill and up into the thermocouple bracket clamp.
11. See drawing for specific length.
12. Tighten clamp, put window back on, and put wire cover on.
13. Connect thermocouple to motherboard following + and - symbols.
14. Put smart combustion cover back on motherboard.
15. Put hopper service panel back on grill.
16. Reinstall lid.

Ironwoods

For Ironwood thermocouple replacement, keep the bracket that is currently on your grill and only change out the thermocouple wire. Discard the bracket that will come with KIT0659.

1. Remove pellets from the grill.
2. Remove the hopper service panel with an impact a manual impact driver.
3. Remove the lid of the grill.
4. Locate the Thermocouple wire cover, between the hopper and the grill lid.
   • Remove this by removing one Phillips head screw.
5. Remove the Thermocouple window on the back of the grill by removing 2 Phillips head screws.
6. Locate the stainless steel clip holding the thermocouple wire in place.
   • Loosen the bolt on the silver bracket enough that the tip of the thermocouple can fit.
7. Remove the thermocouple by loosening the thermocouple bracket clamp screw.
8. Inside the hopper locate the bright yellow thermocouple wire and gently pull old thermocouple out now that all fasteners are removed.
9. Take new thermocouple wire and feed it into the opening of the back of the hopper.
10. Feed the wire though the window on the back of the grill and up into the thermocouple bracket clamp. 
    1. Insert the thermocouple through the base of the bracket and then slide the wire under the silver bracket.
11. Tighten clamp, put window back on, and put wire cover on.
12. Connect thermocouple to motherboard following + and - symbols.
13. Put smart combustion cover back on motherboard.
14. Put hopper access panel back on grill.
15. Reinstall lid.