Hopper Assembly Replacement Instructions for Touchscreen Grills

What's in This Article?

How to remove and install a new hopper assembly on a touchscreen Timberline or Ironwood grill.

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What Is a Hopper Assembly?

The hopper assembly is a part that encompasses multiple components including the hopper, motherboard, display, and auger screw.

A hopper assembly is a combination your grill's hopper (the black box on the right side of your grill that holds your pellets) and the components within it such as the grill's motherboard, controller display, aux fan, lid light, and more. To learn more about this part, see Hopper Burner Assemblies & Hopper Assemblies.

 

Applicable SKUs

  • KIT0661
  • KIT0662
  • KIT0700
  • KIT0757
  • KIT0882
  • KIT0883
  • KIT0885
  • KIT0886

How to Replace a Hopper Assembly

TOOLS NEEDED:

Replacing a hopper assembly is easiest when done with 2 people.

  • Phillips screwdriver
  • Impact driver (if first time removing hopper service panel - see below)

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.
     

Remove the Existing Hopper Assembly

Once the hopper service panel has been removed, continue with instructions as outlined below:

  1. Turn off and unplug the grill.
  2. Empty the hopper.
  3. Remove the 6 screws from the hopper access panel on the right side of the hopper: 2 on top, 2 on the bottom, and 2 just under the side P.A.L Rail.                    Hopper Panel removal Touchscreen.png
  4. Remove the hopper access panel.
  5. Remove the 4 screws from the Smart Combustion cover and pull off the cover.
  6. Remove the following connections from the motherboard.  Wires that need to be removed for HA replacement Touchscreen.png
    • At time marker 0:49 - 1:24 in the video above, it is seen that all wires located on the motherboard are removed. This is fine to follow but it's unnecessary. Replacement can be made with just removing the TC, AC Ignitor, Fan and Smart Combustion connections. 
    • The wire connectors are unique and will only be able to be replaced in the same spot. So, there is no need to worry about remembering where each wire connects to the motherboard.
  7. Remove the two bolts and washers that connect the front P.A.L Rail to the hopper.
  8. Remove the 6 screws inside the hopper assembly that connect the assembly to the grill barrel and the cabinet.
    • 4 connecting to the barrel and 2 to the cabinet.
  9. Loosen and arrange cables, so they are not caught on anything.
    • At time marker 1:49-2:04 the instructional video shows 4 wires being run from the hopper to the air chamber. We only have 3 components in this section, the Fan, the Flame Sensor, and the Hotrod. 
  10. Lift the hopper assembly slightly and pull it away from the grill, carefully directing the wires through their entry points, if needed.

 

Install the New Hopper Assembly

NOTE: When replacing the Hopper Assembly, make sure all included wiring harnesses are also replaced. Harnesses included: Smart Combustion Harness (Motherboard to Flame Sensor and Lid Sensor Harness Kit: Ignitor Harness: AC Wiring Harnesses. 

  1. Lift the new assembly and have one person balance the assembly on the grill frame while the other person feeds the wires (including the Smart Combustion wire and Ignitor wire) through their appropriate entry points.
    •  See Wiring Harnesses for visuals of the wiring diagram, and images of the individual harnesses.
    • Be aware that on some of the touchscreen grills, the Smart Combustion wire is accessible by removing the small panel under the grease and ash keg.

                   smart combustion wire access.png

    • Run a SELF-TEST to make sure your wires are correctly connected.
      • On the controller display, go to MENU > MAINTENANCE & CARE > SELF-TEST
  1. Slide the new hopper into place, making sure the auger enters the auger tube.
  2. Screw the hopper into place using the 6 screws you removed when uninstalling the previous hopper assembly (4 to the barrel and 2 to the cabinet).
  3. Reattach the P.A.L Rail to the hopper.
  4. New Hopper Assemblies already have all the wires pre-attached to their needed components and the wire harnesses are actually zip tied inside the hopper. The Smart comb and Ignitor harness is already attached and bundled in the HA. The rest of the wires to the components are already installed and ready to go. The 2 wires that need to be run from the air chamber are the flame sensor and the ignitor wire. 
  5. Reinstall the Smart Combustion cover.
  6. Reinstall the access panel.
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