Display shows ERR4 and grill will not start a cook cycle

Safety first: Unplug the grill and ensure it is completely cool before working near the auger or hopper.

• Empty the hopper: Scoop out pellets from the hopper into a clean container. Vacuum remaining dust and small pieces with a shop vac.
• Check for foreign objects: Inspect the hopper and visible auger area for screws, tools, or other debris that may have fallen in and caused a jam.
• Test auger movement: With the hopper empty and grill plugged in, briefly start a feed or prime cycle while watching the auger shaft (if visible). If the motor hums but the auger does not turn, unplug the grill and proceed to disassembly.
• Clear auger jam: Remove the fasteners securing the auger motor and gearbox assembly at the rear or underside of the hopper. Slide the auger out of the tube. Scrape off compacted pellets and sawdust. Use a wooden dowel to gently push out any remaining blockage from the tube.
• Inspect motor and coupler: Check the auger motor shaft, coupler, and any shear pin for damage or stripping. Replace damaged components with Char‑Broil compatible parts.
• Reassemble and test: Reinstall the auger into the tube, reconnect the motor, and secure all fasteners. Refill the hopper with fresh, dry pellets. Plug in the grill and run a prime cycle to confirm smooth auger operation and that ERR4 is cleared.