The Pit Boss Pro Series 850 is popular because it delivers real wood-smoke flavour with the convenience of digital control.
But like any pellet grill, it can run into a few common issues especially if it’s used often, stored outdoors, or cleaned irregularly.
The good news is most problems are fixable at home with simple checks, basic cleaning, and a few smart settings adjustments.
In this guide, you’ll learn 11 common Pit Boss Pro Series 850 problems, why they happen, and the easiest step-by-step fixes.
We’ll cover ignition failures, temperature swings, flameouts, pellet jams, excessive smoke, error codes, auger issues, fan problems, and more without complicated technical jargon. Each issue is explained in an easy way so even beginners can troubleshoot confidently.
Before you start, remember two simple rules: keep pellets dry and keep the fire pot clean. Many “mystery problems” on pellet grills come from damp pellets, heavy ash buildup, or poor airflow.
Also, try to use quality hardwood pellets and store them in an airtight container. If your grill is in a humid area, moisture can cause swelling pellets and blockages that lead to errors and shutdowns.
11 Common Pit Boss Pro Series 850 Problems[Short Overview]
- Grill won’t start or ignite due to wet pellets, ash buildup, or a faulty igniter.
- Temperature swings usually come from airflow issues, dirty sensors, or low-quality pellets.
- Flameouts happen when pellets feed poorly or the fire pot is overloaded with ash.
- Auger jams and pellet bridging can stop fuel flow and trigger shutdowns or errors.
- Uneven heat, too much smoke, or weak smoke flavour often comes from setup and maintenance gaps.
Problems, Reasons, and Fixes (Step-by-Step)
1) Pit Boss Pro Series 850 Won’t Turn On
Reason
- Loose power connection or faulty outlet
- Blown fuse in the control board area
- Damaged power cord or controller failure
Fix
- Plug into a different wall outlet (avoid extension cords if possible).
- Check the power cord for cuts, heat damage, or looseness.
- Locate and inspect the fuse (if your model has an accessible fuse).
- Reset the unit: unplug for 5 minutes, then plug back in.
- If the screen stays dead, the controller may need replacement.
Read Also: (10 Common) Traeger Ironwood 650 Problems (With Fixes)
2) Pit Boss Pro Series 850 Turns On But Won’t Ignite
Reason
- Damp pellets or no pellets reaching the fire pot
- Fire pot full of ash, blocking ignition
- Hot rod/igniter not heating properly
Fix
- Empty pellets and add fresh, dry pellets (store pellets airtight).
- Remove grates and heat deflector, then vacuum ash from the fire pot.
- Prime the auger (if your unit supports priming) so pellets reach the pot.
- Restart and watch: you should see pellets drop and heat build in a few minutes.
- If there’s no heat in the pot area, the igniter may be faulty and may require replacement.
3) Temperature Swings Up and Down (Unstable Heat)
Reason
- Dirty temperature probe (RTD sensor)
- Ash buildup restricting airflow
- Low-quality pellets causing inconsistent burn
- Lid opened too often or windy/cold conditions
Fix
- Clean the internal temp probe gently using a damp cloth.
- Vacuum ash from fire pot and bottom chamber.
- Switch to quality hardwood pellets and avoid dusty pellet bags.
- Use a thermal blanket in cold weather if available.
- Keep the lid closed as much as possible to stabilise heat.
4) Grill Won’t Reach Target Temperature (Low Heat)
Reason
- Not enough airflow due to ash or grease buildup
- Pellets feeding slowly or bridging in hopper
- Heat deflector installed incorrectly
- Very cold outdoor temperatures
Fix
- Deep clean the fire pot and interior ash areas.
- Stir pellets in the hopper to break bridging, then refill with fresh pellets.
- Re-check heat deflector placement so heat circulates correctly.
- Preheat longer (15–25 minutes) and avoid opening lid early.
- In winter, use a grill blanket and cook with wind protection.
5) Grill Overheats or Runs Too Hot
Reason
- Excess pellets in the fire pot from repeated restarts
- Grease fire starting under the drip tray
- Controller settings too aggressive for conditions
- Lid thermometer mismatch causing confusion
Fix
- Shut down properly and let it cool fully.
- Remove parts and clean the fire pot, drip tray, and grease channels.
- Avoid restarting multiple times without cleaning the pot.
- Use lower settings and let the grill stabilise before adjusting again.
- Confirm temperature using a reliable digital probe to verify actual heat.
6) Flameouts (Fire Goes Out Mid-Cook)
Reason
- Dirty fire pot causing poor combustion
- Pellets not feeding consistently
- Wind blowing into the cooking chamber
- Pellet quality issues (crumbly, damp, excessive dust)
Fix
- Vacuum ash and clean the fire pot before long cooks.
- Ensure pellets flow freely—break pellet clumps and remove dust.
- Position the grill away from direct wind or use a windbreak.
- After a flameout, empty the pot before restarting to prevent flare-ups.
- Use fresh pellets and store them dry to prevent swelling and feed issues.
7) Auger Jam (Pellets Stop Feeding)
Reason
- Wet pellets swell and harden inside the auger tube
- Pellet dust compacts and blocks the auger
- Long storage with pellets left in hopper
Fix
- Power off and unplug the grill first.
- Empty the hopper completely and remove pellet dust.
- Check for visible clogs in the auger path.
- Use only dry pellets; discard any soft, swollen, or crumbling pellets.
- Prevent future jams by emptying pellets if you won’t use the grill for weeks.
8) “Er” or Error Codes on the Display
Reason
- Temperature probe reading issue
- Flameout detected (temperature dropped too low)
- Overheat safety triggered
- Power interruption during cooking
Fix
- Turn off, unplug for 5 minutes, then restart.
- Clean the temperature probe and ensure it’s not covered in grease.
- Inspect fire pot for ash or pellet overflow and clean it out.
- Avoid extension cords and plug into a stable outlet.
- If error returns repeatedly, the probe or controller may need replacement.
9) Excessive White Smoke (Or Smoke That Smells “Off”)
Reason
- Smouldering pellets from weak ignition
- Fire pot overloaded with pellets
- Damp pellets producing dirty smoke
- Grease buildup burning slowly
Fix
- Use fresh, dry pellets only.
- Clean the fire pot and restart with a proper ignition cycle.
- Let the grill preheat fully until smoke becomes thin and steady.
- Clean grease tray and drain path to prevent dirty smoke.
- If smoke stays thick for long, stop and inspect the burn area.
10) Not Enough Smoke Flavour
Reason
- Cooking at high temps reduces visible smoke output
- Mild pellet wood blends
- Short cook times don’t absorb much smoke
- Airflow and heat balance not optimised
Fix
- Start cooking at lower temps for the first 45–90 minutes for more smoke.
- Try stronger wood pellets (like hickory/mesquite blends).
- Keep meat surface slightly moist early on (light spritz helps smoke adhesion).
- Avoid opening the lid repeatedly.
- Ensure fire pot and airflow are clean for a stable burn.
11) Uneven Cooking or Hot Spots
Reason
- Heat deflector/drip tray placement issues
- Grease and carbon buildup affecting airflow
- Using wrong rack position for the food type
- Wind and ambient temperature affecting one side
Fix
- Reinstall drip tray and heat deflector correctly and evenly.
- Clean grease buildup under the tray and around airflow areas.
- Rotate food halfway through long cooks for consistent results.
- Use an external thermometer to map hot zones once, then cook accordingly.
- Shield the grill from wind for steadier chamber heat.
Conclusion
The Pit Boss Pro Series 850 is a solid pellet grill, but it still relies on three things to perform well: clean airflow, dry pellets, and a stable ignition cycle. Most of the common Pit Boss Pro Series 850 problems (with fixes) are not “major failures”—they’re usually caused by ash buildup in the fire pot, pellet moisture, pellet dust, or a dirty temperature probe. When those small issues stack up, you get temperature swings, flameouts, error codes, or ignition trouble.
To keep your grill running smoothly, build a simple routine: vacuum ash regularly, wipe the temperature probe, clean the grease tray, and store pellets in an airtight container. Also, avoid repeated restarts without checking the fire pot. That one habit alone prevents overheating, excessive smoke, and flare-ups. If you cook in winter or windy weather, give the grill extra preheat time and use wind protection for stable performance.
With the step-by-step fixes above, you can solve most problems quickly and get back to cooking—whether you’re smoking brisket, grilling burgers, or running long low-and-slow sessions. A little maintenance goes a long way, and your Pit Boss Pro Series 850 will reward you with consistent heat, better flavour, and fewer interruptions.
FAQs
1) Why does my Pit Boss Pro Series 850 keep shutting off?
It usually shuts off due to flameouts from ash buildup, wet pellets, or poor pellet feeding. Clean the fire pot and use fresh, dry pellets.
2) How often should I clean the fire pot?
For best performance, vacuum the fire pot every 2–3 cooks, and always before long smoking sessions to avoid flameouts and ignition problems.
3) What pellets work best for stable temperature?
Use dry, premium hardwood pellets with low dust. Avoid crumbly pellets because dust can compact and cause feeding issues.
4) Why is my Pit Boss producing thick white smoke?
Thick white smoke often means smouldering pellets, damp pellets, or a dirty fire pot. Clean the pot, replace pellets, and let preheat complete fully.
5) Can cold weather cause temperature problems on the Pro Series 850?
Yes, cold and wind can lower heat and cause swings. Use a thermal blanket, wind protection, and allow extra preheat time for better stability.
