Char-Broil 12701705 Vertical Gas Smoker 595 Manual

PRODUCT GUIDE
MODEL
12701705
VERTICAL GAS SMOKER 595

The serial number
Date purchased
If you have questions or need assistance during assembly, please call 1-800-241-7548.

This instruction manual contains important information necessary for the proper assembly and safe use of the appliance.
Read and follow all warnings and instructions before assembling and using the appliance.
Follow all warnings and instructions when using the appliance.
Safety Symbols
The symbols and boxes are shown below explain what each heading means. Read and follow all of the messages found throughout the manual.

CAUTION: Indicates a potentially hazardous situation or unsafe practice which, if not avoided, may result in minor or moderate injury.

WARNING: Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury.

DANGER: Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.

INSTALLER/ASSEMBLER:
Leave this manual with the consumer.
CONSUMER:
Keep this manual for future reference.

CALIFORNIA PROPOSITION 65

Combustible by-products produced when using this product contain chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
This product contains chemicals, including lead and lead compounds, known to the State of California to cause cancer, birth defects, or other
reproductive harm.

Wash your hands after handling this product.
THIS GRILL IS FOR OUTDOOR USE ONLY.

If you smell gas:

Shut off gas to the appliance.
Extinguish any open flame.
Open lid.
If odor continues, keep away from the appliance and immediately call your fire department.

Failure to follow these instructions could result in fire or explosion, which could cause property damage, personal injury, or death.

Never operate this appliance unattended.
Never operate this appliance within 10ft (3m) of any structure, combustible material, or gas cylinder.
Never operate this appliance within 25 ft (7.5 m) of any flammable liquid.
If a fire should occur, keep away from the appliance and immediately call your fire department.

Failure to follow these instructions could result in fire, explosion, or burn hazards, which could cause property damage, personal injury, or death.

Failure to follow all manufacturer’s instructions could result in serious personal injury and/or property damage.

For residential use only. Do not use it for commercial cooking.

Read and follow all safety statements, assembly instructions, and use and care directions before attempting to assemble and cook.

Some parts may contain sharp edges. Wear protective gloves if necessary.

Do not attempt to repair or alter the hose/valve/regulator for any “assumed” defect.
Any modification to this assembly will void your warranty and create the risk of a gas leak and fire.
Use only authorized replacement parts supplied by the manufacturer.

Grease Fires

Putting out grease fires by closing the lid is not possible. Grills are well ventilated for safety reasons.
Do not use water on a grease fire. Personal injury may result. If a grease fire develops, turn knobs and LP tank off.
If the grill has not been regularly cleaned, a grease fire can occur that may damage the product. Pay close attention while preheating or burning off food residue to insure that a grease fire does not develop. Follow instructions on General Grill Cleaning and Cleaning The Burner Assembly to
prevent grease fires.
The best way to prevent grease fires is regular cleaning of the grill.

If the smoker should go out accidentally, turn the burner control OFF, wait 5 minutes and repeat the lighting procedure.

Installation Safety Precautions

Use your appliance, as purchased, only with LP (propane) gas and the regulator/valve assembly supplied.
The appliance installation must conform to local codes, or in their absence of local codes, with either the National Fuel Gas Code, ANSI Z223.1/ NFPA 54, Natural Gas and Propane Installation Code, CSA B149.1, and Propane Storage and Handling, CSA B149.2, Canadian Electrical Code, CSA C22.1 or The standard for Recreational Vehicles, ANSI A 119.2/NFPA 1192, and CSA Z240 RV Series, Recreational Vehicle
Code, as applicable.
This appliance is not for use in or on recreational vehicles and/or boats.
This appliance is safety certified for use in the United States and/or Canada only. Do not modify for use in any other location. The modification will result in a safety hazard.

Food Safety

Food safety is a very important part of enjoying the outdoor cooking experience. To keep food safe from harmful bacteria, follow these four basic steps:
Clean: Wash hands, utensils, and surfaces with hot soapy water before and after handling raw meat and poultry.
Separate: Separate raw meats and poultry from ready-to-eat foods to avoid cross-contamination. Use a clean platter and utensils when removing cooked foods.
Cook: Cook meat and poultry thoroughly to kill bacteria.
Use a thermometer to ensure proper internal food temperatures.
Chill: Refrigerate prepared foods and leftovers promptly.
For more information call: USDA Meat and Poultry Hotline at 1-800-535-4555 In Washington, DC (202) 720-3333, 10:00 am-4:00 pm EST.
How To Tell If Meat Is Cooked Thoroughly

Meat and poultry cooked in the appliance often brown very fast on the outside. Use only thawed meat and a meat thermometer to be sure food has reached a safe internal temperature, and cut into food to check for visual signs of doneness.
We recommend food to be at least 40°F before cooking in your appliance.
Whole poultry should reach 165° F. Juices should run clear and the flesh should not be pink.
Beef, veal and lamb steaks, roasts, and pork chops can be cooked to 145° F.
NEVER partially cook meat or poultry and finish cooking later. Cook food completely to destroy harmful bacteria.
Use a meat thermometer to ensure proper internal food temperatures.

USDA Recommended
Internal Cooking Temperatures
Ground Meat
Beef, Pork, Veal, Lamb………………………………..160°F
Turkey, Chicken………………………………………….165°F
Fresh Beef, Veal, Lamb
Medium Rare……………………………………………….145°F
(let stand 3 minutes before cutting)
Medium……………………………………………………….160°F
Well Done……………………………………………………170°F
Poultry
Chicken & Turkey, whole……………………………….165°F
Poultry Parts……………………………………………….165°F
Duck & Goose…………………………………………….165°F
Fresh Pork
Medium Rare………………………………………………145°F
(let stand 3 minutes before cutting)
Medium……………………………………………………..160°F
Well Done………………………………………………….170°F

Storing Your Appliance

Store in a dry location.
When an LP cylinder is connected to an appliance, store outdoors in a well-ventilated space and out of reach of children.
If Regulator is disconnected from the LP cylinder, a hook is provided to hang the Regulator from the handle as shown.
Cover appliance if stored outdoors. Choose from a variety of covers offered by the manufacturer.
Store indoors ONLY if the LP cylinder is turned off and disconnected, removed from the appliance, and stored outdoors.
When removing an appliance from storage, follow “Cleaning the Burner Assembly” instructions before starting.

USE AND CARE

NEVER store a spare LP cylinder under or near the appliance or in an enclosed area.
Never fill a cylinder beyond 80% full.
An overfilled or improperly stored cylinder is a hazard due to possible gas release from the safety relief valve. This could cause an intense fire with a risk of property damage, serious injury, or death.
If you see, smell or hear gas escaping, immediately get away from the LP cylinder/appliance and call your fire department.
Keep LP tank at a minimum distance of 24” (inches) away from the appliance at all times.

LP Cylinder Removal, Transport, and Storage

Turn OFF all control knobs and LP cylinder valve. Turn coupling nut counterclockwise by hand only – do not use tools to disconnect. Loosen cylinder screw beneath a bottom shelf or disconnect other retention means, then lift LP cylinder up and out of the cart. Install safety cap onto
LP cylinder valve. Always use cap and strap supplied with valve.
Failure to use the safety cap as directed may result in serious personal injury and/or property damage.
A disconnected LP cylinder in storage or being transported must have a safety cap installed (as shown). Do not store an LP cylinder in enclosed
spaces such as a carport, garage, porch, covered patio, or other building. Never leave an LP cylinder inside a vehicle that may become overheated by the sun.
Do not store an LP cylinder in an area where children play.

LP (Liquefied Petroleum Gas)

LP gas is nontoxic, odorless, and colorless when produced. For Your Safety, LP gas has been given an odor (similar to rotten cabbage) so that it can be smelled.
LP gas is highly flammable and may ignite unexpectedly when mixed with air.

LP Cylinder

The LP cylinder used with your grill must meet
the following requirements:
Use LP cylinders only with these required measurements: 12″ (30.5cm) (diameter) x 18″ (45.7 cm) (tall) with 20 lb. (9 kg.) capacity maximum.
LP cylinders must be constructed and marked in accordance with specifications for LP cylinders of the U.S. Department of Transportation (DOT) or for Canada, CAN/CSA-B339, cylinders, spheres, and tubes for transportation of dangerous goods, Transport Canada (TC). See LP cylinder collar for marking.
LP cylinder valve must have:
Type 1 outlet compatible with regulator or grill.
Safety relief valve.
UL listed Overfill Protection Device (OPD). This OPD safety feature is identified by a unique triangular handwheel. Use only LP cylinders equipped with this type of valve.
LP cylinder must be arranged for vapor withdrawal and include a collar to protect the LP cylinder valve. Always keep LP cylinders in an upright position during use, transit, or storage.

LP Cylinder Filling

Use only licensed and experienced dealers.
LP dealer must purge new cylinder before filling.
The dealer should NEVER fill LP cylinder more than 80% of LP cylinder volume. The volume of propane in the cylinder will vary by temperature.
A frosty regulator indicates gas overfill. Immediately close the LP cylinder valve and call the local LP gas dealer for assistance.
Do not release liquid propane (LP) gas into the atmosphere. This is a hazardous practice.
To remove gas from the LP cylinder, contact an LP dealer or call a local fire department for assistance. Check the telephone directory under “Gas Companies” for the nearest certified LP dealers.

LP Cylinder Exchange

Many retailers that sell grills offer you the option of replacing your empty LP cylinder through an exchange service. Use only those reputable exchange companies that inspect, precision fill, test, and certify their cylinders.
Exchange your cylinder only for an OPD safety feature-equipped cylinder as described in the “LP Cylinder” section of this manual.
Always keep new and exchanged LP cylinders in an upright position during use, transit, or storage.
Leak test new and exchanged LP cylinders BEFORE connecting to grill.
Place safety cap on cylinder valve outlet whenever the cylinder is not in use. Only install the type of safety cap on the cylinder valve outlet that is provided with the cylinder valve. Other types of caps or plugs may result in leakage of propane.
LP Cylinder Leak Test For your safety
The leak test must be repeated each time the LP cylinder is exchanged or refilled.
Do not smoke during leak test.
Do not use an open flame to check for gas leaks.
Grill must be leak tested outdoors in a well-ventilated area, away from ignition sources such as gas-fired or electrical appliances. During leak test, keep the grill away from open flames or sparks.
Use a clean paintbrush and a 50/50 mild soap and water solution. Brush soapy solution onto areas indicated by arrows in the figure below.
Do not use household cleaning agents. Damage to gas train components can result.

If “growing” bubbles appear do not use or move the LP cylinder. Contact an LP gas supplier or your fire department!
Connecting Regulator to the LP Cylinder

LP cylinder must be properly secured onto the grill. (Refer to assembly section.)
Turn all control knobs to the OFF position.
Turn the LP cylinder OFF by turning the hand-wheel clockwise to a full stop.
Remove the safety cap from the LP cylinder valve. Always use cap and strap supplied with valve.
Hold regulator and insert nipple into LP cylinder valve. Hand-tighten the coupling nut, holding regulator in a straight line with LP cylinder valve
so as not to cross-thread the connection.
Turn the coupling nut clockwise and tighten to a full stop.
The regulator will seal on the back-check feature in the LP cylinder valve, resulting in some resistance. An additional one-half to three-quarters turn is required to complete the connection. Tighten by hand only – do not use tools.

NOTE:
If you cannot complete the connection, disconnect the regulator and repeat steps 5 and 6. If you are still unable to complete the connection, do not use this regulator!

Do not insert any tool or foreign object into the valve
outlet or safety relief valve. You may damage the
valve and cause a leak. Leaking propane may result
in an explosion, fire, severe personal injury, or death.

Do not use the grill until leak-tested.
If a leak is detected at any time, STOP!
If you cannot stop a gas leak by closing the LP cylinder valve leave area and call your fire department!

Leak Testing Valves, Hose and Regulator

Turn all grill control knobs to OFF.
Be sure the regulator is tightly connected to the LP cylinder.
Completely open LP cylinder valve by turning hand wheel counterclockwise. If you hear a rushing sound, turn gas off immediately. There is a major leak at the connection. Correct before proceeding.
Brush soapy solution onto areas circled.
If “growing” bubbles appear, there is a leak. Close the LP cylinder valve immediately and retighten connections. If leaks cannot be stopped do not try to repair them. Call for replacement parts.
Always close the LP cylinder valve after performing the leak test by turning the handwheel clockwise.

The outdoor gas appliance is not intended to be installed in or on a boat.
The outdoor gas appliance is not intended to be installed in or on an RV.
Never attempt to attach this grill to the self-contained LP gas system of a camper trailer or motor home.

For Safe Use of Your appliance and to Avoid Serious Injury:

The use of alcohol, prescription, or non-prescription drugs may impair the consumer’s ability to properly assemble or safely operate the appliance.
When cooking, the appliance must be on a level, stable non-combustible surface in an area clear of combustible material. An asphalt surface (blacktop) may not be acceptable for this purpose.
Do not leave appliances unattended. Keep children and pets away from the appliance at all times.
Do not place an empty cooking vessel on the appliance while in operation. Use caution when placing anything in the cooking vessel while the appliance is in operation.
Do not move the appliance when in use. Allow the cooking vessel to cool to 115°F (45°C) before moving or storing.
This appliance is not intended for and should never be used as a heater.
This appliance will be hot during and after use. Use insulated oven mitts or gloves and long-handled barbecue utensils for protection from hot surfaces or splatter from cooking liquids.
Keep appliance area clear and free from materials that burn.
Keep appliance area clear and free from combustible materials, gasoline, and other flammable vapors and liquids.
Keep fuel supply hose away from any heated surfaces.
Use appliance only in well-ventilated space. NEVER use in enclosed space such as carport, garage, porch, covered patio, or under an overhead structure of any kind.
Use appliance at least 3 ft. from any wall or surface.
Maintain 10 ft. clearance to objects that can catch fire or sources of ignition such as pilot lights on water heaters, live electrical appliances, etc.
NEVER attempt to light the burner with any type of closed cover. A buildup of non-ignited gas inside a closed appliance is hazardous.
Never operate the appliance with an LP cylinder out of the correct position specified in assembly instructions.
Always close the LP cylinder valve and remove the coupling nut before moving the LP cylinder from the specified operation position.
Apartment Dwellers:
Check with management to learn the requirements and fire codes for using an LP gas appliance in your apartment complex. If allowed, use outside on the ground floor with a three (3) foot clearance from walls or rails. Do not use on or under balconies.

Safety Tips

Before opening the LP cylinder valve, check the coupling nut for tightness.
When this appliance is not in use, turn off the control knob and LP cylinder valve.
The smoker Chamber door should be open while attempting to light the burner.
The grease tray must be inserted into the appliance and emptied after each use.
If you notice grease or other hot material dripping from the appliance onto the valve, hose, or regulator, turn off the gas supply at once. Determine the cause, correct it, then clean and inspect the valve, hose, and regulator before continuing. Perform a leak test.
Do not store objects or materials under the appliance enclosure that would block the flow of combustion air to the underside of either the control panel or the firebox bowl.
The regulator may make a humming or whistling noise during operation. This will not affect the safety or use of the appliance.
If you have an appliance problem see the “Troubleshooting Section”.
If the regulator frosts, turn off the appliance and LP cylinder valve immediately. This indicates a problem with the cylinder and it should not be used on any product.
Return to a supplier!
Clean smoker often, preferably after each cookout. If a bristle brush is used to clean any of the cooking surfaces, ensure no loose bristles remain on cooking surfaces prior to coking. It is not recommended to clean cooking surfaces while hot.

Ignitor Lighting
• Do not lean over appliances while lighting.

Turn ON LP gas cylinder.
Open the Smoke Chamber door.
Press and turn the control knob to HIGH.
Turn the ROTARY IGNITOR knob rapidly.
Pull out the Smoker Drawer to verify that the burner is lit.
If ignition does not occur in 5 seconds, turn the burner control knob OFF, wait 5 minutes, and repeat the lighting procedure.

If ignition still does not occur, follow match lighting instructions.

Turn control knob and LP cylinder OFF when not in use.

If ignition does NOT occur in 5 seconds, turn the control knob OFF, wait 5 minutes and repeat the lighting procedure. If the burner does not ignite with the valve open, gas will continue to flow out of the burner and could accidentally ignite with the risk of injury.
Match-Lighting
Do not lean over appliances while lighting.

Turn ON the LP cylinder.
Open the Smoke Chamber door.
Place lit match into match lighting hole of the appliance as pictured below. Make sure a lit match is placed inside the hole and near the burner.
Push in and turn the control knob to HIGH. Be sure burner lights and stays lit.
Pull out the Smoker Drawer to verify that the burner is lit

Burner Flame Check

Light burner, rotate knob from HIGH to LOW. Looking through the match light holes underneath the appliance, you should see the flame height decrease when turning the knob from HIGH to LOW. Always check flame prior to each use. If the only low flame is seen refer to “Sudden drop or low flame” in the Troubleshooting Section.

Turning Appliance Off
• Turn the control knob to OFF the position. Turn the LP cylinder off by turning the hand-wheel clockwise to a full stop.
Ignitor Check
• Turn gas off at LP cylinder. Turn ignitor knob. “Click” should be heard each time at the electrode. See “Troubleshooting” if no click or spark.
Valve Check
• Important: Make sure gas is off at the LP cylinder before checking the valve. Knob locks in position. To check the OFF valve, first push in knob and release, the knob should spring back. If the knob does not spring back, replace valve assembly before using Oil-less Fryer. Turn knob to HIGH position then turns back to position. OFF Valve should turn smoothly.
Hose Check
• Before each use, check to see if the hose is cut, worn, or kinked. Replace the damaged hose before using the appliance. Use only valve/hose/regulator specified by the manufacturer.

General Appliance Cleaning

Do not mistake brown or black accumulation of grease and smoke for paint. Interiors are not painted at the factory (and should never be painted). Apply a strong solution of detergent and water or use a grill cleaner with a scrub brush on the insides of the appliance lid and bottom. Rinse and allow to completely air dry. Do not apply a caustic grill/oven cleaner to painted surfaces.
Plastic parts: Wash with warm soapy water and wipe dry.
Do not use cortisol, abrasive cleaners, degreasers, or a concentrated grill cleaner on plastic parts. Damage to and failure of parts can result.
Painted surfaces: Wash with a mild detergent or non-abrasive cleaner and warm soapy water. Wipe dry with a soft non-abrasive cloth.
Stainless steel surfaces: To maintain the high-quality appearance, wash with mild detergent and warm soapy water and wipe dry with a soft cloth after each use. Baked-on grease deposits may require the use of an abrasive plastic cleaning pad. Use only in direction of brushed finish to avoid damage. Do not use an abrasive pad on areas with graphics.

Safety Precautions while cooking:

The exterior surfaces of your smoker can become extremely hot during use. Be sure to wear insulated oven mitts or gloves before making adjustments to the Top Damper or when opening the Smoker door.

Water Level

Watch water level. Always keep water in a water pan (unless you wish to brown your food), Food can burn quickly if water completely evaporates. When using a smoker, be very careful when adding water to the hot smoker.

Cleaning the Burner Assembly
Follow these instructions to clean and/or replace parts of the burner
assembly or if you have trouble igniting an appliance.

Turn gas off at control knob and LP cylinder and disengage regulator from cylinder.
Remove the smoker drawer and water pan, shown A.
Remove the Electrode Wire from the Rotary Ignitor, shown B.
Remove 4 Control Panel screws and nuts. Shown C
Disengage Control Panel/Control Valve from the burner.
Slide Control Panel Assembly from the unit, shown D.
The clean inner burner is recommended below, shown E.
We suggest three ways to clean the burner tube.
Use the one easiest for you.
(A) Bend a stiff wire (a lightweight coat hanger works well) into a small hook. Run hook through burner tube several times.
(B) Use a narrow bottle brush with a flexible handle (do not use a brass wire brush), run the brush through the burner tube several times.
(C) Wear eye protection: Use an air hose to force air into the burner tube and out the burner ports. Check each port to make sure air comes out
of each hole.
Check burner for damage, due to normal wear and corrosion some holes may become enlarged. If any large cracks or holes are found replace the burner.
Attach electrode to the burner.
Carefully replace control panel assembly.
VERY IMPORTANT: Burner tube must re-engage over the valve opening. See illustration, shown F.
Reverse steps for re-assembly.

Setup Instructions
Using Wood Chips or Chunks

Dried aromatic wood chips or chunks need to be saturated with water so that when placed in the water pan, a smoldering smoke will result. Wood chips or chunks can be soaked too long; however, 2 hours is adequate. As a rule of thumb, use wood
chunks for smoking for 3 or more hours and wood chips when smoking for less than 3 hours. Start with 3 wood chunks or 1½ cups of wood chips.

Spray inside door and body with nonstick vegetable oil-based spray. Place water pan onto brackets in the smoker drawer. Using a 4 quart (one gallon) container fill the water pan 2/3 full with hot tap water. Do not overfill the water pan.

Water or Juice?
Placing water alone in the water pan is adequate; however, it is not the only viable choice. Fruit juice, cola, beer, wine, drained marinades and even the water in which the wood has soaked make flavorful sources.
In addition, celery stalks, onions, carrots, apples, peppercorns, and bay leaves are just a few of the other popular flavor sources to add to the water pan.
Before each use, inspect the interior lid and body surface areas for loose particle buildup. Clean away any loose or flaking residue so it will not fall onto food while being cooked.
Before cooking, coat cooking grates with oil or with a vegetable oil-based spray. Using oven mitts, carefully place cooking grates into a smoker. Larger cuts of meat or food that cook for long periods of time should be placed on the lower cooking grate. If you are cooking foods with several pieces, such as racks of ribs or Cornish hens, be sure to allow adequate spacing for even heat circulation. Using oven mitts, carefully insert the upper cooking grate into a smoker. Smaller food items require less cooking time and should be placed on the upper cooking grate. After filling the smoker, close the door and leave undisturbed until the suggested minimum cooking time.
Meats that require more than 4 hours of cooking time to reach doneness may require additional water. The initial amount of hot water added (4 quarts) should last 4-6 hours. After 4-6 hours, check the water level and add more hot water as necessary.
Use a meat thermometer for measuring the internal heat of any food. The appearance of smoked foods resembles no other method of cooking, particularly in light-colored meats such as pork, turkey, chicken, and Cornish hens. The outside will be pinkish-red while the inside when cooked to perfection, is often pink. The juices from fully cooked poultry will run clear when pierced with a fork. Fish is done when it flakes easily when tested with a fork. Shrimp should be resilient to the touch when done. Remove foods from smokers before carving. To brown meats, cook for an additional ½ hour or more with no water in the water pan.
The performance of the smoker is dependent on ambient temperature and wind conditions. With temperatures below 60°F and winds of 5 MPH or more, the smoker can lose a significant amount of heat and it may not be possible to raise the internal temperature of meat high enough to cook it in a reasonable time.
Your smoker is designed with a drawer that is used to hold the water pan. This drawer will allow you to keep a check on the water level in the smoker without having to open the door. Opening the door during cooking will allow heat to escape and will significantly increase cooking time.
You may use your smoker without water in the water pan. However, DO NOT use the smoker without the water pan properly installed. To do so will allow grease and drippings from the food being cooked to drop through the unit and onto the floor or surface on which the unit sits.
Brush poultry and naturally lean meats with cooking oil, butter, or margarine before cooking. When cooking more than one piece of meat, the cooking
time is determined by the largest piece being cooked. The meat bastes itself during cooking. No basting or turning is necessary while cooking in the smoker. For variety, a marinade or barbeque sauce may be applied before placing it into the smoker.
Resist the temptation to open the door during cooking time. Opening the door will cause a loss of heat, which will result in longer cooking times.

SPIDER ALERT!
SPIDER AND WEBS INSIDE BURNER

If your appliance is getting hard to light or the flame is weak, check and clean the venturi and burners.
Spiders or small insects are known to create “flashback” problems by building nests and laying eggs in the appliance venturi or burner obstructing the flow of gas. The backup gas can ignite behind the control panel. This flashback can damage your appliance and cause injury. To prevent flashbacks and ensure good performance the burner and venturi tube assembly should be removed and cleaned whenever the appliance has been idle for an extended period of time.

LIMITED WARRANTY

This warranty only applies to units purchased from an authorized retailer. The manufacturer warrants to the original consumer purchaser only that this product shall be free from defects in workmanship and materials after correct assembly and under normal and reasonable home use for the periods indicated below beginning on the date of purchase*. The manufacturer reserves the right to require that defective parts be returned, postage, and or freight pre-paid by the consumer for review and examination.

SCOPE OF COVERAGE	PERIOD OF COVERAGE	TYPE OF FAILURE COVERAGE
All Parts	1 year from date of purchase*	PERFORATION, MANUFACTURING,

*Note: A dated sales receipt WILL be required for warranty service.
The original consumer-purchaser will be responsible for all shipping charges for parts replaced under the terms of this limited warranty.
This limited warranty is applicable in the United States and Canada only is only available to the original owner of the product and is not transferable.
The manufacturer requires proof of your date of purchase. Therefore, you should retain your sales slip or invoice. Registering your product is not a substitute for proof of purchase and the manufacturer is not responsible for or required to retain the proof of purchase records.
This limited warranty applies to the functionality of the product ONLY and does not cover cosmetic issues such as scratches, dents, corrosions or discoloring by heat, abrasive and chemical cleaners or any tools used in the assembly or installation of the appliance, surface rust, or the discoloration of stainless steel surfaces.
RUST is not considered a manufacturing or materials defect.
This limited warranty will not reimburse you for the cost of any inconvenience, food, personal injury, or property damage.
ITEMS MANUFACTURER WILL NOT PAY FOR:

Shipping cost, standard or expedited, for warranty and replacement parts
Service calls to your home.
Repairs when your product is used for other than normal, single-family household or residential use.
Damage, failures, or operating difficulties resulting from accident, alteration, careless handling, misuse, abuse, fire, flood, acts of God, improper installation or maintenance, installation not in accordance with electrical or plumbing codes, or use of products not approved by the manufacturer.
Any food loss due to product failures or operating difficulties.
Replacement parts or repair labor costs for units operated outside the United States or Canada.
Pickup and delivery of your product.
Repairs to parts or systems resulting from unauthorized modifications made to the product.
The removal and/or reinstallation of your product.

DISCLAIMER OF IMPLIED WARRANTIES and LIMITATION OF REMEDIES
Repair or replacement of defective parts is your exclusive remedy under the terms of this limited warranty. In the event of parts availability issues, the manufacturer reserves the right to substitute like or similar parts that are equally functional.
The manufacturer will not be responsible for any consequential or incidental damages arising from the breach of either this limited warranty or any applicable implied warranty, or for failure or damage resulting from acts of God, improper care and maintenance, grease fire, accident, alteration, replacement of parts by anyone other than Manufacturer, misuse, transportation, commercial use, abuse, hostile environments (inclement weather, acts of nature, animal tampering), improper installation or installation not in accordance with local codes or printed manufacturer instructions.
THIS LIMITED WARRANTY IS THE SOLE EXPRESS WARRANTY GIVEN BY THE MANUFACTURER. NO PRODUCT PERFORMANCE SPECIFICATION OR DESCRIPTION WHEREVER APPEARING IS WARRANTED BY THE MANUFACTURER EXCEPT TO THE EXTENT SET FORTH IN THIS LIMITED WARRANTY. ANY IMPLIED WARRANTY PROTECTION ARISING UNDER THE LAWS OF ANY STATE, INCLUDING IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR USE, IS HEREBY LIMITED IN DURATION TO THE DURATION OF THIS LIMITED WARRANTY.
Neither dealers nor the retail establishment selling this product has any authority to make any additional warranties or to promise remedies in addition to or inconsistent with those stated above. The manufacturer’s maximum liability, in any event, shall not exceed the purchase price of the product paid by the original consumer.
NOTE: Some states do not allow an exclusion or limitation of incidental or consequential damages, so some of the above limitations or exclusions may not apply to you. This limited warranty gives you specific legal rights as set forth herein. You may also have other rights which vary from state to state. In the state of California only, if refinishing or replacement of the product is not commercially practicable, the retailer selling this product or the Manufacturer will refund the purchase price paid for the product, less the amount directly attributable to use by the original consumer-purchaser prior to the discovery of the nonconformity. In addition, in the state of California only, you may take the product to the retail establishment selling this product in order to obtain performance under this limited warranty.

If you wish to obtain performance of any obligation under this limited warranty, you should
write to:
Consumer Relations
P. O. Box 1240
Columbus, GA 31902-1240

Consumer returns will not be accepted unless a valid Return Authorization is first acquired. Authorized returns are clearly marked on the outside of the package with an RA number and the package is shipped freight/postage pre-paid. Consumer returns that do not meet these standards will be refused.
WS_1 Rev04

PARTS LIST

Key	Qty	Description
A	1	SMOKER CHAMBER
B	1	DOOR, SMOKER CHAMBER
C	1	SMOKER DRAWER
D	1	BURNER HOUSING
E	1	CONTROL PANEL
F	4	LEG
G	1	BURNER
H	1	DAMPER ASSEMBLY, TOP
I	3	GRATE, COOKING
J	1	PAN, WATER
K	1	HOSE, VALVE, REGULATOR
L	3	HANDLE
M	4	HANDLE SPRING
N	1	KNOB, CONTROL
O	1	IGNITOR, ROTARY
P	1	KNOB, IGNITOR
Q	1	TEMPERATURE GAUGE
R	1	LOGO PLATE
S	2	WIRE RACK, SMOKER CHAMBER
T	1	WIRE, ELECTRODE
U	1	TOP GRATE, PORCELAIN
—	1	HARDWARE PACK
—	1	ASSEMBLY INSTRUCTIONS, ENGLISH, FRENCH, SPANISH

Hardware List

Item	Description	Qty.
1	#1/4 Flat washer	2
2	#10-24 Keps nut	4
3	1/4-20 Keps nut	6
4	#10-24×3/8″ Screw	4
5	#1/4-20 Reversible Lock Nut	1
6	#1/4-20×3/4″ Combo truss head screw	6
7	#1/4-20×1/2″ Hex head bolt	9
8	#1/4-20×1/2″ Combo truss head screw	3

NOTE: Some grill parts shown in the assembly steps may differ slightly in appearance from those on your particular model. However, the method of assembly remains the same.

PARTS DIAGRAM

ASSEMBLY STEPS

1

Carefully remove the door from the unit by swinging it opening it and lifting it up and away from the smoker chamber. Lay
the door aside.
Place the Smoker Chamber on its back with the door opening facing up.
CAUTION: This unit is heavy!

CAUTION: THIS UNIT IS HEAVY!
DO NOT ASSEMBLE WITHOUT A HELPER!

2

Install Burner Housing to Smoker Chamber using three 1/4-20×1/2” bolts. Install all bolts hand tight, then tighten with a #2 Phillips screwdriver. (not provided)
NOTE: The venturi tube MUST face up (towards the door opening).

NOTE: The venturi tube MUST be installed as shown

3

Place Control Panel Assembly onto Smoker Chamber by placing tabs under the front edge of the Smoker Chamber. The Control valve must engage the burner venturi tube as shown A.
From the inside of the Smoker Chamber, Install 2 #10-24×3/8” screws through the smoker chamber and through the Control panel Tabs as shown. Thread 1 #10-24 Keps Nut onto each screw and tighten As shown B. Install 2 #10-24×3/8” screws through the control panel tabs and into the burner assembly housing. Thread 1 #10-24 Keps Nut onto each screw and tighten securely. Shown B

4

Be sure the electrode wire exits the hole UNDER the venturi tube hole. DO NOT route the wire through the same hole as the burner venturi tube.
Install Ignitor Wire by pushing the round connector onto the Ignitor as shown.

5

Install legs by placing 2 – 1/4-20×1/2” Hex Head Bolt through the smoker body and through each leg as shown. Thread the bolts into the 1/4-20 nut welded to the underside of each leg. Tighten bolts by hand. Using an adjustable wrench (not provided), tighten each bolt securely.
Install the leg with the rating label on the backside of the smoker’s body, as shown.

6

With the assistance of a helper – stand the unit upright on its legs.

CAUTION: THIS UNIT IS HEAVY!

7

Insert 1/4-20×1/2” Hex Head Bolt and flat washer through the top smoker body, in the center of the damper holes as shown.(A)
Insert the damper as shown. (B)
Place the 1/4” flat washer onto the bolt and thread the 1/4-20 nut onto the bolt. Tighten the nut sufficiently to allow the damper to move. (B)
The damper is shown properly installed in figure C.
Install the side handles with 1/4-20X3/4” screws and 1/4-20 Keps nuts as shown (D)
NOTE: If the handle springs are not installed on the handle rod, Install them per inset E.

8

Install Drawer Handle using 2 – 1/4-20x 3/4” screws and 2 1/4-20 Keps nuts. Tighten securely.
Place the Water Pan onto the drawer rack as shown.
Slide the Drawer, with Water Pan, into the Smoker’s body.

9

Insert the 3 Cooking Grates into the smoker’s body.
Slip the edge of the Top Grate under the Damper Handle (A), Then carefully align the grate so that the wire ends fit into the holes in the Smoker Body top.(B)
Carefully place the door back onto the Smoker Body hinges.

10

Remove wingnut from Thermometer, insert Thermometer through the hole in the door from the front, reinstall the wingnut to the Thermometer.

EMERGENCIES: If a gas leak cannot be stopped, or a fire occurs due to gas leakage, call the fire department.

Emergencies	Possible Cause	Prevention/Solution
Gas leaking from cracked/cut/burned hose.	•Damaged hose.	•Turn off gas at LP cylinder or at source on natural gas systems. Discontinue use of the product and replace valve/hose/regulator. Once valve/hose/regulator replaced conduct complete leak check per manual.
Gas leaking from LP cylinder.	•Mechanical failure due to rusting or mishandling.	•Replace LP cylinder.
Gas leaking from LP cylinder valve.	• Failure of cylinder valve from mishandling or mechanical failure.	•Turn off the LP cylinder valve. Return LP cylinder to gas supplier.
Gas leaking between LP cylinder and regulator connection.	•Improper installation, connection not tight, and/or failure of the rubber seal.	•Turn off the LP cylinder valve. Remove regulator from the cylinder and visually inspect rubber seal for damage. See LP Cylinder Leak Test and Connecting Regulator to the LP Cylinder.
Fire coming through the control panel.	•Fire in burner tube section of burner due to blockage.	•Turn off control knobs and LP cylinder valve. Leave the lid open to allow flames to die down. After the fire is out and the grill is cold, remove the burner and inspect for spider nests or rust. See Natural Hazard and Cleaning the Burner Assembly pages.
Grease fire or continuous excessive flames above the cooking surface.	•Too much grease buildup in the burner area.	•Turn off control knobs and LP cylinder valve. Leave the lid open to allow flames to die down. After cooling, clean food particles and excess grease from inside the firebox area, grease cup, and other surfaces.

Troubleshooting

Problem	Possible Cause	Prevention/Solution
Burner(s) will not light using ignitor. Continued on next page.	GAS ISSUES: •Trying to light the wrong burner. •Burner not engaged with control valve. •Obstruction in the burner. •No gas flow. •Vapor lock at coupling nut to LP cylinder. •Coupling nut and LP cylinder valve not fully connected. ELECTRICAL ISSUES: •Electrode cracked or broken; “sparks at the crack.” •Electrode tip not in the proper position. •Wire and/or electrode covered with cooking residue. •Wires are loose or disconnected. •Wires are shorting (sparking) between ignitor and electrode.	•See instructions on the control panel and in the Use and Care section. •Make sure valves are positioned inside burner tubes. •Ensure burner tubes are not obstructed with spider webs or other matter. See cleaning section of Use and Care. •Make sure the LP cylinder is not empty. If the LP cylinder is not empty, refer to “Sudden drop in the gas flow” in the Troubleshooting section. •Turn off knobs and disconnect coupling nut from LP cylinder. Reconnect and retry. •Turn the coupling nut approximately one-half to three-quarters additional turn until solid stop. Tighten by hand only – do not use tools. •Replace electrode(s). Main Burners: •Tip of electrode should be pointing toward as port opening on burner. The distance should be 1/8” to 1/4”. Adjust if necessary. Sideburner (if featured): •Tip of electrode should be pointing toward gas port opening on burner. the distance should be 1/8” to 3/16”. Adjust if necessary. •Clean wire and/or electrode with rubbing alcohol and clean swab. •Reconnect wires or replace electrode/wire assembly. •Replace ignitor wire/electrode assembly.
The burner will not light using the ignitor.	• Rotary knob rotates without clicking. • Sparking between ignitor and electrode.	• Replace knob. • Inspect wire insulation and proper connection. Replace wire if insulation is roken.
The burner will not match the light.	• See “GAS ISSUES:” on the previous page. • Match will not reach. • Improper method of match-lighting.	• Use long-stem match (fireplace match). • See the “Match-Lighting” section of Use and Care.
A sudden drop in gas flow or low flame.	• Out of gas. • Excess flow valve on regulator tripped. • Vapor lock at coupling nut/LP cylinder connection.	• Check for gas in the LP cylinder. • Turn off the control knob, wait 30 seconds, and light appliance. If flames are still low, turn off the knob and LP cylinder valve. Disconnect regulator. Reconnect regulator and leak test. Turn on the LP cylinder valve, wait 30 seconds, and then light the appliance. • Turn off knob and LP cylinder valve. Disconnect coupling nut from the cylinder. Reconnect and retry.
Flames blow out.	• Low on LP gas. • Excess flow valve tripped.	• Refill LP cylinder. • Refer to “Sudden drop in the gas flow” above.
Flare-up.	• Grease buildup. • Excessive fat in the meat. • Excessive cooking temperature.	• Clean burner and inside of fryer body. • Trim fat from meat before grilling. • Adjust (lower) temperature accordingly.
Persistent grease fire.	• Grease trapped by food buildup around burner system.	• Turn knob to OFF. Turn gas off at LP cylinder. Let the fire burn out. After the fryer cools, remove and clean all parts.
Flashback… (fire in burner ).	• Burner is blocked.	• Turn knob to OFF. Clean burner. See burner cleaning section of Use and Care.
Cooking slower than expected	• Vapor Lock • Valve not properly aligned to the burner • High wind conditions	• Turn off control knob and disconnect coupling nut from LP cylinder. Reconnect and retry. • Loosen control panel and valve. Be sure the valve is centered top to bottom and left to right in the burner. Tighten all components once proper alignment is achieved. • Relocate the appliance to a less windy area. Use Top Cover during cooking.

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