SPORTSMAN 5005166 Wood Pellet Grill and Smoker Owner’s Manual

SPORTSMAN 5005166 Wood Pellet Grill and Smoker

IMPORTANT, READ CAREFULLY, RETAIN FOR FUTURE REFERENCE. MANUAL MUST BE READ BEFORE OPERATING!

WARNING: Please read the entire manual before installation and use of this electric, pellet fuel-burning appliance. Failure to follow these instructions could result in property damage, bodily injury or even death. Contact local building or fire officials about restrictions and installation inspection requirements in your area.

SAFETY INFORMATION

MAJOR CAUSES OF APPLIANCE FIRES ARE A RESULT OF POOR MAINTENANCE AND A FAILURE TO MAINTAIN REQUIRED CLEARANCE TO COMBUSTIBLE MATERIALS. IT IS OF UTMOST IMPORTANCE THAT THIS PRODUCT BE USED ONLY IN ACCORDANCE TO THE FOLLOWING INSTRUCTIONS.

Please read and understand this entire manual before attempting to assemble, operate or install the product. This will ensure you receive the most enjoyable and trouble-free operation of your new wood pellet grill. We also advise you retain this manual for future reference.

DANGERS AND WARNINGS

You must contact your local home association, building or fire officials, or authority having jurisdiction, to obtain the necessary permits, mission or information on any installation restrictions, such as any grill being installed on a combustible surface, inspection requirements or even ability to use, in your area.

1.  A minimum clearance of 305mm (12 inches) from combustible constructions to the sides of the grill, and 305mm (12 inches) from the back of the grill to combustible constructions must be maintained. Do not install appliance on combustible floors, or floors protected with combustible surfaces unless proper permits and permissions are obtained by authorities having jurisdiction. Do not use this appliance indoors or in an enclosed, unventilated area. This wood pellet appliance must not be placed under overhead combustible ceiling or overhang. Keep your grill in an area clear and free from combustible materials, gasoline and other flammable vapors and liquids.
   Should a grease fire occur, turn the grill OFF and leave the lid closed until the fire is out. Do not unplug the power cord. Do not throw water on the unit. Do not try to smother the fire. Use of an all-class (class ABC) approved fire extinguisher is valuable to keep on site. If an uncontrolled fire does occur, call the Fire Department.

2. Keep electrical supply cords and the fuel away from heated surfaces. Do not ue your grill in the rain or around any water source.

3. After a period of storage, or non-use, check the burn pot for obstructions, the hopper for foreign objects, and any air blockage around the fan intake or rear barrel exhaust holes. Clean before use. Regular care and maintenance is required to prolong the lifespan of your unit. If the grill is stored outside during the rainy season or seasons of high humidity, care should be taken to insure that water does not get into the hopper. When wet or exposed to high humidity, wood pellets will expand greatly, decompose, and may jam the feed system. Always disconnect the power, before performing any service or maintenance.
   Do not transport your grill while in use or while the grill is hot. Ensure the fire is completely out and that the grill is completely cool to the touch before moving.

4. It is recommended to use heat-resistant barbecue mitts or gloves when operating the grill. Do not use accessories not specified for use with this appliance. Do not put a barbecue cover or anything flammable in the storage space area under the barbecue.

5. To prevent fingers, clothing or other objects from coming in contact with the auger feed system, the appliance is equipped with a metal safety screen, mounted to the interior of the hopper. This screen must not be removed unless directed by Customer Care or an authorized dealer.
   This appliance is not recommended for children, persons with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they are under direct supervision or instruction by a person responsible for their safety.

6. Parts of the barbecue may be very hot, and serious injury may occur. Keep young children and pets away while in use.

7. Do not enlarge igniter holes or burn pots. Failure to follow this warning could lead to a fire hazard and bodily harm and will void your warranty.

8. Product may have sharp edges or points. Contact may result in injury. Handle with care.

DISPOSAL OF ASHES

Ashes should be placed in a metal container with a tight-fitting lid. The closed container of ashes should be placed on a noncombustible floor or on the ground, well away from all combustible materials, pending final disposal. When ashes are disposed by burial in soil, or otherwise locally dispersed, they should be retained in a closed container until all cinders have thoroughly cooled.

WOOD PELLET FUEL

This pellet cooking appliance is designed and approved for pelletized, all natural, wood fuel only. Any other type of fuel burned in this appliance will void the warranty and safety listing. You must only use all natural wood pellets, designed for burning in pellet barbecue grills. Do not use fuel with additives. Wood pellets are highly susceptible to moisture and should always be stored in an airtight container. If you are storing your grill, without use, for an extended period, we recommend clearing all pellets from your grill’s hopper and auger, to prevent jams. The pellet fuel mean heating value in 8000-8770 BTU/LB, ash content < 1%.
Do not use spirit, petrol, gasoline, lighter-fluid or kerosene for lighting or refreshing a fire in your grill. Keep all such liquids well away from the appliance when in use.

At this time, there is no industry standard for barbecue wood pellets, although most pellet mills use the same standards to make wood pellets for domestic use. Further information, can be found at www.pelletheat.org or the Pellet Fuel Institute.

Contact your local dealer on the quality of pellets in your area, and for information on brand quality. As there is no control over the quality of pellets used, we assume no responsibility to damage caused by poor quality of fuel.

CREOSOTE

Creosote, or soot, is a tar-like substance. When burning, it produces black smoke with a residue which is  also black in color. Soot or creosote is formed when the appliance is operated incorrectly, such as: blockage of the combustion fan, failure to clean and maintain the burn area, or poor air-to- fuel combustion.

It is dangerous to operate this appliance should the flame become dark, sooty, or if the burn pot is overfilled with pellets. When ignited, this creosote makes an extremely hot and uncontrolled fire, similar to a grease fire. Should this happen, turn the unit OFF, let it cool completely, then inspect for maintenance and cleaning. It commonly accumulates along exhaust areas.

If creosote has formed within the unit; allow the unit to warm up at a low temperature, turn off the appliance, then wipe away any formation with a hand towel. Similar to tar, it is much easier to clean when warm, as it becomes liquid.

CARBON MONOXIDE (“the silent killer”)

Carbon monoxide is a colorless, odorless, tasteless gas produced by burning gas, wood, propane, charcoal or other fuel. Carbon monoxide reduces the blood’s ability to carry oxygen. Low blood oxygen levels can result in headaches, dizziness, weakness, nausea, vomiting, sleepiness, confusion, loss of consciousness or death. Follow these guidelines to prevent this colorless, odorless gas from poisoning you, your family, or others:

• See a doctor if you or others develop cold or flu-like symptoms while cooking or in the vicinity of the appliance. Carbon monoxide poisoning, which can easily be mistaken for a cold or flu, is often detected too late.
• Alcohol consumption and drug use increase the effects of carbon monoxide poisoning.

Carbon monoxide is especially toxic to mother and child during pregnancy, infants, the elderly, smokers, and people with blood or circulatory system problems, such as anemia, or heart disease.

SAFETY LISTING

In accordance with the procedures and specifications listed in the UL SUB. 2728-2009 “pellet fuel cooking appliances” and ULC/ORD C2728-13 “for electrical features of fuel burning equipment.” Pit Boss® Grills pellet cooking appliances have been independently tested and listed by INTERTEK (an accredited testing laboratory) to ETL, UL, ULC and CSA standards.

OPERATING INSTRUCTIONS

With today’s lifestyle of striving to eat healthy and nutritious foods, one factor to consider is the importance of reducing fat intake. One of the best ways to cut down on fat in your diet is to use a low fat method of cooking, such as grilling. As a pellet grill uses natural wood pellets, the savory wood flavor is cooked into the meats, reducing the need for high sugar content sauces. Throughout this manual, you will notice the emphasis on grilling food slowly at LOW or MEDIUM temperature settings.

GRILL ENVIRONMENT

1. WHERE TO SET-UP THE GRILL
   With all outdoor appliances, outside weather conditions play a big part in the performance of your grill and the cooking time needed to perfect your meals. All Pit Boss® units should keep a minimum clearance of 305mm (12 inches) from combustible constructions and this clearance must be maintained while the grill is operational. This appliance must not be placed under an overhead combustible ceiling or overhang. Keep your grill in an area clear from combustible materials, gasoline and other flammable vapors and liquids.

2. COLD WEATHER COOKING
   As it becomes cooler outside, that does not mean that grilling season is over! The crisp cool air and heavenly aroma of smoked foods will help cure your winter blues. Follow these suggestions on how to enjoy your grill throughout the cooler months:
   • If smoking at low temperatures fails, increase the temperature slightly to achieve the same results.
   • Organize – Get everything you require ready in the kitchen before you head outdoors. During the winter, move your grill to an area that is out of the wind and direct cold. Check local bylaws regarding the proximity of your grill in relation to your home and/or other structures. Put everything you need on a tray, bundle up tight, and get it done!
   • To help keep track of the outside temperature, place an outdoor thermometer close to your cooking area. Keep a log or history of what you cooked, the outdoor temperature, and the cooking time. This will help later down the road to help you determine what to cook and how long it will take.
   • In very cold weather, increase your preheating time by at least 20 minutes.
   • Avoid lifting the lid any more than necessary. Cold gusts of wind can completely cool your grill temperature. Be flexible with your serving time; add extra cooking time each time you open the lid.
   • Have a heated platter or a dish cover ready to keep your food warm while making the trip back inside.
   • Ideal foods for winter cooking are those that require little attention, such as roasts, whole chickens, ribs, and turkey. Make your meal preparation even easier by adding simple items such as vegetables and potatoes.

3. HOT WEATHER COOKING
   As it becomes warmer outdoors, the cooking time will decrease. Proper dress is important when it gets really hot: shorts, shirt, shoes, hat, apron and a generous slab of suntan lotion is recommended. Follow these few suggestions on how to enjoy your grill throughout the hot months:
   • Adjust your cooking temperatures downward. This helps to avoid unwanted flare-ups.
   • Use a meat thermometer to determine the internal temperature of your foods. This helps in preventing your meat from over cooking and drying out.
   • Even in hot weather it is still better to cook with the lid of your grill down.
   • You can keep foods hot by wrapping them in foil, and placing them in an insulated cooler. Stuff crumpled up newspaper around the foil and this will keep food hot for 3 to 4 hours.

GRILL TEMPERATURE RANGES

Temperature readouts on the control board may not exactly match the thermometer. All temperatures listed below are approximate and are affected by the following factors: outside ambient temperature, the amount and direction of wind, the quality of pellet fuel being used, the lid being opened, and the quantity of food being cooked.

• HIGH TEMPERATURE (205-260°C / 401-500°F)
  This range is best used to sear and grill at a high heat. Use in tandem with the flame broiler (slide plate) for indirect or direct flame cooking. With the flame broiler open, direct flame is used to create those “blue” steaks, as well as flame kissed vegetables, garlic toast or s’mores! When the flame broiler is closed, the air circulates around the barrel, resulting in convection heat. High temperature is also used to preheat your grill, burn-off the cooking grids, and to achieve high heat in extreme cold weather conditions.

• MEDIUM TEMPERATURE (135-180°C / 275-356°F)
  This range is best for baking, roasting, and finishing off that slow smoked creation. Cooking at these temperatures will greatly reduce the chances of a grease flare-up. Ensure that the flame broiler slider in the closed position, covering the slotted openings. Great range for cooking anything wrapped in bacon, or where you want versatility with control.

• LOW TEMPERATURE (82-125°C / 180-257°F)
  This range is used to slow roast, increase smoky flavor, and to keep foods warm. Infuse more smoke flavor and keep your meats juicy by cooking longer at a lower temperature (also known as low and slow). Recommended for the big turkey at Thanksgiving, juicy ham at Easter, or the huge holiday feast.
  Smoking is a variation on true barbecuing and is truly the main advantage of grilling on a wood pellet grill. Hot smoking, another name for low and slow cooking, is generally done between 82-125oC / 180-257oF. Hot smoking works best when longer cooking time is required, such as large cuts of meats, fish, or poultry.
  TIP: To intensify that savory flavor, switch to SMOKE (low) temperature range immediately after putting your food on the grill. This allows the smoke to penetrate the meats.
  The key is to experiment with the length of time you allow for smoking, before the meal is finished cooking. Some outdoor chefs prefer to smoke at the end of a cook, allowing the food to keep warm until ready to serve. Practice makes perfect!

UNDERSTANDING THE PROBES

• GRILL PROBE
  Located inside the main barrel, on the left wall, is the Grill Probe. It is a small, vertical piece of stainless steel. The Grill Probe measures the internal temperature of the unit. When the temperature is adjusted on the Control Board, the Grill Probe will read the actual temperature inside the unit and adjust to the desired temperature. IMPORTANT: The temperature of your unit is highly affected by ambient outdoor weather, quality of pellets used, flavor of pellets, and the quantity of food being cooked.

• MEAT PROBE
  The meat probe measures the internal temperature of your meat in the grill, similar to your indoor oven. Plug-in the meat probe adapter to the meat probe connection port on the Control Board and insert the stainless steel meat probe into the thickest portion of your meat and the temperature will be displayed on the control board. To ensure the meat probe is connected properly to the connection port, feel and hear it snap into place.

NOTE: When placing the meat probe into your meat, ensure the meat probe and meat probe wires avoid direct contact with flame or excess heat. This can result in damage to your meat probe. Run the excess wire out the rear exhaust holes of the main grill or the top of the main grill (near the grill lid hinge). When not in use, disconnect from the meat probe connection port and place aside to keep protected and clean.

UNDERSTANDING THE CONTROL BOARD

connected to a power source. Press the button again to turn the unit off.
| The Temperature Control Dial allows you to set your desired smoking temperature. Once connected to a power source and the Power Button is pressed, turn the dial and select from any of the ten preset temperatures, between 82-260°C / 180-500°F. When the dial is turned to a temperature preset, the Digital LCD Screen with light up, displaying that it is ready to operate. When the dial is turned to off, the Digital LCD Screen will remain off.

**“P” SET

**

| The “P” Set Button is used to select one of the eight fine tunings when the Temperature Control Dial is set to the Smoke Setting . Press the button to change the “P” setting to accommodate to your cooking style and cooking environment, as preferred. With a short push of the button, the setting increases from P0 to P7, then repeats. Adjustments are only possible in the Smoke Setting. Factory default setting is “P4”. If the “P” setting is adjusted, your preference will be locked-in (saved) until further adjustment is made.

The “P” Set Button is also used as a Temperature Switch Control to change the temperature readout on the LCD Screen. Press and hold the button for two seconds to switch to Celsius (ºC) or to Fahrenheit (ºF), as preferred. Default is set to Fahrenheit.

| The LCD Screen is used as the information center for your unit. The LCD screen will display your Desired Cook Temperature, Actual Cook Temperature, and Meat Probe Temperatures (if connected). If only one Meat Probe is connected, only one reading will be displayed.
| Press and hold the Prime Button to activate an extra feed of pellets to the burn pot. This can be used to add more fuel to the fire before opening the barrel lid, resulting in a quick heat recovery time. It can also be used while smoking, to increase the intensity of clean smoke flavor. Requested from competition cookers.

SMOKE

| The Smoke Setting on the Temperature Control Dial operates unit at  the lowest temperature, without the fire going out.
| The plug-in connection port(s) on the front of the Control Board are for a Meat Probe(s). When a meat probe is connected, the temperature is displayed on the LCD Screen. When not in use, disconnect the meat probe from the connection port. Compatible with Pit Boss® branded meat probes only. Additional meat probe(s) sold separately.

UNDERSTANDING THE “P” SETTING

When the recessed “P” SET button is pushed, the “P” setting displayed on the LCD screen will change to the next value (upward). Once P7 is reached, it will restart at P0. There are eight “P” settings, ranging from P0 to P7. The recessed “P” SET button can be pushed using a thin-tipped object.

IMPORTANT: Do not push the “P” SET button too hard, as this may cause damage. Only a light push is needed.

• USING THE “P” SETTING IN SMOKE MODE
  Anytime the temperature dial is set to SMOKE, such as the start-up cycle, the auger will run on more of a manual mode of cooking versus using one of the preset dial temperatures. First, the auger will continuously turn and feed pellets for four minutes. After four minutes, the auger begins to run a feed cycle based on the “P’ setting selected on the Digital Control Board. The default setting is P4.| AUGER CYCLE (seconds)
  ---|---
  “P” SET| ON| OFF
  P0| 18| 55
  P1| 18| 70
  P2| 18| 85
  P3| 18| 100
  *P4| 18| 115
  P5| 18| 130
  P6| 18| 140
  P7| 18| 150

*default setting

HOPPER PRIMING PROCEDURE

These instructions should be followed the first time the grill is ignited, and each time the grill runs out of pellets in the hopper. The auger must be primed to allow pellets to travel through the length of the auger, and fill the burn pot. If not primed, the igniter will timeout before the pellets are ignited, and no fire will start. Follow these steps to prime the hopper:

1. Open the hopper lid. Make sure there are no foreign objects in the hopper or blocking the auger feed system at the bottom.

2. Remove all cooking components from the interior of the grill. Locate the burn pot in the bottom of the main barrel.

3. Plug the power cord into a power source. Press the Power Button to turn the unit on, and turn the Temperature Control Dial to the SMOKE position. Check the following items:
   • That you can hear the auger turning. Place your hand above the burn pot and feel for air movement. Do not place your hand or fingers inside the burn pot. This can cause injury.
   • After approximately a minute, you should smell the igniter burning and begin to feel the air getting warmer in the burn pot. The igniter tip does not glow red, but gets extremely hot and will burn. Do not touch the igniter.

4. Once verified that all electric components are working correctly, press the Power Button to turn the unit off.

5. Fill the hopper with all natural barbecue wood pellets.

6. Press the Power Button to turn the unit on. Keep the Temperature Control Dial in the SMOKE position. Press and hold the Prime Button until you see pellets on the inside of the grill from the auger tube. Once pellets begin to drop into the burn pot, release the Prime Button.

7. Press the Power Button to turn the unit off.

8. Re-install the cooking components into the main barrel. The grill is now ready to use. (See Assembly Instructions to ensure proper installation of cooking components.)

FIRST USE – GRILL BURN-OFF

Once your hopper has been primed and before cooking on your grill for the first time, it is important to complete a grill burn-off. Start the grill and operate at any temperature over 176°C / 350°F (with the lid down) for 30 to 40 minutes to burn-off the grill and rid it of any foreign matter.

AUTOMATIC START-UP PROCEDURE

1. Plug the power cord into a grounded power source. Open the main barrel lid. Check the burn pot to ensure there is no obstruction for proper ignition. Open the hopper lid. Ensure there are no foreign objects in the hopper or auger feed system. Fill the hopper with dry, all natural barbecue hardwood pellets.
2. Ensure the Temperature Control Dial is in the SMOKE position. Press the Power Button to turn the  unit on. This will activate the start-up cycle. The auger feed system will begin to turn, the igniter will begin to glow and the fan will supply air to the burn pot. The grill will begin to produce smoke while the start-up cycle is taking place. The barrel lid must remain open during the start-up cycle. To confirm the start-up cycle has begun properly, listen for a torchy roar, and notice some heat being produced.
3. Once the heavy, white smoke has dissipated, the start-up cycle is complete and you are ready to enjoy your grill at your desired temperature!

IGNITER FAILURE PROCEDURE

If for any reason your electric igniter fails or your grill’s flame dies out during a cook, check the following steps, or start your grill using the manual method.

1. Press the Power Button to turn the unit OFF, and turn the Temperature Control Dial to the OFF position. Open the barrel lid. Remove the cooking components from inside. Remove all un burnt pellets and ash from the burn pot. Avoid touching the igniter to avoid injury, as it may be extremely hot.

2. Once all cooking components are removed and cleaned, press the Power Button to turn the unit ON. Check the following:
   • Visually confirm that the igniter is working by placing your hand above the burn pot and feeling for heat.
   • Visually confirm that the igniter is protruding approximately 13mm / 0.5 inches in the burn pot.
   • Visually confirm that the auger is dropping pellets into the burn pot.
   • Confirm that the combustion fan is working by listening for a torchy roar.

3. If any of the above points are not working, follow Troubleshooting instructions.

MANUAL START-UP PROCEDURE

1. Ensure the Temperature Control Dial is in the SMOKE position. Plug the power cord into a grounded power source.

2. Check burn pot to ensure there is no obstruction for proper ignition. Open the hopper lid. Ensure there are no foreign objects in the hopper or auger feed system. Fill hopper with dry, all natural hardwood barbecue pellets.

3. Open the barrel lid. Remove the cooking components to expose the burn pot. Place a generous handful of pellets into the burn pot. Squirt a gelled fire starter, or other appropriate pellet starter, over the top of the pellets. A small amount of solid fuel fire starter, such as one composed of sawdust and wax, or wood shavings, is also appropriate. Add another small amount of pellets in the burn pot.
   NOTE: Do not use spirit, petrol, gasoline, lighter-fluid or kerosene for lighting or refreshing a fire in your grill.

4. Light the contents of the burn pot using a long match or long-nosed lighter. Allow the starter to burn for 3 to 5 minutes. Do not attempt to add more starter into the burn pot. This can cause injury.

5. Quickly and carefully replace the cooking components to the inside of the main barrel. Continue start-up at step two of Automatic Start-Up Procedure.

SHUTTING OFF YOUR GRILL

1. When finished cooking, with the main barrel lid remaining closed, press the Power Button to turn the unit off and turn the Temperature Control Dial to OFF. The grill will begin its automatic cool-down cycle. The auger system will stop feeding fuel, the flame will burn out, and the fan will continue to run until the cool-down cycle is complete.

Any Pit Boss® unit will give you many years of flavorful service with minimum cleaning. An important step is allowing the grill and cooking grids to self- clean by running the grill at a high temperature for 5 to 10 minutes after each  use. Follow these cleaning and maintenance tips to service your grill:

1. HOPPER ASSEMBLY
   • The hopper includes a clean-out feature to allow for ease of cleaning and change out of pellet fuel flavors. To empty, locate the plate and the cover of the drop chute on the back side of the hopper. Place a clean, empty pail under the drop chute cover, then remove the cover piece. Unscrew the plate, slide outwards, and pellets will empty.
   NOTE: Use a long handled brush or shop-vac to remove excess pellets, sawdust, and debris for a complete clean-out through the hopper screen.

• Check and clean off any debris from the fan air intake vent, found on the bottom of the hopper. Once the hopper access panel is removed (see Electric Wire Diagram for diagram), carefully wipe off any grease build up directly on the fan blades. This ensures airflow is sufficient to the feed system.

2. PROBES
   • Kinks or folds in the probe wires may cause damage to the part. Wires should be rolled up in a large, loose coil.
   • Although the probes are stainless steel, do not place in the dishwasher or submerge in water. Water damage to the internal wires will cause the probe to short-out, causing false readings. If a probe is damaged, it should be replaced.

3. INSIDE SURFACES
   • It is recommended to clean your burn pot after every few uses. This will ensure proper ignition and  avoid any hard build-up of debris or ash in the burn pot.
   • Use a long-handled grill cleaning brush, remove any food or build-up from the cooking grids. Best practice is to do this while they are still warm from a previous cook. Grease fires are caused by too much fallen debris on the cooking components of the grill. Clean the inside of your grill on a consistent basis. In the event you experience a grease fire, keep the grill lid closed to choke out the fire. If the fire does not go out quickly, carefully remove the food, turn the grill off, and shut the lid until the fire is completely out. Lightly sprinkle baking soda, if available.
   • Check your grease bucket or tray often, and clean out as necessary. Keep in mind the type of cooking you do.
   IMPORTANT: Due to high heat, do not cover the flame broiler or probes with aluminum foil.

4. OUTSIDE SURFACES
   • Wipe your grill down after each use. Use warm soapy water to cut the grease. Do not use oven cleaner, abrasive cleansers or abrasive cleaning pads on the outside grill surfaces. All painted surfaces are not covered under warranty, but rather are part of general maintenance and upkeep. For paint scratches, wearing, or flaking of the finish, all painted surfaces can be touched up using high heat BBQ paint.
   • Use a grill cover to protect your grill for complete protection! A cover is your best protection against  weather and outside pollutants. When not in use or for long term storage, keep the unit under a cover in a garage or shed.

CLEANING FREQUENCY TIME TABLE (NORMAL USE)

Excess Debris
Burn pot| Every 2-3 Grill Sessions| Scoop Out, Shop-Vac Excess Debris
Cooking Grids| After Each Grill Session| Burn Off Excess, Brass Wire Brush
Flame Broiler| Every 5-6 Grill Sessions| Scrape Main Plate with Slider, Do Not Wash Clean
Front Shelf| After Each Grill Session| Scrub Pad & Soapy Water
Grease Bucket / Tray| After Each Grill Session| Scrub Pad & Soapy Water
Auger Feed System| When Pellet Bag is Empty| Allow Auger to Push Out Sawdust, Leaving Hopper Empty
Hopper Electric Components| Once A Year| Dust Out Interior, Wipe Fan Blades with Soapy Water
Air Intake Vent| Every 5-6 Grill Sessions| Dust, Scrub Pad & Soapy Water
Meat Probe| After Each Grill Session| Scrub Pad & Soapy Water
Grill Probe| Every 2-3 Grill Sessions| Scrub Pad & Soapy Water

**USING WOOD PELLET FUEL

**

These clean-burning barbecue wood pellets generate about 8200 BTU’s per pound with very little ash, a low moisture content (5-7%), and are carbon neutral. Barbecue wood pellets are produced by pure raw material (sawdust) being pulverized with a hammer-mill, and the material is pushed through a die with pressure. As the pellet is forced through the die, it is cut, cooled, screened, vacuumed, and then bagged for consumer use. Check with your local dealer for flavors available in your area.

HICKORY BLEND

Rich, smoky bacon-like flavor. Considered the “Kings of the Woods”.

MESQUITE BLEND

Strong, tangy, spicy flavor. Think Tex-Mex cuisine.

APPLE BLEND

Smoky, mild sweetness flavor. Highly recommended for baking.

MAPLE BLEND

Sweet and savory flavor.

ALDER BLEND

Sweet and earthy flavor. Alder, Maple and Pine Blend.

FRUITWOOD BLEND

Cherry, Apple and Maple Blend.

CHERRY BLEND

Slightly sweet, but also tart. Gives a rosy tint to light meals.

WHISKEY BARREL BLEND

Strong, sweet smoke with aromatic tang. Perfect for red meats.

COMPETITION BLEND

Perfect blend of sweet, savory, and tart. Used by many professional grillers.

PECAN BLEND

Bold, buttery and smooth flavor.

OAK BLEND

Rich and smokey flavor.

CLASSIC BLEND

Pecan , Hickory and Mesquite Blend.

NOTE: Always store wood pellets in a dry area. Avoid any contact or exposure to moisture will result  in lower heat output or cause the pellets to swell and break apart. Use a moisture proof, resealable tub or bucket for proper storage.

COOKING GUIDELINES

Smoking and grilling styles of cooking can give you different results based on time and temperature. For best results, keep a record of what you cooked, at what temperature, how long you cooked for, and the results. Adjust to your taste for the next time. Practice makes perfect. The culinary art of hot smoking refers to longer cooking times, but results in more natural wood flavor (and a sought-after smoke ring) on your meats. Higher cooking temperatures result in a shorter cooking time, locking in less smoke flavor.

TIP: For best results, allow time for meats to rest after cooking. This allows the natural juices to migrate back into the meat fiber, giving a much juicer, flavorful cut. Resting times can be as little as 3 minutes and up to 60 minutes, depending on the size of the protein.

STYLE OF COOKING| HOT SMOKING (Very Low)| ROAST (Low)| BAKING (Medium)| GRILL/BAKE (Medium/High)| SEAR (High)
---|---|---|---|---|---
Temp Range| 93-135°C / 199-275°F| 135-162°C / 275-323°F| 162-190°C / 323-374°F| 190-232°C / 374-449°F| 232-260°C / 449-500°F
POULTRY| Size| Rare – 54°C / 130°F| Medium – 60°C / 140°F| Well Done – 77°C / 170°F
---|---|---|---|---
Turkey (whole)| 4.5-5.0 kg / 10-11 lbs.
5.3-6.4 kg / 12-14 lbs.
6.8-7.7 kg / 15-17 lbs.
8.2-10.0 kg / 18 22 lbs.
10.4-11.3 kg / 23 25 lbs| | | Grill 90 – 120 minutes
Grill 110 – 140 minutes
Grill 130 – 160 minutes
Grill 140 – 170 minutes
Grill 150 – 180 minutes
Chicken (whol| 1.36-2.26 kg / 3-5 lbs| | | Grill 1 – 1.5 hours
Drumsticks, Breasts| 0.45 – 0.86 kg / 1 – 1½ lbs.| | | Grill 30-60 minutes
Small Game Birds| 0.45 – 0.86 kg / 1 – 1½ lbs.| | | Grill 30-45 minutes
Duck| 1.36-2.26 kg / 3-5 lbs.| | | Roast or grill 2 – 2.5 hours
PORK| SIZE| Precooked to Reheat 60°C / 140°F| Medium 66°C / 150°F| Well Done 71°C / 160°F
---|---|---|---|---
Ham

(Fully Cooked & Boneless Portion, Smoked Picnic

Whole & Bone-In)

| 2.5 cm / 1″

1.36-1.81 kg / 3-4 lbs.

1.81-2.72 kg / 4-6 lbs.

2.26-3.62 kg / 5-8 lbs.

4.53-5.44 kg / 10-12 lbs.

| 12 minutes

50 minutes – 1 hour

1 – 2 hours

1   – 2½ hours

2     – 2¾ hours

| |
Loin Roast| 1.36-1.81 kg / 3 – 4 lbs.| | 1 – 2 hours| 2 – 3 hours
Rib Crown Roast| 1.81-2.26 kg / 4 – 5 lbs.| | 1½ – 2 hours| 2 – 3 hours
Chop

(loin, rib)

| 1.9-2.5 cm / ¾” – 1″

3.1-3.9 cm / 1¼” – 1½”

| | 10 – 12 minutes

14 – 18 minutes

|
Tenderloin| 1.9-2.5 cm / ¾” – 1″| | 20 – 30 minutes| 30 – 45 minutes
Loin Roast (boneless)| 1.36-2.26 kg / 3-5 lbs.| | 1¼ – 1¾ hours| 1¾ – 2½ hours
Boston Butt

(Pork Shoulder)

| 3.62-4.53 kg / 8-10 lbs.| | | 93 – 98°C / 200 – 210°F Internal Temperature
BEEF| SIZE| HEAT| Rare – 54°C / 130°F| Medium – 60°C / 140°F| Well Done – 65°C / 150°F
---|---|---|---|---|---
Steak (New York, Porter-house, Rib- eye, Sirloin, T bone, or Tenderloin)| 1.9 cm / ¾”
2.5 cm / 1″
3.8 cm / 1½”
5 cm / 2″| High| Sear 8-10 minutes
Sear 10-12 minutes
Sear 10 minutes, grill 8-10 minutes
Sear 10 minutes, grill 10-14 minutes
Skirt Steak| 0.6 – 12.7 cm / ¼” – ½”| High| Sear 5-7 minutes
Flank Steak| 0.45 – 0.86 kg

/ 1 – 1½ lbs., 1.9 cm / ¾”

| Medium| Sear 4 minutes, grill 8-10 minutes
Kabob| 2.5 – 3.8 cm / 1 – 1½” cubes| Medium| Grill 10 – 12 minutes
Tenderloin, whole| 1.58 – 1.81 kg / 3½ – 4 lbs.| High/Medium| Sear 10 minutes, grill 15-20 minutes
Ground Beef Patty| 1.9 cm / ¾”| High/Medium| Sear 4 minutes, grill 4-6 minutes
Rib-eye Roast (boneless)| 2.26 – 2.72 kg / 5 – 6 lbs.| Medium| Grill 1½ – 2 hours
Tri-tip Roast| 0.9 – 1.13 kg / 2 – 2½ lbs.| High/Medium| Sear 10 minutes, grill 20-30 minutes
Rib Roast| 5.44 – 6.35 kg / 12 – 14 lbs.| Medium| 2½ – 2¾ hours
Veal Loin Chop| 2.5cm / 1″| Medium| 10 – 12 minutes direct
Brisket| 7.25 – 3.62 kg / 16 -18 lbs.| Hot Smoke| Cook until internal temperature reaches 91°C / 195°F
LAMB| Size| Rare – 54°C / 130°F| Medium – 60°C / 140°F| Well Done – 71°C / 160°F
---|---|---|---|---
Roast (fresh)| 2.26 – 2.72 kg / 5 – 6 lbs.| | 1 – 2 hours|
Rib Crown Roast| 1.36-2.26 kg / 3-5 lbs.| | 1 – 1½ hours| 1½ hours
SEAFOOD| Size| Rare – 54°C / 130°F| Medium – 60°C / 140°F| Well Done – 82°C / 180°F
---|---|---|---|---
Fish (whole)| 0.5 kg / 1 lb.
0.9 – 1.1 kg / 2 – 2½ lbs.
1.4 kg / 3 lbs.| | | Grill 10 – 20 minutes
Grill 20 – 30 minutes
Grill 30 – 45 minutes
Fish (filets)| 0.6-1.3 cm / ¼” – ½”| | | Grill 3 – 5 minutes, until flaky
Lobster Tail| 0.15 kg / 5 oz.

0.3 kg / 10 oz.

| | | Grill 5 – 6 minutes
Grill 10 – 12 minutes
WILD GAME| Size| Rare – 60°C / 140°F| Medium – 71°C / 160°F| Well Done – 77°C / 170°F
---|---|---|---|---
Roast (fresh)| 2.26 – 2.72 kg / 5 – 6 lbs.| | 1 – 1½ hours| 1½ – 2 hours
Large Cuts (fresh)| 3.62-4.53 kg / 8-10 lbs.| | 1 hours| 1½ hours

 TIPS & TECHNIQUES

Follow these helpful tips and techniques, passed on from Pit Boss® owners, our staff, and customers just like you, to become more
familiar with your grill:

1. FOOD SAFETY
   • Keep everything in the kitchen and cooking area clean. Use different platters and utensils for the cooked meat than the ones you used to prepare or transport the raw meat out to the grill. This will prevent cross contamination of bacteria. Each marinade or basting sauce should have its own utensil.
   • Keep hot foods hot (above 60ºC / 140ºF), and keep cold foods cold (below 3ºC / 37ºF).
   • A marinade should never be saved to use at a later time. If you are going to use it to serve with your meat, be sure to bring it to a boil before serving.
   • Cooked foods should not be left out in the heat for more than an hour. Do not leave hot foods out of refrigeration for more than two hours.
   • Defrost and marinade meats by refrigeration. Do not thaw meat at room temperature or on a counter top. Bacteria can grow and multiply rapidly in warm, moist foods. Wash hands thoroughly with hot, soapy water before starting any meal preparation and after handling fresh meat, fish and poultry.

2. COOKING PREPARATION
   • Be prepared, or Mise en Place. This refers to preparing the cooking recipe, fuel, accessories, utensils, and all ingredients you require at grill side before you start cooking. Also, read the entire recipe, start to finish, before lighting the grill.
   • A BBQ floor mat is very useful. Due to food handling accidents and cooking spatter, a BBQ floor mat would protect a deck, patio, or stone platform from the possibility of grease stains or accidental spills.

3. GRILLING TIPS AND TECHNIQUES
   • To infuse more smoke flavor into your meats, cook longer and at lower temperatures (also known as low and slow). Meat will close its fibers after it reaches an internal temperature of 49ºC / 120ºF. Misting, or mopping, are great ways to keep meat from drying out.
   • While searing your meats, cook with the lid down. Always use a meat thermometer to determine the internal temperature of the foods you are cooking. Smoking foods with hardwood pellets will turn meats and poultry pink. The band of pink (after cooking) is referred to as a smoke ring and is highly prized by outdoor chefs.
   • Sugar-based sauces are best applied near the end of cooking to prevent burning and flare ups.
   • Leave open space between the foods and the extremities of the barrel for proper heat flow. Food on a crowded grill will require more cooking time.
   • Use a set of long-handled tongs for turning meats, and a spatula for turning burgers and fish. Using a piercing utensil, such as a fork, will prick the meat and allow the juices to escape.
   • Foods in deep casserole dishes will require more time to cook than a shallow baking pan.
   • It’s a good idea to put cooked food onto a heated platter, keeping the food warm. Red meats, such as steak and roasts, benefit from resting for several minutes before serving. It allows the juices that were driven to the surface by heat to ease back to the center of the meat, adding more flavor.

TROUBLESHOOTING

Proper cleaning, maintenance and the use of clean, dry, quality fuel will prevent common operational problems. When your Pit Boss grill is operating poorly, or on a less frequent basis, the following troubleshooting tips may be helpful. For FAQ, please visit www.pitboss-grills.com . You may also contact your local Pit Boss authorized dealer or contact Customer Care for assistance.

WARNING: Always disconnect the electrical cord prior to opening the grill for any inspection, cleaning, maintenance or service work. Ensure the grill is completely cooled to avoid injury

Press the Power Button, and ensure the button glows blue to show there is a power connection. Turn the Temperature Control Dial to a temperature setting.
Not Connected To Power Source| Ensure unit is plugged into a working power source. Reset breaker. Ensure GFCI is a minimum 10 Amp service (see Electric Wire Diagram for access to electric components) Ensure all wire connections are firmly connected and dry.
Fuse Blown On The Control Board| Remove hopper access panel (see Electric Wire Diagram for diagram), press in plastic tabs holding the control board in place and carefully pull controller inside the hopper to release controller. Check the fuse for a broken wire or if the wire has turned black. If yes, fuse needs to be manually replaced.
The GFCI outlet has been tripped.| Ensure GFCI is a minimum 10 Amp service.
Faulty Control Board| Control Board needs to be replaced. Contact Customer Care for a replacement part.
Fire in Burn pot Will Not Light| Auger Not Primed| Before the unit is used for the first time or anytime the hopper is completely emptied out, the auger must be primed to allow pellets to fill the auger tube. If not primed, the igniter will timeout before the pellets reach the burn pot. Follow Hopper Priming Procedure.
Auger Motor Is Jammed| Remove cooking components from the grill body. Press the Power Button to turn the unit on, turn Temperature Control Dial to SMOKE, and inspect the auger feed system. Visually confirm that the auger is dropping pellets into the burn pot. If not operating properly, call Customer Care for assistance.
Igniter Failure| Remove cooking components from the grill body. Press the Power Button to turn the unit on, turn Temperature Control Dial to SMOKE, and inspect the igniter. Visually confirm that the igniter is working by placing your hand above the burn pot and feeling for heat. Visually confirm that the igniter is protruding approximately 13mm / 0.5 inches in the burn pot. If not operating properly, follow Manual Start-up Procedure to continue use of grill; however, call Customer Care for assistance or a replacement part.
Insufficient Air Flow Through Burn pot| Check burn pot for ash build-up or obstructions. Follow Care and Maintenance instructions for ash build-up. Check fan. Ensure it is working properly and air intake is not blocked. Follow Care and Maintenance instructions if dirty.
Flashing Dots On LCD Screen| The Igniter Is On| This is not an error that effects the grill. Used to show that the unit has power and is in Start-Up mode (igniter is on). The igniter will turn off after five minutes. Once the flashing dots disappear, the grill will begin to adjust to the desired temperature selected.
Flashing Temperature On LCD Screen| Grill Temperature Is Below 65°C /150°F| This is not an error that effects the unit; however, it is used to show that there is some risk that the fire could go out. Check hopper for sufficient fuel or if there is an obstruction in the feed system. Remove pellets and follow Care and Maintenance instructions. Check grill Grill Probe and follow Care and Maintenance instructions if dirty. Check burn pot for ash build up or obstructions, and follow Care and Maintenance instructions for ash build-up. Check fan. Ensure it is working properly and air intake is not blocked. Follow Care and Maintenance instructions if dirty. Check auger motor to confirm operation (rotation), and ensure there is no blockage in the auger tube.
“ErH” Error Code| The Unit Has Overheated, Possibly Due To Grease Fire Or Excess Fuel.| Press the Power Button to turn the unit off, and allow grill to cool. Follow Care and Maintenance instructions. After maintenance, remove pellets, and confirm positioning of all component parts. Once cooled, press the Power Button to turn the unit on, then select desired temperature. If error code still displayed, contact Customer Care.

Remove hopper access panel (see Electric Wire Diagram for diagram), and check for any damage to the Grill Probe wires. Ensure Grill Probe molex connectors are firmly connected, and connected correctly, to the Control Board.

Check proper positioning of cooking components. Check hopper for sufficient fuel or if there is an obstruction in the feed system. Remove pellets and follow Care and Maintenance instructions. Check grill probe. Confirm if actual temperature is correct and accurate. Follow Care and Maintenance instructions if dirty. Check ignitor positioning and that it is heating up properly. In extreme cold, the grill may require a second start. Turn grill off, wait, then turn on again. Check fan. Ensure it is working properly. Follow Care and Maintenance instructions if dirty.

Disconnect meat probe from connection port on the Control Board, and reconnect. Ensure the meat probe adapter is firmly connected. Check for signs of damage to the adapter end. If still failed, call Customer Care for replacement part.

“Err” Error Code| Grill Probe wire not making connection.|
“ErL” Error Code| Grill fails to perform start-up cycle|
Grill will not stay lit|
“noP” Error Code| Bad Connection At Connection Port|
Meat Probe Damaged| Check for signs of damage to the wires of the meat probe. If damaged, call Customer Care for replacement part.
Faulty Control Board| Control Board needs to be replaced. Contact Customer Care for a replacement part.
Grill Temperature on SMOKE is

too high

| “P” Setting is too LOW| Push the “P” SET button, and increase the “P” setting.
Grill Will Not Achieve Or Maintain Stable Temperature| Insufficient Air Flow Through Burn pot| Check burn pot for ash build-up or obstructions. Follow Care and Maintenance instructions for ash build-up. Check fan. Ensure it is working properly and air intake is not blocked. Follow Care and Maintenance instructions if dirty. Check auger motor to confirm operation, and ensure there is no

blockage in the auger tube. Once all the above steps have been done, start the grill, set temperature to SMOKE and wait for 10 minutes. Check that the flame produced is bright and vibrant.

Lack Of Fuel, Poor Fuel Quality, Obstruction In Feed System| Check hopper to check that fuel level is sufficient, and replenish if low. Should the quality of wood pellets be poor, or the length of the pellets too long, this may cause an obstruction in the feed system. Remove pellets and follow Care and Maintenance instructions.
Grill Probe| Check status of Grill Probe. Follow Care and Maintenance instructions if dirty. Contact Customer Care for a replacement part if damaged.
Grill Produces Excess Or Discolored Smoke| Grease Build-Up| Follow Care and Maintenance instructions.
Wood Pellet Quality| Remove moist wood pellets from hopper. Follow Care and Maintenance instructions to clean out. Replace with dry wood pellets.
Burn pot Is Blocked| Clear burn pot for ash and other debris. Follow Hopper Priming Procedure.
Insufficient Air Intake For Fan| Check fan. Ensure it is working properly and air intake is not blocked. Follow Care and Maintenance

instructions if dirty.

Frequent Flare-Ups| Cooking Temperature| Attempt cooking at a lower temperature. Grease does have a flash point. Keep the temperature under 176°C / 350°F when cooking highly greasy food.
Grease Build-Up On Cooking Components| Follow Care and Maintenance instructions.

ELECTRICAL WIRE DIAGRAM

The Digital Control Board system is an intricate and valuable piece of technology. For protection from power surges and electrical shorts, consult the wire diagram below to ensure your power source is sufficient for the operation of the unit.

PB – ELECTRIC REQUIREMENTS
110-120V, 60Hz, 275W, 3-PRONG GROUNDED PLUG

NOTE: Electrical components, passed by product safety testing and certification services, comply with a testing tolerance of ± 5-10 percent

**LOCATE AND REMOVE THE EIGHT SCREWS OF ACCESS PANEL ON UNDERSIDE OF UNIT

**

FUEL INPUT RATING:
1.12 KG/H (2.48 LB/H)|
---|---
INDEX
W : WHITE
Y : YELLOW
P : PURPLE
R : RED
K : BLACK
G : GREEN

PB0500SP GRILL REPLACEMENT PARTS

NOTE: Due to ongoing product development, parts are subject to change without notice.

PB0820SP GRILL REPLACEMENT PARTS

NOTE: Due to ongoing product development, parts are subject to change without notice.

PB1000SP GRILL REPLACEMENT PARTS

NOTE: Due to ongoing product development, parts are subject to change without notice

PB1100SP GRILL REPLACEMENT PARTS

NOTE: Due to ongoing product development, parts are subject to change without notice

HOPPER REPLACEMENT PARTS

WARRANTY

CONDITIONS

All wood pellet grills by Pit Boss®, manufactured by Dansons, carry a limited warranty from the date of sale by the original owner. The warranty coverage begins on the original date of purchase and proof of date of purchase, or copy of original bill of sale, is required to validate the warranty. Customers will be subject to parts, shipping, and handling fees if unable to provide proof of the purchase or after the warranty has expired.

Dansons carries a five (5) year warranty against defects and workmanship on all parts, and five (5) years on electrical components. Dansons warrants that all part(s) are free of defects in material and workmanship, for the length of use and ownership of the original purchaser. Warranty does not cover damage from wear and tear, such as scratches, dents, dings, chips or minor cosmetic cracks. These aesthetic changes of the grill do not affect its performance. Repair or replacement of any part does not extend past the limited warranty beyond the five (5) years from date of purchase.

During the term of the warranty, Dansons’ obligation shall be limited to furnishing a replacement for defective and/or failed components. As long as it is within the warranty period, Dansons’ will not charge for repair or replacement for parts returned, freight prepaid, if the part(s) are found by Dansons’ to be defective upon examination. Dansons’ shall not be liable for transportation charges, labor costs, or export duties. Except as provided in these conditions of warranty, repair or replacement of parts in the manner and for the period of time mentioned heretofore shall constitute the fulfillment of all direct and derivate liabilities and obligations from Dansons to you.

Dansons takes every precaution to utilize materials that retard rust. Even with these safeguards, the protective coatings can be compromised by various substances and conditions beyond Dansons’ control. High temperatures, excessive humidity, chlorine, industrial fumes, fertilizers, lawn pesticides and salt are some of the substances that can affect metal coatings. For these reasons, the warranty does not cover rust or oxidization, unless there is loss of structural integrity on the grill component. Should any of the above occur, kindly refer to the care and maintenance section to prolong the lifespan of your unit. Dansons recommends the use of a grill cover when the grill is not in use.

This warranty is based on normal domestic use and service of the grill and neither limited warranty coverage’s apply for a grill which is used in commercial applications.

EXCEPTIONS

There is no written or implied performance warranty on Pit Boss® grills, as the manufacturer has no control over the installation, operation, cleaning, maintenance or the type of fuel burned. This warranty will not apply nor will Dansons assume responsibility if your appliance has not been installed, operated, cleaned and maintained in strict accordance with this owner’s manual. Any use of gas not outlined in this manual may void the warranty. The warranty does not cover damage or breakage due to misuse, improper handling or modifications.

Neither Dansons, or authorized Pit Boss® dealer, accepts responsibility, legal or otherwise, for the incidental or consequential damage to the property or persons resulting from the use of this product. Whether a claim is made against Dansons based on the breach of this warranty or any other type of warranty expressed or implied by law, the manufacturer shall in no event be liable for any special, indirect, consequential or other damages of any nature whatsoever in excess of the original purchase of this product. All warranties by manufacturer are set forth herein and no claim shall be made against manufacturer on any warranty or representation.

Some states do not allow the exclusion or limitation of incidental or consequential damages, or limitations of implied warranties, so the limitations or exclusions set forth in this limited warranty may not apply to you. This limited warranty gives you specific legal rights and you may have other rights, which vary from state to state.

ORDERING REPLACEMENT PARTS

To order replacement parts, please contact your local Pit Boss® dealer or visit our online store at: www.pitboss-grills.com

CONTACT CUSTOMER CARE

If you have any questions or problems, contact Customer Care.

www.pitboss-grills.com

USA: (480) 923-9630 | CANADA (TOLL FREE): 1-877-942-2246

WARRANTY SERVICE

Contact your nearest Pit Boss® dealer for repair or replacement parts. Dansons requires proof of purchase to establish a warranty claim; therefore, retain your original sales receipt or invoice for future reference. The serial and model number of your Pit Boss® can be found on the back of the hopper. Record numbers below as the label may become worn or illegible.

RECIPES

CLASSIC BRISKET

Makes 4 – 6 Servings

A whole beef brisket weighs 7.25-3.62 kg / 16-18 pounds and has three separate parts: the cap, the point, and the flat. Use the flat section, as it is lean, compact, and creates nice slices when carved.

Ingredients:

1 Beef Brisket 2.2-3.6 kg / 5-8 lbs, Layer of fat is at least 0.6 cm / ¼” thick
1 bottle Prepared Yellow Mustard
75 ml / 5 tbsp Seasoning
1 bottle Chili Sauce
1 pack Dry Onion Soup Mix
375 ml / 1 1/2 c. Beef Broth
40 ml / 8 tsp Black Pepper

Suggested Wood Pellet Flavor: Hickory / Competition

Instructions:

1. Lay out a large piece of plastic wrap on your working station. Large enough to encase the brisket. Using a sharp knife, cut a single cut on the underside of the brisket against the grain. This will aid in slicing the finished brisket, against the grain which results in a tender, melt-in-your-mouth cut. The underside is the non-fat cap side. Slather on a generous amount of prepared mustard. Rub lightly onto the entire area. Sprinkle a generous amount of seasoning onto the mustard, then again light rub into the meat. Flip the brisket over and repeat the process. Wrap the prepared brisket in the plastic wrap and refrigerate 2 to 4 hours, or overnight.
2. Prepare the basting mixture. Mix the chili sauce, dry onion soup mix, beef broth, and black pepper. Set aside.
3. Turn on grill to SMOKE or low temperature.
4. Place the brisket, fat side up, in the center of the grill. Close the grill lid. Slow cook until tender, about 10 to 12 hours.
5. Baste the brisket with the basting mixture every half hour for the first 3 hours.
6. Continue the slow cooking process until the internal temperature reaches 60-66°C / 140-150°F. Remove from grill. Turn grill up to 176°C / 350°F.
7. Place the brisket into a pouch of double-layered aluminum foil. Pour 50 ml / ¼ cup of basting mixture over the brisket in the pouch. Close the pouch shut.
8. Lay foil pouch carefully on the grill. Steam for 1 to 1 ½ hours.
9. Open the pouch, and use a meat thermometer; internal temperature should reach 91°C / 195°F. The brisket should be firm but be able to pull the meat apart with your fingers.
10. Transfer the meat to a cutting board, and let it rest for 10 minutes. Thinly slice across the grain to serve.

SAUSAGE WITH MANGO CHUTNEY

Makes 4 – 6 Servings

Ingredients:

2 Mangoes (finely chopped)
0.9 kg / 2 lbs Italian Sausage (hot or mild)
10 ml / 2 tsp Fresh Parsley (minced)
15 ml / 1 tbsp Red Pepper (diced)
10 ml / 2 tsp Honey
½ Red Onion (diced)
½ bulb Fennel (diced)
5 ml / 1 tsp Lime Juice
Pinch Salt

Suggested Wood Pellet Flavor: Hickory / Competition

Instructions:

1. Turn on grill to LOW-MEDIUM (82 – 107°C / 180 – 225°F)
2. Place sausages on grill, spaced evenly apart. Rotate every ten minutes so all sides are grilled.
3. Combine all remaining ingredients to make the chutney. Chill until ready to serve.
4. Slice grilled sausage diagonally, then serve with side of chutney

BLUE CHEESE STEAK

Makes 4 Servings

Ingredients:

4 Steak, T-bone or Rib-Eye 2.54cm / 1″ thick 0.28-0.62 kg / 10-12 ounces each
113 g / 4 oz. Blue Cheese (crumbled)
50 ml / ¼ c. Green Onion (thinly sliced)

Suggested Wood Pellet Flavor: Hickory / Competition / Whiskey

Instructions:

1. Turn on grill to higher temperature (204-260°C / 400-500°F)
2. Trim excess fat from meat and discard.
3. Place steaks on grill. Sear each side, flipping every few minutes.
4. Reduce heat to 135°C/275°F or 163°C/ 325°F. Flip the steaks a final time. Combine blue cheese and onions. Sprinkle over steaks, close grill lid, and grill until desired doneness. Check doneness by cutting a slit in meat near the bone

Variation: REVERSE-SEAR METHOD

Turn grill to SMOKE, then place steaks on grill. Smoke at 82°C / 180°F for 5 to 15 minutes. Once smoked to desired doneness, turn grill up to HIGH and sear to your liking.

BBQ RIBS

Makes 4 – 6 Servings

Ingredients:

1.3-1.8 kg / 3-4 lbs Ribs Meaty pork spareribs / loin back ribs
45 ml / 3 tbsp Oil
5 ml / 1 tsp Salt
5 ml / 1 tsp Pepper
2 whole Onions (chopped)
30 ml / 2 tbsp Vinegar
30 ml / 2 tbsp Worcestershire sauce
125 ml / ½ c. Apple Juice or Soda
5 ml / 1 tsp Paprika
5 ml / 1 tsp Chili Powder

Suggested Wood Pellet Flavor: Hickory / Competition / Apple

Instructions:

1. Turn on grill to SMOKE or low (82-107°C / 180-225°F).
2. Prepare ribs by peeling off the tough layer of skin on the back side. Season the ribs with salt and pepper, to taste.
3. Place ribs on grill, spaced evenly apart. Smoke for 3 to 4 hours.
4. Mix remaining ingredients in a saucepan and bring to a boil. Let sauce boil for five minutes to thicken.
5. Remove from grill. Turn grill up to 176°C / 350°F.
6. Place each rack into a pouch of double-layered aluminum foil. Pour 50 ml / ¼ cup of sauce over the ribs in the pouch. Close the pouch shut.
7. Lay foil pouch carefully on the grill. Steam for 1 to 1 ½ hours.
8. Open the pouch. The meat will have exposed the rib ends and be very tender. Turn grill up to HIGH (260°C / 500°F). Place ribs back on the grill and baste with sauce on both sides of ribs.
9. Once the sauce is caramelized and the ribs are sticky, remove from grill and serve.

Variation: MEMPHIS-DRY METHOD

Turn grill up to HIGH (260°C / 500°F). Place ribs back on the grill and season with a dry seasoning or rub. Sear the ribs, remove from grill and serve.

MOM’S JUICY HAMBURGERS

Makes 4 – 6 Servings

Ingredients:

900 g /2 lbs Ground Beef or Buffalo
15 ml / 3 tsp Seasoning
2 whole Eggs, room temperature
500 ml / 2 c. Bread Crumbs (Dried, Fine)
6 – 8 Hamburger / Kaiser Buns
6 – 8 slices Cheese (slices, thin)
30 ml / 2 tbsp Butter

Suggested Wood Pellet Flavor: Hickory / Competition

Instructions:

1. Turn on grill to higher temperature (204-260°C / 400-500°F)
2. Combine meat, seasoning, eggs and bread crumbs in a mixing bowl and blend together. Divide the meat into portions, and gently shape into patties to fit the buns. Make patties about 1.9 cm / ¾ inches thick.
3. Place patties on grill. Grill six minutes per side, taking care not to press down on the meat. Test for doneness, using a meat thermometer; internal temperature should reach 71ºC / 160ºF. Meat may turn pink on the outside due to smoking.
4. In the last few minutes of grilling, brush buns with butter and lightly toast on the grill.
5. Remove buns, burgers when done. Top the burgers with cheese to melt, and serve.

TIP: A slightly fattier meat makes for a juicier burger. For a lean alternative, try ground buffalo.

SIRLOIN STEAK WITH SWEET ONION & PEPPERS

Makes 4 Servings

Ingredients:

2 Steak, Top Sirloin 1″ thick, cut into 4 pieces. 0.45kg/1 lb
10 ml / 2 tsp Seasoning or rub
5 medium Sweet Onions (coursed chopped)
2 whole Bell Peppers (all kinds, chopped)
60 ml / 4 tbsp Soy Sauce
60 ml / 4 tbsp Olive Oil
Dash Salt

Suggested Wood Pellet Flavor: Hickory / Mesquite / Whiskey

Instructions:

1. Turn on grill to 218°C / 425°F.
2. Season both sides of the steak with the seasoning or rub. Cover and refrigerate at least 1 hour.
3. Place onions and bell peppers into a covered tray of aluminum foil. Mix soy sauce and olive oil together, then drizzle over tray. Sprinkle with salt. Seal the foil packet completely.
4. Place the foil on the grill for 10 – 15 minutes or until vegetables are soft and tender. Remove from grill, and keep covered.
5. Place steaks on grill. Sear each side, flipping every few minutes.
6. Grill until desired doneness, then remove from grill. Place on serving plates and top with warm vegetables.

CORNISH HENS WITH MANDARIN RICE

Makes 4 Servings

Ingredients:

4 whole Cornish Game Hens
750 ml/ 3 c. Mandarin Rice
15 ml / 1 tbsp Olive Oil
5 ml / 1 tsp Smoked Paprika
250 ml / 1 c. Orange Marmalade

Mandarin Rice

59 ml / ¼ c. Almonds (slivered)
30 ml / 2 tbsp Celery (chopped)
1 small Green Onion (sliced, thin)
30 ml / 2 tbsp Butter
1 can Mandarin Orange Segments (drained) 0.4 kg/11oz.

30 ml / 2 tbsp Orange Juice (concentrate)
500 ml / 2 c. Cooked Rice

Suggested Wood Pellet Flavor: Hickory / Mesquite / Competition

Instructions:

1. Prepare mandarin rice by cooking almonds, celery, green onion, and butter in small skillet until almonds are lightly toasted. Combine mixture with orange segments, orange juice and cooked rice in a bowl, and set aside.
2. Turn on grill to medium temperature (135-177°C / 275-350°F).
3. Rinse Cornish hens and pat dry with paper towel. Stuff with rice mixture and tie legs with a string. Brush Cornish hens lightly with olive oil, and sprinkle with paprika.
4. Place Cornish hens on grill. Grill for 45 to 60 minutes, until the drumstick meat is tender when pressed.
5. Baste with orange marmalade during last 20 minutes of cooking time. Remove from grill and arrange on serving platter.

TIP: If you want to catch the drippings to make gravy, place the hens in a foil pan and add enough water or juice to cover the bottom about 0.6 cm / ¼ inch thick.

SHRIMP KABOBS WITH CURRY BUTTER

Makes 4 Servings

Ingredients:

900g / 2 lbs Shrimp (peeled, deveined)
125ml / ½ c. Curry Butter
15 ml / 1 tbsp Olive Oil
1 Lime Fresh Dill

Curry Butter

125 ml / ½ c. Butter
30 ml / 2 tbsp Onion (chopped)
15 ml / 1 tbsp Fresh Dill
5 ml / 1 tsp Curry Powder
Dash Garlic Powder

Suggested Wood Pellet Flavor: Mesquite / Competition

Instructions:

1. Soak wooden skewers in water for 1 hour.
2. Turn on grill to 135-163°C / 275-325°F.
3. Prepare curry butter by melting butter in small pan over medium-high heat. Stir in onion, dill, curry powder and garlic powder. Cook for five minutes, then remove from heat.
4. Thread shrimp on skewers, leaving space between pieces. Lightly brush with olive oil.
5. Place skewers on grill, and grill until shrimp are white and tender. Shrimp grill quickly; take care not to overcook. Turn skewers of shrimp once and brush with curry butter halfway through cooking time.
6. Arrange grilled shrimp on serving plate. Garnish with lime wedge and dill.

TIP: To skewer shrimp so that it is straight, hold it in a stretched-out position with one hand. Start at the tail end and insert a bamboo or wooden skewer into the shrimp so that it runs the full length. Keep unbending the shrimp with your fingers as you go.

BACON BASIL SHRIMP ON A STICK

Makes 4 – 6 Servings

Ingredients:

24 large Shrimp (peeled, deveined)
24 whole Fresh Basil Leaves
24 slices Bacon (sliced thin)

Suggested Wood Pellet Flavor: Cherry / Apple

Instructions:

1. Soak wooden skewers in water for 1 hour.
2. Turn on grill to 135-163°C / 275-325°F.
3. Wrap a piece of shrimp and basil leaf in a thin slice of bacon, then thread onto skewer, leaving space between pieces.
4. Place skewers on grill, and cook until shrimp are white and tender, and the bacon is nicely browned. Shrimp grill quickly; take care not to overcook. Turn skewers often to avoid burning.
5. Remove from heat and serve.

WHOLE SMOKED TURKEY

Feeds a small army – leftovers are great!

Ingredients:

1 whole Turkey (thawed) 9-11.3 kg / 20-25 lbs
60 ml /4 tbsp Seasoning
5 ml / 1 tsp Smoked Paprika
45 ml /3 tbsp Butter

Suggested Wood Pellet Flavor: Hickory / Cherry / Competition

Instructions :

1. Turn on grill to 135-177°C / 275-350°F.
2. Remove the turkey neck and giblets. Rinse turkey thoroughly and pat the exterior dry with paper towel.
3. In a small bowl, mix butter, ¼ of the seasoning and paprika together to form a paste. Gently insert your hand between the outer skin and the breast meat. Rub paste into the meat.
4. With the remaining seasoning, rub the outer surface of the turkey.
5. Place turkey, breast side up, in center of grill, and cook until turkey is tender and golden brown; internal temperature should reach 82°C / 180°F in the thickest part of the thigh and 77°C / 170°F in the breast.
6. Remove turkey, cover with foil and let rest for 10 minutes before carving.

TIP: If you want to catch the drippings to make gravy, place the turkey on a rack inside a large aluminum foil roast pan. Add 0.6 cm / ¼” of water or broth and some seasoning into the bottom of the pan. Monitor the juices, as you may need to add more during the roasting period.

BEER CAN CHICKEN

Makes 2 – 6 Servings

Ingredients:

1 whole Chicken 1.8-2.7 kg / 4-6 lbs
1 can Beer, any kind
45 ml /3 tbsp Seasoning

Suggested Wood Pellet Flavor: Hickory / Apple / Competition

Instructions:

1. Turn on grill to 135-177°C / 275-350°F.
2. Open can, and pour half of the beer into a glass to drink. Leave half in the can, and make a few more holes in the top of the can to increase ventilation. Add a ¼ of the seasoning to the can.
3. Rinse chicken thoroughly and pat the exterior dry with paper towel. Add a 1/4 of the rub inside the cavity of the chicken. With the remaining seasoning, rub the outer surface of the chicken.
4. Insert the upright can into the cavity of the chicken, place on the grill, and close the grill lid. Cook until the chicken is golden brown and crispy; internal temperature should reach 74°C/165°F.
5. Using tongs, carefully remove the upright chicken and can from the grill. Let rest for five minutes, then carefully remove the can from the cavity of the chicken. Be cautious not to spill, as the liquid will be hot.
6. Carve chicken and serve.

Variation: NON- ALCOHOLIC, BEER-CAN CHICKEN

Using the same instructions as above, but substitute the can of beer with a can of your favorite non-diet cola, fruit juice, or water with additional seasoning.

EASY RANCH CHICKEN SATAY

Makes 2 – 6 Servings

Ingredients:

450g / 1 lb Chicken Breasts or Thighs (boneless, skinless)
112 ml / ½ c. Prepared Ranch or Italian Salad Dressing
Dash Salt
Dash Pepper

Suggested Wood Pellet Flavor: Apple / Cherry

Instructions:

1. Cut chicken, lengthwise, into 0.63 cm / 1/4″ or slightly thicker pieces. Rinse chicken and pat dry with paper towel.
2. Place chicken pieces into a plastic lock-top bag. Add salad dressing, salt and pepper. Seal the bag closed, and carefully shake, coating chicken evenly. Place in refrigerator for 1 – 2 hours, or overnight. Shake the bag once or twice so the chicken marinades evenly.
3. Soak wooden skewers in water for 1 hour before use.
4. Turn on grill to 218°C / 425°F.
5. Remove chicken from plastic bag, and weave in-and-out onto the skewers, like a ribbon.
6. Place skewers on grill, and cook until chicken is white and firm. Turn skewers often to avoid burning.
7. Remove from heat and serve.

IMPORTANT

DO NOT RETURN PRODUCT TO STORE

For all questions, comments, or inquiries, please contact Dansons our Customer Care department.

USA: (480) 923-9630 | CANADA (TOLL FREE): 1-877-942-2246 service@pitboss- grills.com

WARNING: This product can expose you to chemicals including wood dust, which is known to the State of California to cause cancer, and carbon monoxide, which is known to the State of California to cause birth defects or other reproductive harm. For more information go to WWW.P65WARNINGS.CA.GOV

©2022 DANSONS 602220124UMV

MADE IN CHINA

For outdoor and household use only. Not for commercial use.

Customer Service

COPYRIGHT NOTICE

Copyright 2022. All right reserved. No part of this manual may be copied, transmitted, transcribed, stored in a retrieval system, in any form or by any means without expressed written permission of,

Dansons
3411 North 5th Avenue, Suite 500, Phoenix, AZ, USA 85013
www.pitboss-grills.com

Customer Care
USA: (480) 923-9630
CANADA (TOLL FREE): 1-877-942-2246

Documents / Resources

| SPORTSMAN 5005166 Wood Pellet Grill and Smoker [pdf] Owner's Manual
5005166 Wood Pellet Grill and Smoker, 5005166, Wood Pellet Grill and Smoker, Pellet Grill and Smoker, Grill and Smoker
---|---

References

• grills.com
• P65WARNINGS.CA.GOV
• Pellet Fuels Institute
• Home | Pit Boss® Grills

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