GASCRAFT KY8540 Charcoal Smoker and Grill Instruction Manual

CHARCOAL
SMOKER & GRILL
Model No. KY8540

FOR OUTDOOR USE ONLY
Retain these instructions for future use
Important: The installer or seller must leave these instructions with the consumer.

IMPORTANT SAFETY WARNINGS

** We want you to assemble and use your Gascraft Smoker & Grill as safely as possible. When you see this safety alert symbol please pay particular attention to the information which follows it.
Read all safety warnings and instructions carefully before assembling and operating the Smoker & Grill.
WARNING**

• Only use this Smoker & Grill on a hard, level, noncombustible, stable surface.
  Never use on a wooden surface or one that could burn.

• Always use a drip pan/ash guard under Smoker & Grill to protect surface from heat damage and/or discoloration and to catch ashes, embers and drippings. Place a thin layer of water in drip pan/ash guard to help extinguish falling ashes and embers. A drip
  pan/ash guard is designed for use with the Smoker & Grill for easy clean up of drippings that can cause discoloration of surface and to catch falling ashes and embers.

• Proper clearance of 3 metres between the smoker and any combustible material (bushes, trees, wooden decks, wooden fences, buildings, etc.) or construction should be maintained at all times when Smoker & Grill is in use. Do not place Smoker & Grill under a roof overhang or other enclosed area.

• For household use only. Do not use this Smoker & Grill for other than its intended purpose.

• For outdoor use only. Do not operate Smoker & Grill indoors or in an enclosed area.

• Water bowl should always be used when smoking. Do not allow liquid in water bowl to completely evaporate. Check water bowl every 2 hours and add water if level is low (a sizzling should may indicate a need for water).
  Follow instructions in “Adding Water or Wood during Cooking” section of this manual.

• Always keep water in the water bowl even after food is removed from Smoker. Water will evaporate and grease in water bowl can catch on fire.

• Do not move Smoker & Grill when water bowl contains hot liquids and while it is in use.

• Do not leave Smoker & Grill unattended when in use.

• Use extreme caution when adding charcoal/wood. Follow instructions in “Adding Water or Wood during Cooking” section of this manual.

• Do not store or use Smoker & Grill near gasoline or other flammable liquids, gases or where flammable vapors may be present.

• We do not recommend the use of lighting fluid. If you choose to use charcoal lighting fluid, only use lighting fluid approved for lighting charcoal. Carefully read instructions on the charcoal lighting fluid and charcoal prior to use.

• Do not use self-starting charcoal. Use only high grade plain charcoal or charcoal/wood mixture.

• Do not use gasoline, kerosene or alcohol for lighting charcoal. Use of any of these or similar products can cause an explosion possibly leading to severe bodily injury.

• Never add charcoal lighting fluid to hot or even warm charcoal.

• During grilling, grease from meat may drip into the charcoal and cause a grease fire. If this should happen, replace dome lid to suffocate the flame. Do not use water to extinguish grease fires.

• Use caution since flames can flare-up when fresh air suddenly comes in contact with fire. When opening the dome lid, keep hands, face and body safe from hot steam and flame flare-ups. Remove the dome lid by tilting it toward you to allow heat and steam to escape away from your face.

• Use caution when assembling and operating your Smoker & Grill to avoid scrapes or cuts from sharp edges of metal parts.

• Check support brackets to make sure they are secure and notches are upright before each use.

• Place Smoker & Grill in an area where children and pets cannot come into contact with unit. Close supervision is necessary when Smoker & Grill is in use.

• Use caution when lifting or moving Smoker & Grill to prevent strains and back injuries.

• In windy weather, place Smoker & Grill in an outdoor area that is protected from the wind.

• Do not wear loose clothing or allow hair to hang freely while using Smoker & Grill.

• Use caution when reaching into or under Smoker & Grill. Always wear oven mitts or gloves to protect your hands from burns. Avoid touching hot surfaces.

• We advise that a fire extinguisher be on hand. Refer to your local authority to determine proper size and type of fire extinguisher.

• Any accessory attachments not included with this unit are not recommended and may lead to personal injury or property damage.

• Never leave coals and ashes in Smoker & Grill unattended.

• Before Smoker & Grill can be left unattended, remaining coals and ashes must be removed from Smoker & Grill. Use caution to protect yourself and property. Place remaining coals and ashes in a non-combustible metal container and completely saturate with water. Allow coals and water to remain in metal container 24 hours prior to disposing.

• Extinguished coals and ashes should be placed a safe distance from all structures and combustible materials.

• With a garden hose, completely wet the surface beneath and around Smoker to extinguish any ashes, coals or embers which may have fallen during the cooking or cleaning process.

• Store the Smoker & Grill out of reach of children, indoors in a dry location when not in use.

• Do not attempt to service Smoker & Grill other than normal maintenance as explained in “After-Use Safety and Proper Care & Maintenance” sections of this manual.

• Properly dispose of all packaging material.

• **** Use caution and common sense when using your Smoker & Grill.

• Failure to adhere to the safety warnings and guidelines in this manual could result in bodily injury or property damage.

• Please keep this manual for future reference.

OPERATING INSTRUCTIONS

• **** Place the Smoker & Grill outdoors on a hard, level and non-combustible surface away from roof overhangs or any combustible material. Never use on wooden or other surfaces that could burn. Place the Smoker & Grill away from open windows or doors to prevent smoke from entering your house. In windy weather, place the Smoker & Grill in an outdoor area that is protected from the wind.
• Never attempt to remove water bowl when hot.
• Before each use, check handles and support brackets to make sure they are securely fastened.

Smoking

1. Remove dome lid and upper body from lower body.

2. Always use high quality charcoal. We recommend using a Charmate Chimney Starter which speeds up the lighting process and avoids the dangers associated with charcoal lighter fluid. Directions for use can be found with the Chimney Starter.

3. If you do not use a Chimney Starter, carefully place 2.5-3.5 kilos of charcoal in the charcoal bowl. If you chose to use lighter fluid or fire starters carefully follow the manufacturer’s warnings.

4. If using lighter fluid, saturate charcoal with lighter fluid and wait 2 to 3 minutes for fluid to soak in. Store charcoal lighter fluid safely away from Smoker & Grill.

5. Carefully light the charcoal and allow to burn until covered with a light ash prior to closing door and continuing to Step 6. This may take up to 30 minutes, if you use a Charmate Chimney Starter this may take less time.
   WARNING
   Failure to do this could trap fumes from charcoal lighting fluid in Smoker & Grill and may result in a flash-fire or explosion when door is opened or dome lid is removed.

6. Refer to “Flavoring Wood” section overleaf for the recommended amount of flavoring wood. Use long cooking tongs to carefully place flavoring wood directly on top of hot charcoal or into water bowl.

7. Place empty water bowl inside Smoker & Grill body on the lower support brackets. Position water bowl so rim is resting securely on notched out step of all three support brackets.

8. Carefully, fill water bowl with warm water or marinade to 2.5cm below the rim. A full pan holds 4.5 – 5.5 litres of water and will last for approximately 3-4 hours. Do not over fill or allow water to overflow from water bowl.

9. Place a cooking rack on the lower support brackets directly above the water bowl.

10. Place food on the cooking rack in a single layer with space between each piece. This will allow smoke and moist heat to circulate evenly around all pieces of food.

11. Place the upper body on lower body, making sure the water bowl is still in place.

12. Place the other cooking rack on the upper support brackets. Make sure the rim is resting securely on the notched-out step of all three support brackets. Place food on the cooking rack and cover with dome.

13. Allow food to cook. After 3-4 hours of cooking, check water level and refer to “Adding Water or Wood during Cooking” section of this manual.

14. Always use a meat thermometer to ensure food is fully cooked before removing from Smoker & Grill.

15. After cooking, allow Smoker & Grill to cool completely then follow instructions in the “After-Use Safety and Proper Care & Maintenance” sections of this manual.

Grilling & Searing

1. Remove dome lid and upper body from lower body.

2. Always use high quality charcoal. We recommend using a Charmate Chimney Starter which speeds up the lighting process and avoids the dangers associated with charcoal lighter fluid. Directions for use can be found with the Chimney Starter.

3. If you do not use a Chimney Starter, carefully place 2.5-3.5 kilos of charcoal in the charcoal bowl. If you chose to use lighter fluid or fire starters carefully follow the manufacturer’s warnings.

4. If using lighter fluid, saturate charcoal with lighter fluid and wait 2 to 3 minutes for fluid to soak in. Store charcoal lighter fluid safely away from Smoker & Grill.

5. Carefully light the charcoal and allow to burn until covered with a light ash prior to closing door and continuing to Step 6. This may take up to 30 minutes, if you use a Charmate Chimney Starter this may take less time.
   WARNING
   Failure to do this could trap fumes from charcoal lighting fluid in Smoker & Grill and may result in a flash-fire or explosion when door is opened or dome lid is removed.

6. Place a cooking rack on the lower body.

7. Place food on the cooking rack in a single layer with space between each piece.

8. For best results, the dome lid should be placed on the lower body when grilling food.

9. Always use a meat thermometer to ensure food is fully cooked before removing from Smoker & Grill.

10. After cooking, allow Smoker & Grill to cool completely then follow instructions in the “After-Use Safety and Proper Care & Maintenance” sections of this manual.

WARNING
When grilling, dripping from meat may cause flame flare-ups. Use extreme caution when removing the dome lid. Do not use water to extinguish a grease fire.
Flavoring Wood
To obtain your favorite smoke flavor, experiment by using chunks, sticks or chips of flavor-producing wood such as manuka, apple or cherry.
Most fruit or nut tree wood can be used for smoke flavoring. Do not use resinous woods such as pine as it will produce an unpleasant taste.
Wood chunks or sticks 7.5-10cm long and 1.25-2.5cm thick work best. Unless the wood is still green, soak the wood in water for 20 minutes or wrap each piece in foil and tear several small holes in the foil to produce more smoke and prevent the wood from  burning too quickly. A lot of wood is not required to obtain a good smoke flavor. A recommended amount is 3-4 wood chunks or sticks. Experiment by using more wood for stronger smoke flavor or less wood for milder smoke flavor.

Option 1: Adding Water or Wood during Cooking

Additional flavoring wood should not have to be added during the cooking process, however it may be necessary when cooking very larger pieces of meat. Follow the instructions and cautions below to avoid injury while adding water and/or wood.

1. Remove dome lid by tilting it away from you to allow heat and steam to escape away from your face.
   Use caution since flames can flare-up when fresh air suddenly comes in contact with fire.

2. Wearing oven mitts carefully remove upper body from lower body.
   WARNING
   The water in water bowl will be extremely hot.
   When lifting upper body from lower body, use extreme caution and make sure the water bowl is securely in place on the three lower support brackets.
   Keep legs and feet out from under the upper body to avoid being scalded by hot liquids spilling from water bowl. Be extremely careful not to tilt or jar the Smoker & Grill so that hot water does not spill out of water bowl.

3. Set the upper body on a hard, level non-combustible surface.

4. Stand back a safe distance and use long cooking tongs to add wood, being careful not to splash water.

5. If water level is low, add water to water bowl. If food is on top cooking rack only, water may be added to the water bowl by moving food aside on cooking rack and pouring water down through the cooking rack.
   Fill water bowl to 2.5cm below the rim. Pour slowly to avoid splashing or overfilling.

6. Using oven mitts replace upper body on lower body.
   Keep legs and feet out from under Smoker & Grill body to avoid being scalded by hot liquids spilling from water bowl. Be extremely careful not to tilt or jar Smoker & Grill so hot water does not spill out of water bowl.

7. Replace food on cooking racks then place the dome lid on upper body.

Option 2: Adding Charcoal or Wood during Cooking

1. Stand back and carefully open side door using pliers or similar tool. Use caution since flames can flare-up when fresh air suddenly comes in contact with fire.
2. Add charcoal or wood using long tongs.
3. Close side door and allow food to continue cooking.

Cooking Tips

• Variations in flavor can be achieved by adding wine, soft drinks, herbs, spices, bits of citrus peel, fruit juice, onion or marinades to the water bowl.
• Brush poultry and naturally lean meats with cooking oil, butter or margarine before cooking.
• Meat should be completely thawed before cooking.
• When cooking more than one piece of meat, the cooking time is determined by the largest single piece being cooked.
• The meat bastes itself while cooking in the Smoker & Grill. No basting or turning is necessary after the meat is placed on the rack. For added variety, barbecue sauce or marinade may be applied on meat before placing on rack.
• There is very little difference in temperature and cooking time between top and bottom rack levels. When cooking different types or cuts of meat at the same time, place the meat that requires the least cooking time on the top cooking rack so that it may be easily removed first. If only one cooking rack is required, use the upper rack level for the best result.
• During the smoking process, avoid the temptation to lift dome lid to check food. Lifting the dome lid allows heat to escape, making additional cooking time necessary.
• Always use a meat thermometer to determine if food is done. Many variables (outside cooking temperature, amount of charcoal, the number of times the dome lid is removed, proximity of food to heat source, etc) will affect actual cooking times. When using a meat thermometer, place probe mid-way into the thickest part of the meat, making sure that it does not touch any fat or bone. Allow five minutes for the thermometer to properly regulate temperature.

After-Use Safety

• Always allow Smoker & Grill and all components to cool completely before handling.
• Never leave coals and ashes in Smoker & Grill unattended.
• Before Grill can be left unattended, remaining coals and ashes must be removed from Smoker & Grill. Use caution to protect yourself and property. Place remaining coals and ashes in a non-combustible metal container and completely saturate with water. Allow coals and water to remain in metal container 24 hours prior to disposing.
• With a garden hose, completely wet surface beneath and around the Smoker & Grill to extinguish any ashes, coals or embers which may have fallen during the cooking or cleaning process.
• Extinguished coals and ashes should be placed a safe distance from all structures and combustible materials.
• Cover and store Smoker & Grill in a protected area, out of reach of children.

Proper Care & Maintenance

• Wash cooking racks, water and charcoal pans with hot soapy water, rinse well and dry. Lightly coat cooking racks with vegetable oil or vegetable cooking spray.
• Clean inside and outside of Smoker & Grill by wiping off with a damp cloth. After cleaning, apply a light coat of vegetable oil or vegetable cooking spray to the interior surface of the dome lid, smoker body, cooking racks and water bowl. This simple process will help reduce interior rusting. Do not apply oil to the charcoal pan.

Note:
Smoke will accumulate and leave a residue in the dome lid of your unit that may drip onto food during cooking.
To minimize accumulation of residue, wipe off dome lid after each use.

• If rust appears on the exterior surface of your Smoker & Grill, clean and buff the affected area with steel wool or fine grit emery cloth. Touch-up with a good hightemperature resistant paint.
• Never apply paint to the interior surface. Rust spots on the interior surface can be buffed, cleaned, then lightly coated with vegetable oil or vegetable cooking spray to minimize rusting.
• Always keep your Smoker & Grill covered when not in use to protect against excessive rusting.

WARNING
Failure to read and follow this manual and the safety warnings herein may result in serious bodily injury or death, or ina fire or an explosion causing damage to property.
Important
Check with your local council regarding fire bans before using your Charcoal BBQ.
Check with your local council regarding air quality regulations.
IMPORTANT Only use this Charcoal BBQ on a flat, level non-flammable surface or ground.
** This product is for OUTDOOR USE ONLY. NEVER use in an enclosed space such as a carport, garage, veranda, covered patio, or under an overhead structure of any kind.
ATTENTION! This Charcoal BBQ will become very hot. Do not attempt to move it during operation.
WARNING! Keep children and pets away from the Charcoal BBQ when in use. Any modification of this BBQ may be dangerous.
**When positioning, ensure the Charcoal BBQ is a minimum of 1 metre from flammable items or structures.
Do not overfill metal tray with burnable products.
Never handle hot parts with unprotected hands.
** Do not use indoors. If used indoors, toxic fumes can build up and cause bodily injury or death. Only use outdoors in a well-ventilated area.
ATTENTION! This Charcoal BBQ should not be used under overhead combustible construction.
** Do not leave this Charcoal BBQ unattended when in use.
Do not add starter fluid or Charcoal impregnated with starter fluid to warm or hot fires.
Do not use clothing with long or loose sleeves when operating the BBQ.
Do not use the BBQ in high winds. Do not touch the BBQ with your hands to check if it is hot.
Do not use water to control flare-ups or extinguish Charcoal. Always extinguish your BBQ when not being monitored
Do not dump hot Charcoal s where they may cause a fire hazard. Do not store away or cover the BBQ until the embers are extinguished and removed, and the BBQ is fully cooled.
This BBQ is not intended to be used in recreational vehicles or boats.
CAUTION! Do not use petrol, spirit or lighter fluid for lighting or re- lighting the BBQ!
Do not allow grease, fat or food residue to build up in or on the barbecue — RISK OF FIRE.
Do not hang any combustible materials from the handrails of this Charcoal BBQ.
Never overload the cooking grill with food — evenly space food over the cooking grill surface.
Barbecue mitts should always be used while cooking, lighting or adjusting barbecue vents and handling the barbecue.

EXPLODED DIAGRAM

ASSEMBLY INSTRUCTIONS

For Easiest Assembly:

• To avoid losing any small components or hardware, assemble the product on a hard level surface that does not have cracks or openings. You may wish to lay down a blanket or similar, to avoid possible damage to the finish during assembly.
• Clear an area large enough to lay out all components and hardware.
• Great care has been taken during manufacturing to remove sharp edges but you should handle all components with care to avoid injury.
• Check you have all components before beginning assembly.
• When applicable, tighten all hardware connections by hand first. Once the step is completed go back and fully tighten all hardware.
• Follow all steps in order to properly assemble the product.

Tools required:

• Adjustable Spanner or Socket Wrench
• Phillips Screwdriver

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RECIPE IDEAS

Smoked Chicken
1 chicken
50ml olive oil
Juice of one lemon
Salt & Pepper
Mix the olive oil and lemon juice together in a cup or ramekin and then use a meat injector to inject into the breast and the thighs. Use the last few drops of the mix to rub over the skin and then sprinkle with salt and pepper.
Load the chicken onto the cooking rack and place it in the smoker at 110°C or 225°F for 60 minutes per .5 kilo.
It’s important to make sure the chicken is properly cooked so ensure the juices run clear when a skewer is placed in the meat or use a thermometer. Breast meat should be at 165°F and thigh meat at 175°F.

Smoked Herbed Chicken
1 (approx. 2 kilos) whole chicken
45 g butter
4 g chopped fresh parsley
6 g chopped fresh oregano
3 g chopped fresh basil
3 g fresh chives, finely chopped
Preheat outdoor Smoker & Grill for low heat. Using hickory is a great option if you want to add additional flavour to the chicken.
Rinse chicken inside and out and pat dry. Loosen skin around the breast area.
Place three tablespoons of butter in various places under the skin. Mix herbs together and place half under the skin and the other half inside the chicken.
Cook chicken in Smoker & Grill for 4 hours or until juices run clear when poked with a fork.

Smoked Mushrooms
4 cups mushrooms
2 tablespoons lemon pepper
2 tablespoons garlic powder
Cut mushroom stems off and wash. Sprinkle lemon pepper and garlic powder lightly over mushrooms. Smoke at 225°F for 45 minutes. Cool; serve immediately.

Manuka Smoked Trout
120 g x 4 portions Trout
Brown sugar
Salt & Pepper
2 handfuls Manuka chips
Coriander
Fillet trout taking care to remove all bones. Tie 2 fillets together at a time with string, having placed a sprig of coriander inside each. Sprinkle trout with the brown sugar, salt and pepper. Place Manuka wood chips into Smoker & Grill and place seasoned fish onto the grill above the chips.
Starting with a high heat to get a strong scent of Manuka, then turning down to allow a slow consistent cooking with the Manuka smoke. This results in a beautiful caramel colour and tender pink centres. When cooked, remove string and serve as required.

Smoked Mussels
Steam required quantity of mussels open. Marinate in sweet chilli sauce for 4 – 24 hours with a little brown sugar added. Smoke for approximately 20 minutes.
Smoked Corn on the Cob
6 to 12 ears of corn with husks on
1/2 cup olive oil
1 bunch finely chopped green onions (including tops)
Gently pull back the husks on the each ear. Remove the silk but not the husks. Place the ears in a large pot and cover with water. Let sit for several hours.
Remove from water and brush each ear of corn with olive oil, then sprinkle about 2 teaspoons green onion over.
Cover corn with husks. Repeat with each ear of corn.
Prepare smoker. The ears of corn will need to smoke at 225°F for about 1 1/2 hours.
When done smoking, remove husks and eat.

Distributed by: The Warehouse LTD.,
PO Box 33-470, Takapuna, Auckland, New Zealand

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