Grillstar 6024 User manual

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GAS SMOKER

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Please read the instructions carefully before assembling
and using the appliance
General hints for a successful assembly:
Carefully read the assembly instructions and the listed safety hints.Take time to
assemble the barbecue and allow for a free area of approximately two - three square
metres.

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Parts：
R: M6X10 Bolts(18)
M6 Nuts(18)
S: Air Vent(3)
M6X10 Bolts(3)
M6 Nuts(3)
T: Dial(1)
Thermometer(1)
M5X8 Bolts(2)
Push Nut(1)
Silicone Washer(1)
U: Door Handle(1)
Cam Latch(1)
Wave Washer(1)
M12 Nuts(2)
V: Wire Handle(2)
M6X15 Bolts(4)
M6 Nuts(4)

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Preparation:
Check that all parts are complete as per the list and drawing. Have the tools ready:
Box wrench 8 mm or Pliers and a suitable Philips screwdriver.
Note: Firstly assemble all parts in a loose way, upon completion tighten all nuts and
bolts securely. WARNING !
Carefully read the assembly instructions and the listed safety hints.
Use outdoor only.
Mounting steps:

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Assemble Legs
1. With the smoker cabinet in the upright position remove the door by
lifting it from the hinges. Set the door panel aside. This will make
assembly much easier.
2. Set the smoker assembly upside down. Set the smoker cabinet on a
padded surface such as cardboard or carpet to prevent scratching or
damaging your smoker.
3. Assemble 4 legs and the front panel as shown using M6X10
Bolts/M6 Nuts. Assemble Burner & Attach Regulator Hose
Important: Assemble the front panel to the front legs before installing
the inside bolts as this bolt must pass through the front panel and the
leg.

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Assemble Burner & Attach Regulator Hose
1.Leave the smoker cabinet upside down.
2.Assemble the burner drum assembly as shown to the smoker
cabinet using M6X10 Bolts/M6 Nuts.
3.Attach the regulator hose to the brass fitting on the manifold as
shown. Use a wrench to tighten the hose to the brass fitting.
4.Stand the smoker upright on its legs.
5.After installing the burner and regulator hose, check for leaks
around the hose connection and manifold using a soap solution.
Checking for Leaks.

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Attach Damper Vents
1. Assemble 1 damper venton top of smoker as shown using the
hardware provided.
2. Tighten the nut enough to keep the damper vent snug but allow it to
rotate with little resistance.
3. Repeat steps 1 and 2 for the two remaining side damper vents.
Assemble Handles

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1. Assemble the carry handle as shown to the smoker cabinet using
M6X10 Bolts/M6 Nuts.
2. The nuts should be firmly tightened to the bolts.
3. Repeat steps 1 and 2 for handles on both sides of the smoker
cabinet.
Assemble Door
1. Re-mount the door panel by sliding the door’s hinge pins into the
cabinet’s hinge seats.
2. Assemble the door handle as shown using the handle, wave washer,
and two M12 nuts.

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3. Tighten the first M12 nut until the desired resistance of the handle
is achieved.
4. Tighten the second M12 nut on the first to keep the nuts from
loosening.
5. Install the dial as shown using two M5X8 bolts.
6. Install the thermometer through the dial and door and secure using
the supplied push nut.
Knob, Trays and Grids
1.Push the knob onto the valve stem as shown.

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2.Set the grease pan in the bottom of the smoker as shown.
3.Set the chip tray in the first rack position of the smoker.
4.Set water tray in the second position of the smoker.Insert the
cooking grids into any of the remaining positions as desired.
Knob, Trays and Grids
When Inserting the smoking
racks, make sure that the
longest bar is on the top as
shown at right.

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ADDITIONAL WARNING
DO NOT use this smoker in a manner other than its intended purpose.
Not intended for commercial use. Not intended to be installed or used in or
on a recreational vehicle or boat.
When cooking with oil/grease, a fire extinguisher must be readily
accessible. In the event of an oil/grease fire do not attempt to extinguish
with water. Use Type BC dry chemical fire extinguisher or smother fire with
dirt, sand of baking soda. In the event of rain while cooking with oil/grease,
cover the cooking vessel immediately and turn off the appliance burners
and gas supply. Do not attempt to move the appliance or cooking vessel.
The use of alcohol, prescription or non-prescription drugs may impair the
consumer’s ability to properly assemble or safely operate this appliance
FOR OUTDOOR USE ONLY! Do not operate the smoker indoors, in a
garage, or in any other enclosed area or under overhead construction.
Don’t use on or under any apartment, condominium, balcony or deck. Do
not operate smoker near flammable materials such as decks, fences,
porches or carports. A minimum clearance range of 36 inches is
recommended. Do not store the smoker near gasoline or other combustible
liquids or where combustible vapors may be present.
Use caution when assembling and operating smoker to avoid cuts and
scrapes from rough or sharp edges.
Use caution when lifting or moving the smoker to avoid strains or back
injury. 2 people are recommended to lift or move the smoker. Do not move
the smoker while it is in use. Allow the smoker to cool to 115°F (45°C)
before moving or storing.
When cooking, the appliance must be on a level, stable surface in an area
clear of combustible material. An asphalt surface (blacktop) may not be
acceptable for this purpose. Do not operate smoker on flammable material
such as carpet or a wood deck. NEVER use gasoline or highly volatile
fluids as a starter.

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Store the smoker in a dry, protected location.
This appliance is not intended for and should never be used as a heater.
DO NOT leave smoker unattended while in use. Operate the smoker with
close supervision. Do not leave hot ashes unattended until the smoker
cools completely.
DO NOT operate around children or animals. Do not conduct activities
around smoker during or following use until cooled. Do not bump or tip
smoker.
If Smoker becomes extremely hot -allow smoker to cool completely before
handling. If you must handle the smoker while it is hot, always wear
protective oven mitts or heat resistant gloves.
The water tray and wood chip box should not be moved while smoker is
operating or until smoker has cooled sufficiently. These contain hot ashes
and liquids that may cause serious injury. If you must move these
components, ALWAYS wear protective oven mitts or heat resistant gloves
when handling the smoker or its components.
Dispose of cold ashes by wrapping them in heavy duty aluminum foil and
placing in a non-combustible container. Be sure there are no other
combustible materials in or near the container.
DO NOT obstruct flow of combustion air and/or ventilation air for smoker.
Use caution when opening the door of smoker while in operation. Keep
hands, face, and body safe from hot steam or flare-ups. Protect your nose
and mouth from smoke inhalation.
Do not wear loose clothing while operating the smoker. Tie back long hair
while operating the smoker. ALWAYS wear fully-covering shoes while
operating the smoker.
Allow smoker and its components to cool completely before conducting any

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routine cleaning or maintenance. Do not move the appliance when in use.
Never use glassware, plastic or ceramic cookware on or in smoker.
NEVER operate smoker without water in the water tray. NEVER allow the
water to completely evaporate. Check the water level at least every 2 hours.
A sizzling sound may indicate a low water level. Follow instructions in this
manual for adding water while operating.
When using flavoring wood, add a sufficient amount prior to operation to
avoid having to add wood while operating. Adding wood while operating
may splash hot water and cause serious injury.
Use of accessories not intended for smoker is not recommended and may
lead to injury or property damage.
An LP cylinder not connected for use should not be stored in the vicinity of
smoker or any other appliance. Do not store spare LP cylinders within 10
feet of smoker. LP cylinders must be stored outdoors, out of reach of
children.
Do not store a spare LP-gas cylinder under or near this appliance. Never fill
the cylinder beyond 80 percent full. Failure to follow these instructions
exactly could result in a fire causing death or serious injury.
The smoker should be shut off and all supply valves (on piping or on fuel
cylinders) should be closed in the event that the odor of unburned gas is
detected. Do not attempt to use the unit until any gas leaks are fixed. Do
not use the smoker if the burner fails to light or fails to remain lit. Under
such conditions, gas should be shut off and fuel cylinders should be
disconnected. Do not operate under high wind conditions.
LP tanks are intended for operation in the upright position only.
Care should be taken to protect the fuel supply hose from damage from
either foot or vehicle traffic.
If the appliance is not in use, the gas must be turned off at the supply
cylinder and the cylinder should be disconnected from the appliance

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Storage of the appliance indoors is only permissible if the cylinder is
disconnected and removed from the appliance.
All installations are to conform to local codes. In the absence of local codes,
installation should conform to the National Fuel Gas Code, ANSI
Z223.1/NFPA 54
Smoker should be installed with the hose regulator assembly extended at
full length of hose directly away from the burner. Keep fuel supply hose
away from any heated surfaces. When so configured, placement results in
maximum tank to smoker distance. When smoker is operated, the
hose/regulator and gas tank should be on a line perpendicular to wind
direction. Placing tank closer than 24” to the smoker can overheat the tank
and cause release of propane through relief openings and can result in
tank fire or explosion.
Gas cylinder
.This barbecue has been adjusted to be operated off 4.5 to 15kg
The regulator can be used must comply with the EN 16129.
. Always connect or replace the cylinder in a well-ventilated area, never
in the presence of a flame, spark or heat source.
. Connect the flexible tubing to the coupling on the bbq and the
connector on the regulator by following the instructions for the
connector assembly.
Use leakage detecter to check the sealing.
. Make sure the flexible tubing is not twisted or under stress and does
not come into contact with any hot surface on the unit.
The length of flexible hose can be used shall not exceed 1.5m. In
Finland, the length of flexible tube cannot exceed 1.2m.
The flexible tube should be changed whenever it is damaged or cracked
or when the expiration date, which is printed on the tubing, is due. Or
change the tubing every 5 years.
It is necessary to change the flexible tube when the national conditions
require it, and/or depending on its validity.
Avoid twisting the flexible tube when the appliance is in use.
. Do not pull or pierce the tubing and keep away from any parts of the
bbq that get hot.
Checking for gas leaks

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1) Work outside, away from all sources of ignition. Do not smoke.
2) Make sure the control knobs are in the “off” position.
3) Push the end of the hose completely onto the regulator nozzle and
secure with a suitable clip.
4) Fit the regulator onto the gas cylinder in accordance with its
instructions.
5) Use a gas leakage detecter to test for leaks. Important : never use a
naked flame to check for gas leaks.
6) Check all the connections: cylinder/regulator/hose/apparatus (the
control knobs should remain closed: off position). Open the gas
cylinder valve.
7) Bubbles in the gas leak solution indicate that there are gas leaks.
8) The leak can be stopped by tightening any hose connection or replacing
any faulty component. The barbecue must not be used until the leak is
stopped. Close the valve on the gas cylinder. Check for leaks at least once
per year and each time the gas cylinder is replaced.
Low Temperature Smoking:
•When smoking at low tempratures for jerky of fish, use a tuna can or tin foil
to place the chips in and set directly over the burner. You will need to soak
the chips and cover with foil to keep from burning.
•Use wood shavings instead of chips or chunks. Leave door open and turn
on high for several minutes until chips begin to smoke. Then turn down to
cooking temperature. This may have to be repeated several times during
the cooking process in order to keep the shavings smoking.
OPERATING INSTRUCTIONS
Pre-Use Procedures
Before you cook food in your smoker,it is important to “season” your
smoker. Seasoning seals the paint and interior of your smoker to enhance
flavoring, durability and overall performance. This is also referred to as the
“break-in” process.If your smoker requires any touch-up paint on the inside
of the cabinet, the only time you should apply paint to the inside is before
the seasoning process. Paint should not be applied to the interior of your
smoker after your smoker has been used. Paint toxins may contaminate
your food. Use only high temp paint. To season your smoker, simply use it

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as you normally would; only do not cook any food. You will need to follow
all of the operating procedures in the next few sections of this manual.
Using your desired flavoring woods and marinades, burn your smoker at
low temperature (around 175°F) for 45-60 minutes. Let the smoker cool,
and clean out the used water and wood. Once seasoning is complete, your
smoker’s interior will have a durable, seasoned coating.
Adding Water
To add water before cooking, simply remove the water tray and fill it with
water up to 1” below the rim. Then replace the tray to the bottom of the rack.
To add water while the smoker is hot, DO NOT pull the water tray out
beyond the rack.
Adding Wood/Charcoal
To add wood chips before cooking, simply fill the wood chip tray with your
favorite choice of flavoring hardwood chips. The amount and type of wood
you use is entirely up to you. One full tray is typically enough for several
hours of smoking. Once the box is filled, set the tray in the smoker. To add
wood chips while cooking, we recommend using tongs or long handled
pliers to place the pieces into the wood chip tray without removing the tray.
It is not recommended to remove the wood chip tray while the smoker is in
operation.
CAUTION: The wood chip tray gets very hot. Avoid handling while in use.
Always wear protective oven mitts or heat resistent gloves when handling
hot components.
Lighting Procedures
1. Check all connections for leaks using the “soapy water” test.
2. Open the smoker cabinet door.
3. Check for any blockage to the venturi tube or burner. Remove
any foreign objects or matter.
4. Be sure the burner control knob is in the “OFF” position.
5. Open the LP cylinder valve ONLY 1-1/2 turns by turning
counter-clockwise.

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6. Turn the burner control knob slowly counter-clockwise to the high setting.
The ignitor should spark and ignite the burner.
7. You should see a small spark and hear the ignitor click. If the burner
doesn’t light, turn the control knob off then repeat the above steps again.
8. Once the burner is lit, then close the door to allow heat to accumulate.
The dampers can then be adjusted to the desired setting to allow proper air
flow and combustion. Damper adjustment tips are listed on the next page.
Long-nose Gas Match Lighting
1. Repeat steps 1 thru 5 of the Ignitor Procedures above.
2. Remove the Wood Chip Tray from inside the smoker. Insert a longnose
gas lighter next to the burner drum, making sure it sits over the burner.
Quickly turn the control knob to the light position. If the burner does not light
within 4 or 5 seconds, turn the control knob off, wait 5 minutes, and repeat
the process.
Shutting the Smoker Off
CAUTION: The smoker can become very hot while in use. Do not touch
any portion of the smoker except for the door handle and burner control
knob. It may be necessary to use protective gloves. Turn the burner control
knob off by pushing in and rotating clockwise. The burner flame should
then go out. Turn off the LP cylinder valve by turning the knob clockwise
until it stops. Following all warnings and safety precautions before
removing meat from the smoker or preparing the unit for storage. Follow
instructions in this manual for proper storage procedures and the important
warnings and safequards on pages.

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Burner Flame Check
• Light burner; rotate knob(s) from HIGH to LOW. You should see a smaller
flame in LOW position than seen on HIGH. Always check flame prior to
each use. A blue flame with little or no yellow flame provides the best heat.
If you have a yellow flame clean the unit following the Cleaning instructions
on the back of this instruction manual.
Cooking Instructions
Fill the wood chip box with flavoring wood chips and place the box inside
the smoker as instructed in the assembly section of this maual. Refer to the
section that explains flavoring wood for recommended use of flavoring
wood.
Place the water tray inside the smoker in the lowest rack position as
explained in the assembly section of this manual. Carefully fill the water
tray with water or marinade up to 1 inch below the rim. A full tray will last for
approximately 2-3 hours. Do not overfill or allow water to overflow from the
water tray.
You are now ready to light the burner. Refer to the Lighting Procedure on
the previous pages of this manual. The heat from the burner will allow the
wood chips to burn, causing the flavoring smoke to accumulate. Adjust the
dampers to control the heat. Place the food on the cooking grids in a single
layer with space between each piece. This will allow smoke and hot
moisture to circulate evenly around all the food pieces. Smoking for 2 to 3
hours at the ideal constant cooking temperature of 200°F to 225°F will get
the best results. This temperature is according to the heat indicator
mounted on the front of the smoker. For more tender and heavily smoked
meat, a lower temperature may be preferred. If time is critical, a higher
temperature range is recommended.
Check water level periodically and add water if low. For best results and
to retain heat, avoid opening the door of the smoker while in use. When the
door must be opened, only open it briefly. The smoker will quickly resume
cooking temperature after the door is closed.
Always use a meat probe thermometer to ensure food is fully cooked
before removing it from the smoker.
After each use, and after the smoker is cooled, carefully remove the grease

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pan from the bottom of the smoker, empty the grease, and clean the grease
pan.
Operation and Maintenance
Do not use charcoal as a substitute for, or in addition to, lava rock.
·Do not use an adjustable low pressure regulator.
·Do not cover the bottom of the base with aluminium foil.
·Never put a metal plate, or accessories on (or in the place of ) the lava
Rock
Follow these instructions carefully to avoid seriously damaging your
barbecue.
a) For your safety
This appliance must be kept away from flammable materials during use.
Do not store or use petrol and other flammable liquids or vapours in the vicinity
of this barbecue. If you smell gas:
1) Close the valve of the cylinder
2) Extinguish all naked flames
3) Open the lid
4) If the smell continues, see for gas leakage or immediately seek advice from
your local retailer.
b) Location
.This barbecue must only be used outdoors.
.Caution: accessible parts may get very hot. Keep young children away.
c) Gas cylinder