Assembly and Owner’s Manual Gas Smoker 2505G 3405G 3405GW 3405BG 3005G 3405GT 3605G 3405BGW ASSEMBLER / INSTALLER: Leave these instructions with the consumer. CONSUMER / USER: Read all of these instructions and keep them in a safe place for future reference. DANGER If you smell gas: 1. Shut off gas to the appliance. 2. Extinguish any open flames. 3. Open door. 4. If odor continues, keep away from the appliance and immediately call your gas supplier or your fire department. WARNING 1.
Statement of Commitment Congratulations and thank you for your purchase of your new Smoky Mountain Series smoker. We are pleased that you have recognized the value of the design, function, and quality of components used in this product. We believe it is among the finest on the market. We are committed to producing quality products that your family will enjoy for years to come.
READ ALL INSTRUCTIONS AND WARNINGS! YOUR SAFETY IS VERY IMPORTANT - FAILURE TO FOLLOW PROPER PROCEDURES AND SAFEGUARDS MAY RESULT IN SERIOUS PERSONAL INJURY OR PROPERTY DAMAGE. DO NOT use this smoker in a manner other than its intended purpose. It is NOT intended for commercial use. It is NOT intended to be installed or used in or on a recreational vehicle and/or boats. The smoker is not to be used as a heater. Keep a fire extinguisher accessible at all times.
Use caution when opening the door of the 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 the smoker and its components to cool completely before conducting any routine cleaning or maintenance.
Assembly Step 1 - Identifying the parts Check your package contents for these parts. If you are missing any parts, or if any parts are damaged, please call our toll-free customer service line to order parts.
Assembly Step 1 - Continued Check your package contents for these parts. If you are missing any parts, or if any parts are damaged, please call our toll-free customer service line to order parts. DO NOT RETURN YOUR SMOKER TO THE RETAILER - CALL US FIRST! 1-800-944-8982 Item No.
Assembly Step 2 Locate these parts: Tools needed: 4 Legs Cabinet Assembly HARDWARE BAG Hardware: 1/4-20 x 5/8” Bolts 16 Required 1. Set the cabinet assembly top side down. 2. For each leg, line up the holes and insert the bolts. Nuts are pre-welded to the cabinet. IMPORTANT: One leg contains an extra hole on its side and must be mounted at the front in the position shown. This hole will later be used to secure the gas hose to the leg with a zip-tie. Leg with extra hole 3.
Assembly Step 3 Locate these parts: Tools needed: Control Panel Assembly HARDWARE BAG Hardware: 1/4-20 x 5/8” Bolts (2 Remaining from previous step) 1. Place the Control Panel Assembly between the front legs as shown. There are slots on the control panel that fit around the legs. The mounting tabs fit to the inside of the legs and line up with the bolt holes. 2. Be sure all the tabs on the back side of the control panel are captured around the legs as shown below. 3.
Assembly Step 4 Locate these parts: Tools needed: Burner Assembly HARDWARE BAG Hardware: 1/4-20 x 1/2” Bolts 3 Required 1. Set the burner assembly onto the cabinet as shown. IMPORTANT: The burner tube must slide properly onto the valve stem as shown below. 2. Secure the burner assembly with the three bolts from the inside of the cabinet. Securely tighten the bolts. 3. Attach the loose igniter wire to the igniter on the control panel as shown below.
Assembly Step 5 Locate these parts: Tools needed: Damper Plate Phillips Head Screwdriver HARDWARE BAG Hardware: 10-24 Nut 1 Required 10-24 Lock Washer 1 Required C 3/8” Wrench 10-24 x 5/8” Bolt 1 Required 1. Turn the smoker upright. 2. Set the damper plate on top of the cabinet and line it up with the corresponding “butterfly” holes. One of the tabs will seat inside one of the holes. Bolt 3. Insert a bolt from the top through the center hole. Damper 4.
Assembly Step 6 Locate these parts: Tools needed: Phillips Head Screwdriver 2 Carry Handles HARDWARE BAG Hardware: 1/4-20 Nuts 8 Required 1/4 Lock Washers 8 Required 1/4-20 x 5/8” Bolts 8 Required 1. Line up the carry handle with the corresponding holes on the side of the cabinet as shown. The handles must be positioned upright with the bolt holes on the bottom as shown. 2. Insert the bolts from the outside and thread the lock washers and nuts from the inside of the cabinet. 3.
Assembly Step 7 Locate these parts: Wood Box Rack Wood Chip Box and Lid No tools or hardware are required for this step. 1. Insert the wood box rack into the bottom of the smoker. The feet of the rack sit in the four indentions in the bottom. 2. Set the wood chip box onto the rack. Make sure it is seated properly and securely in the center of the rack. 3. Place the lid on the wood chip box.
Assembly Step 8 Locate these parts: Cooking Grids Water Pan No tools or hardware are required for this step. 1. Slide the water pan into the bottom rack position as shown. 2. Insert the cooking grids into any of the remaining rack positions as desired. For best access, the grid wires should run front to back as shown.
Assembly Step 9 Locate these parts: HARDWARE BAG Door Handle Kit E Tools needed: Mounting Bracket 1/4-20 x 3/8” Bolts and 1/4-20 Lock Washers (2 ea) Handle Spring Handle Washer Phillips Head Screwdriver 1. Slide the handle washer onto the end of the door handle, followed by the handle spring as shown. 1 2. Feed the door handle into the hole through the front of the door panel. 3. From the back side of the door panel, insert the mounting bracket over the end of the handle as shown. 4.
Assembly Step 10 HARDWARE BAG Locate these parts: F 2 Push Nuts Nameplate with Heat Indicator No tools are required for this step. 1. Insert the name plate mounts and heat indicator prong through the mounting holes in the front of the door panel. 2. From the inside of the door panel, securely attach the push nuts to the name plate mounts.
Assembly Step 11 HARDWARE BAG Locate these parts: G Tools needed: S-Hook Pliers Zip Tie Using the zip tie, secure the hose to the front leg as shown. Do not pull the zip tie tight - leave it just loose enough so that the hose can be adjusted if needed. Tying the hose to the leg helps prevent the hose from coming into contact with the hot burner chamber. Inspect the installation underneath the smoker to ensure that the hose is not rubbing any portion of the burner chamber. 1.
Connecting the LP Tank ALL INSTRUCTIONS AND SAFEGUARDS ON THIS PAGE MUST BE FOLLOWED TO PREVENT FIRE, DAMAGE, AND / OR INJURY. 1. The knob on the LP tank must be closed. See that the knob is turned clockwise to a full stop. 2. Check that the control knob on the smoker is turned off. 3. Remove the protective cap from the LP tank valve and coupling nut, if present. 4. Hold the regulator in one hand and insert the nipple into the valve outlet. Be sure the nipple is centered in the valve outlet.
Connecting the LP Tank - Continued ALL INSTRUCTIONS AND SAFEGUARDS ON THIS PAGE MUST BE FOLLOWED TO PREVENT FIRE, DAMAGE, AND / OR INJURY. Cylinders must be filled before initial use. All handling, transport, filling and storage of LP gas cylinders must be in accordance with NFPA 58 Storage and Handling of Liquid Petroleum Gases, or CSAB 149.1 Natural Gas and Propane Installation Code. Cylinders must be suitably tied down during transport. Do not place any other items on top of cylinders at any time.
Operating Instructions Pre-Use Procedures Your smoker has been packaged with a retail store level point-of-purchase label that hangs on the front of the door panel. This label must be removed before use. To remove the label, simply cut or tear along the indicated line and pull the top portion of the label from behind the name plate. Before you cook food in your smoker, it is important to “season” your smoker.
Adding Wood / Charcoal To add wood chips before cooking, simply fill the wood chip box with your choice of flavoring hardwood chips. The amount and type of wood you use is entirely up to you. One full box is typically enough for several hours of smoking. Once the box is filled, place the lid on top of the box and set the box in the smoker.
Lighting Procedure Igniter Lighting System: 1. Check all connections for leaks using the “soapy water” test as explained on page 16. 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 1-1/2 turn by turning counter-clockwise. 6. To light unit with the igniter, push in and turn the burner control knob counter-clockwise to the high setting. 7.
Cooking Tip – Damper Adjustments: ) For better performance, rotate the smoker to where the front or back of the cabinet is facing the wind. This allows the adjustment of the dampers to be more effective and accurate. ) The dampers should never be fully closed. ) Opening a side damper allows more oxygen to be consumed by the fire, fueling the flames and causing an increase in temperature. ) Opening the top damper helps to exhaust both the heat and smoke.
Cooking Instructions IMPORTANT: Before each use, clean and inspect the hose and the connection to the LP cylinder. If there is evidence of abrasion, wear, cuts or leaks, the hose must be replaced before the smoker is used. Refer to the “leak test” instructions in the LP Tank connection portion of this manual. Fill the wood chip box with flavoring wood chips and place the box inside the smoker as instructed in the assembly section of this manual.
Temperature Chart Here is a chart for measuring properly cooked meat temperature: (USDA Standard) Ground Meat & Meat Mixtures Turkey, Chicken Veal, Lamb Beef, Pork 165° (74° ) 160° F (71°C) 160°F (71°C) Fresh Beef Medium Rare Medium Well Done 145°F (63°C) 160°F (71°C) 170°F (77°C) Fresh Lamb Medium Rare Medium Well Done 145°F (63°C) 160°F (71°C) 170°F (77°C) Fresh Veal Medium Rare Medium Well Done F F C Poultry Chicken, whole Turkey, whole Breasts, roast Thighs, wings Duck and Goose 180°F 180°
After Use Safety and Maintenance Use caution when lifting and moving the smoker to avoid strains or back injury. 2 people are recommended to lift or move the smoker. DO NOT store the smoker near gasoline or other combustible liquids or where combustible vapors may be present. Keep the area around the smoker clear and free of combustible materials and vapors. DO NOT store this smoker in an area accessible to children or pets. Store the smoker in a dry, protected location.
Manufacturer’s Limited Warranty ® TM The Great Outdoors Smoky Mountain Series smoker is guaranteed against broken or damaged parts at the time of purchase. The cast brass burner is guaranteed for 10 years. All other parts carry a 1-year limited warranty except the water bowl, which is guaranteed to be free of defects for 90 days. Paint is guaranteed to be free of defects for 90 days except for rust, which may appear after repeated use.
©2004 CFM Home Products. Smoky Mountain Series, the Smoky Mountain Series logo, and the Great Outdoors Grill Company logo is a trademark of CFM Home Products and not to be used without express permission by the owners and managers of CFM Home Products.
