Broil King Smoke 500 945050 CH Owner's Manual

FOR USE WITH
Broil King® Smoke™ Charcoal Grill

OWNER'S MANUAL

CONTENTS

INTRODUCTION ............................................... 2

SAFETY ............................................................. 2

GRILL PARTS ................................................... 3

CHARCOAL ...................................................... 4

GETTING STARTED ......................................... 4

LIGHTING .......................................................... 5

OPERATON ...................................................... 6

COOKING TECHNIQUES ................................. 7

RECIPES ........................................................... 8

COOKING TIMES AND TEMPERATURES ...... 9

MAINTENANCE .............................................. 10

WARRANTY .................................................... 11

GUIDE DE L’UTILISATEUR ........................... 12

MANUAL DEL USUARIO ............................... 23

This instruction manual contains important information necessary for the proper assembly and

safe use of the appliance. Read and follow all warnings and instructions before assembling and

using the appliance. Follow all warnings and instructions when using the appliance.

Keep this manual for future reference.

1-800-265-2150
[e-mail]

40094-E10 REV A 05/18

INTRODUCTION SAFETY

BROIL KING® SMOKE™ CHARCOAL GRILL

The Broil King® Smoke™ Charcoal Grill is designed to
create mouth-watering, authentic smoke flavored foods.
Every detail of this grill has been precisely engineered; this
attention to detail is evident throughout. From durable
construction and stylish accents to exceptional cooking
versatility, Broil King
flavor, great barbecues every time.

Your Broil King
Roto-Draft™ Intake and Exhaust dampers to give you
precise temperature control. It also includes an internal
damper between the large and small cook box. This feature
allows you to adjust the size of the opening between
chambers, providing maximum control in a variety of
cooking conditions and helps reduce pre-heat and
cooldown
time.

30in[76cm] minimum clearance from any

®

brings it altogether. Great food, great

®

Smoke™ Charcoal Grill is equipped with

combustible surfaces

DANGER

 This grill is designed for outdoor use only. If used

indoors, toxic fumes will accumulate and cause
serious bodily injury and/or death.

 Do not add charcoal starter fluid or charcoal

impregnated with starter fluid to hot or warm
charcoal.

 Do not leave children or pets unattended near a hot

grill.

 Do not attempt to move a hot grill.
 Do not use grill within 30in[76cm] of any

combustible material.

 Do not use unless grill is fully assembled and all

parts are in place.

 Do not remove ashes until all charcoal is

completely burned out and fully extinguished

 Do not use grill in high winds

WARNING

 Keep the grill in a level position at all times.
 Always use charcoal trays and grates.
 Never touch the charcoal tray or grate to see if they

are hot.

 Use barbecue mitts or hot pads to protect hands

while cooking or adjusting the dampers.

 Use proper barbecuing tools with long, heat-

resistant handles.

 To extinguish the coals, close the doors and

dampers completely. Do not use water, it may
damage the smoker’s finish.

 Warning! Do not burn charcoal in both cooking

chambers at the same time.

 WARNING! Do not use spirit or petrol for lighting or

re-lighting! Use only firelighters complying to EN
1860-3!

 WARNING! Keep children and pets away.

Failure to heed these danger and warning
statements may cause serious injury or death; or
fire or explosion resulting in damage to property.

WARNING

DO NOT OPERATE OVER 650°F / 325°C

MULTIPLE PATENTS PENDING

PROPOSITION 65 WARNING

Combustion (burning) of this product, produces carbon
monoxide and other substances known by the State of
California to cause cancer and birth defects or other
reproductive harm. For more information go to

www.P65warnings.ca.gov/product

2

GRILL PARTS

1. Lid

2. Firebox Chamber

3. Roto Draft™ Exhaust Damper

4. Roto Draft™ Intake Damper

5. Clean Out Door

6. Reversible Cast Grids

7. Charcoal Trays

8. Ash Tray

9. Warming Shelf

10. Work Shelf

11. Lower Shelf

3

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CHARCOAL GETTING STARTED

Remove the grates, diffuser trays and ash trays; wash
thoroughly in warm, soapy water. Rinse completely and dry
with a soft towel, don’t air dry and never place components
in a dishwasher.

SEASONING CAST IRON COOKING GRIDS:

Coat your cast iron cooking grids with a high smoke point
cooking oil. Use a paper towel or cloth to coat all edges. In
your smoker or oven, bake the cooking grids at 400°F
(205°C) for up to 1 hour. Cool and place in smoker for use.

INITIAL ‘BURN-IN’

Before you start to cook on your Broil King® Smoke™

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NATURAL LUMP CHARCOAL

Natural Lump Charcoal - Your Broil King® Smoke™
Charcoal grill will run on many types of fuel including
traditional charcoal briquettes and even wood chunks;
however, it works best with Broil King
Charcoal. Good natural lump charcoal contains no
chemicals, additives, or fillers. This means your fire burns
hotter, cleaner, and creates less ash than with charcoal
briquettes. Broil King
TCF5506) is recommended.

®

Hardwood Lump Charcoal (#

®

Hardwood Lump

COOKING WITH WOOD CHUNKS

Wood chunks are a great fuel source for your offset
smoker, they provide a powerful burst of heat and flavor.
Using a combination of charcoal and wood chunks, you can
build a substantial fire in the fire box. Using soaked wood
chips or chunks will provide smoke over a longer time
period. It is recommended to check the fire every hour
during the cooking process. Add charcoal and wood as
required to maintain the desired cook temperature.

FIRE STARTER STICKS

Fire Starters - Starter sticks / cubes made from natural
products work best. Charcoal chimney starters or electric
charcoal starters also work well. Avoid using lighter fluid, as
it imparts an unnatural flavor into the cooking area.

Charcoal Grill you must burn off the protective residues
from manufacturing. Light your smoker, as outlined on page
5: lighting your smoker, and maintain a fire with both intake
and exhaust vents wide open for a minimum of one hour.
This will burn off any of the protective coating from
manufacturing and begin the process of smoke- curing the
internal components of the smoker. The more you use your
smoker, the better the seasoning will be.

WARNING

Always use caution when opening the fire box access door.
Carefully open the door a crack, allow 5 seconds before
opening all the way. This allows some of the heat around
the charcoal tray to escape and limits chances of flare-up

4

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LIGHTING

Step 1:

Set the Roto Draft™ intake and exhaust dampers to
position 5 (wide open) to let the maximum amount of air in
to fuel the fire.

Step 2:

Open the lid on the cook box, remove the cooking grids
using the grid lifter provided (Item # 60750), and fill the tray
with roughly 8-10 lbs. of hardwood lump charcoal.
As you become more familiar with the Broil King
Charcoal Grill, you will get a feel for how much charcoal
you need for various cook times and temperatures.

®

Smoke™

If using a stainless steel chimney starter, fill the Broil

®

King

Charcoal Chimney Starter (Item # 63980) with
charcoal. Fill the bottom of the chimney starter with one or
two pieces of newspaper. Place the chimney starter on
the charcoal tray inside the fire box.

Once charcoal is lit, carefully pour the lit charcoal onto the
charcoal tray closest to the intake damper. This will
encourage the fire to burn and evenly. You can add unlit
charcoal to increase the amount of fuel.

Step 3: Lighting

If using starter sticks, light them and place into the top of
the charcoal bed at two or three locations.

Step 4:

Allow the charcoal to ignite with the fire door open until
charcoal is aflame.

Step 5:

Adjust dampers to achieve desired temperature. Start
closing dampers 50 degrees before target temperature.

SHUTTING DOWN:

When you’re ready to shut down the Broil King® Smoke™
Offset Smoker, close the dampers to snuff the fire out
completely

5

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OPERATION

CONTROLLING TEMPERATURE:

The Broil King® Smoke™ Charcoal Grill allows you to
control cooking temperature by regulating airflow through
the intake Roto-Draft™ dampers and exhaust Roto-Draft™
damper. The more you open the dampers, the more air will
flow through to the charcoal. The more air that gets to the
charcoal the hotter the temperature will get. Small
adjustments to the dampers will make significant changes
to the cooking temperature.

Adjust Roto-Draft™ dampers using the included multi-tool.

WATER PAN:

Given the amount of airflow for cook times exceeding 3
hours, adding a water pan to the main chamber may be
warranted – this will keep food from drying out. Using
disposable foil drip trays (Item # 50420) is a convenient
way to do so.

6

COOKING TECHNIQUES

Smoking: Less than 275°F (135°C)

This classic form of barbecue involves indirect cooking of
larger cuts of meat at low temperatures (less than 275°F
(135°C) for a relatively long time (often 4+ hours). Using
charcoal and wood chips infuses slow cooked meats and
other items with smoky barbecue flavor and yields
incredibly tender results.

Smoke Roasting: 275°F-400°F (135°C-205°C)

Also known as indirect grilling, this is similar setup to
smoking; smoke roasting is an accelerated version of the
same principles. It works well for more conventional roasts,
chickens and items that are frequently oven roasted. The
combination of smoke and cooking time creates great flavor
in a shorter time than true smoking.

Direct grilling: 400°F (205°C) or more

Direct – as in directly above the burning charcoal and wood
chips. This method is the traditional backyard cook-out or
barbecue. Ideal for smaller items – steaks, chops, burgers,
vegetables. The high heat sears the exterior while cooking
the interior.

For more information, visit www.broilkingbbq.com

Preparing The Perfect Steak

Trim excess fat from the steaks. In a heavy, resealable
plastic bag combine the marinade ingredients. Marinate the
steaks for 1 hour at room temperature or up to 24 hours in
the refrigerator. If refrigerating, bring steaks close to room
temperature 1 hour before grilling for more even cooking.

The Perfect Steak Marinade*

4 steaks (preferably New York Strip), 1” thick
2 cloves garlic minced or pressed
2 tbsp worcestershire sauce
2 tbsp balsamic vinegar and freshly ground pepper
2 tsp dijon mustard
2 tbsp soy sauce
2 tbsp olive oil

*Try the Broil King
Perfect BBQ™ (#50990) sauce for fantastic results.

®

The Perfect Steak™ marinade or The

Perfect Steak Grilling Guide

A.

Brush grids with vegetable or olive oil and preheat the
barbecue to 450°F / 275°C. Place food on the
barbecue at a 45 angle and cook according to the
timing on the cooking charts below.

B.

Turn the steak over grilling on the same 45 angle.

C.

Turn the steak over and grill on the opposite 45 angle.

D.

Finally, turn the steak over and grill on the same 45
angle.

7

RECIPES

BBQ RUB*

- 2 tablespoons brown sugar

- 1 teaspoon kosher salt

- 1 teaspoon freshly ground black pepper

- 1 tablespoon cumin

- 2 teaspoons dry mustard

- 2 teaspoons paprika

- 2 tablespoons chili powder

- 1 teaspoon onion salt

- 1 teaspoon celery salt

- 1 teaspoon garlic powder

- 1 tablespoon oregano

*Try the Broil King
(#50975) or The Perfect KC BBQ Rub™ (#50978) for
fantastic results.

®

The Perfect BBQ Spice Rub™

SMOKED CHICKEN

- Preheat grill to 275°F (135°C)

- 1 whole chicken, separated, or chicken pieces – thighs,
wings, drumsticks, up to 5 lbs.

- Rub chicken pieces with general purpose BBQ rub, let
stand 30 minutes

- Add water pan to smoker

- Add handful of apple or other wood chips to burning
charcoal

- Arrange chicken on cooking grids

- Cook 2.5 – 4 hours

- Internal temperature must reach 165°F (74°C)

- Cover, let stand 10 minutes

- Serve and enjoy

RIBS

- Preheat grill to 250°F (121°C)

- 4 racks pork ribs

- Peel membrane from ribs

- Season liberally with barbecue rub

- Add water pan with apple juice to smoker

- Add handful of apple or other wood chips to burning
charcoal

- Arrange ribs on cooking grids, or in the included rib rack

- Cook 3-4 hours

- If desired, apply barbecue sauce at this time and finish
using your Broil King Gas Barbecue at 400°F for 10 to
20 minutes.

- Remove from smoker, cover and let stand 10 minutes

- Serve and enjoy

PULLED PORK

- Preheat grill to 225°F (107°C)

- 4 – 15 lb. Pork Shoulder (Smaller cuts will often be
labelled Boston Butt or picnic shoulder)

- Season liberally with barbecue rub

- Add water pan with apple juice to smoker, set pork
shoulder above pan

- Add handful of wood chips to burning charcoal

- Place pork shoulder on cooking grids

- Cook 4 + hours to an internal temperature of at least
185°F (85°C)

- Remove from smoker, wrap with foil, let stand 30
minutes

- Chop using Broil King
using Broil King

- Apply sauce as desired

- Serve and enjoy

®

®

Super Flipper (#64011) or pull

Meat Claws (#64070)

8

COOKING TIMES AND TEMPERATURES

DESCRIPTION SETTING COOK TEMP COOK TIME FINAL TEMP

Short Ribs
Tenderloin
3 to 4 lbs. (1.36 to 1.81 kg)
Brisket (Pulled)
8 to 12 lbs. (3.63 to 5.44 kg)
Brisket (Thick Sliced)
8 to 12 lbs. (3.63 to 5.44 kg)

225°F(107°C)

Smoke

Brisket (Thin Sliced)
8 to 12 lbs. (3.63 to 5.44 kg)

Prime Rib Roast

350°F(176°C)

Sirloin Tip Roasts 8 Hours

Steak*
Hamburgers* 160°F(71°C)

Roast

Grill

600°F(315°C)

Chicken (Quarters)

5 hours 130°F(54°C)

2.5 to 3 hours

1.5 hrs per lb
(3.3 hrs per kg)

1.5 hrs per lb
(3.3 hrs per kg)

1.5 hrs per lb
(3.3 hrs per kg)
15 min per lb
(33 min per kg)

130°F(54°C) for
Medium Rare

205°F(96°C)

195°F(90°C)

185°F(85°C)
130°F(54°C) for

Medium Rare
130°F(54°C) for
Medium Rare
130°F(54°C) for
Medium Rare

1 to 2 hours 170°F(77°C)
Chicken (Thighs) 1.5 hours 170°F(77°C)
Chicken (Whole)

2.5 to 3.5 lbs. (1.13 to 1.58 kg)
Chicken (Whole)

3.5 to 4.5 lbs. (1.59 to 2.04 kg)
Chicken (Wings) 1.25 hours 170°F(77°C)

350°F(176°C)

Roast
Chicken Breast
5 to 8 oz. (0.14 to 0.23 kg)

2 to 2.5 hours 170°F(77°C)

2 to 3 hours 170°F(77°C)

1 to 2 hours 170°F(77°C)

Turkey (Legs) 2 to 3 hours 170°F(77°C)
Turkey (Whole)

10 to12 lbs. (4.54 to 5.44 kg)
Fish (Whole)
4 to 6 lbs. (1.81 to 2.72 kg)

Lobster (Steamed) 15 minutes/lb To Taste
Shrimp (Steamed) 15 minutes/lb To Taste

225°F(107°C)

Smoke

Ribs (Baby Back)

1.5 to 2.5 lbs. (2.72 to 1.13 kg)
Ribs (Spare Ribs)

2.5 to 3.5 lbs. (1.13 to 1.63 kg)
Pork Butt (Pulled)
6 to 8 lbs. (2.72 to 3.63 kg)
Pork Butt (Sliced)
6 to 8 lbs. (2.72 to 3.63 kg)

Pork Chops
Pork Crown Roast

8 to 10 lbs. (3.63 to 4.54 kg)
Pork Loin
8 to 10 lbs. (3.63 to 4.54 kg)

225°F(107°C)

Smoke
Pork Sausage

1.5 to 2.5 inch (3.8 to 6.4 cm) Dia.
Pork Shoulder (Pulled)
6 to 10 lbs. (2.72 to 4.54 kg)
Pork Shoulder (Sliced)
6 to 10 lbs. (2.72 to 4.54 kg)
Pork Tenderloin

1.5 to 2.5 lbs.(2.72 to 1.13 kg)
Ham (Bone In)

2.5 to 3 hours 170°F(77°C)

3.5 to 4 hours Until Flaky

5 hours 160°F(71°C)

5 to 7 hours 160°F(71°C)

1.5 hrs per lb
(3.3 hrs per kg)

1.5 hrs per lb
(3.3 hrs per kg)

1.5 hrs per lb
(3.3 hrs per kg)

1.5 hrs per lb
(3.3 hrs per kg)

205°F(96°C)

170°F(77°C)

160°F(71°C)
155°F to 165°F

(68°C to 74°C)

4 to 6 hours 160°F(71°C)

1 to 3 hours 165°F(74°C)

8 to 12 hours 205°F(96°C)

5 to 8 hours 175°F(79°C)

2.5 to 3 hours 160°F(71°C)

1.5 hrs per lb
(3.3 hrs per kg)

160°F(71°C)

9

MAINTENANCE

CLEAN OUT

After each cook, it will be necessary to empty the ash
tray. Once cool, open the firebox access door and
carefully remove the ash tray. Empty into a bucket or
other container for disposal.

CARE AND MAINTENANCE

The Broil King® Smoke™ Charcoal Grill will give you many
years of great service with minimal care. The seasoning
process will help preserve the internal steel components.
Use a stainless steel brush to clean cooking grids and
components that are soiled.

It may be necessary to clean and re-season your cooking
grids. Brush them thoroughly with a Broil King® stainless
steel grill brush (#64014) to remove any debris and apply a
thin layer of olive or grapeseed oil. Then, place the cooking
grids into your smoker, and cook at 400°F (205°C) for 1
hour. Repeat as desired. This coating of oil will protect your
cooking grids and provide years of trouble free use.

Clean the exterior using warm, soapy water.

To clean the interior, use a wire-bristle grill brush to
remove any debris from the cook box. The layer of oils
that accumulates inside the smoker – the seasoning – is
protective and does not need to be scrubbed clean with
any frequency.

Always keep your Broil King
covered when not in use - use Broil King



®

Smoke™ Charcoal Grill

®

Cover (#67060)

10

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