Smoker, BBQ and Grill

Tools needed for assembly:

Adjustable Wrench

Screwdriver

WARNING

CALIFORNIA PROPOSITION 65

1. This product is produced with or contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

WARNING

CARBON MONOXIDE HAZARD

Burning charcoal inside can kill you. It gives off carbon monoxide, which has no odor. NEVER burn charcoal inside homes, vehicles or tents.

NEVER LEAVE FIRE UNATTENDED!

Do not allow small children near flame. Hot embers can fly out in breezy conditions. Adequate fire extinguishing material should be readily available.

Wash your hands after handling this product.

WARNING

CAUTION

Some parts may contain sharp edges. Wear protective gloves if necessary.

Read and follow all safety statements, warnings, assembly instructions and use & care directions before attempting to assemble and cook.

All surfaces can be hot during use. Use protection as required to prevent burning.

Do not use this unit on or near combustible surfaces or structures such as wood decks, dry leaves or grass, vinyl or wood siding, etc.

SEE OWNERS MANUAL FOR IMPORTANT SAFETY

INFORMATION.

CAUTION

THIS UNIT IS HEAVY!

DO NOT assemble without a helper.

If you have questions or need assistance during assembly, please call 1-800-241-7548 .

To insure your satisfaction and for follow-up service,

register your grill online at www.grillregistration.com

P/N 42804003 • 02204809 (12-06-07)

H

STOP!

Missing a part?

No need to go back to the store!

The store where you made your purchase does not stock parts for this item. If you need parts, whether they are missing or damaged, call the Customer Service toll free Help Line.

Call us and we will gladly ship the part you need.

Call Grill Service Center for Help and Parts

• If you need assistance with your product or warranty parts call

1-800-241-7548. Hours of Service

Center Operation are 8:00 A.M. To 6:00 P.M. EST

Monday - Friday.

• To order non-warranty replacement parts or accessories please visit us on the web at www.charbroil. com or call

1-800-241-7548 and one of our friendly and knowledgeable agents will be glad to assist you.

E

F

G

H

I

Key Part Number Desription

A

B

29000054

29000055

SMOKER CHAMBER

FIREBOX CHAMBER

C

D

29000056 SMOKE STACK ASSEMBLY

55700057 DAMPER KIT

J

K

L

40690000

29000059

29000060

FRONT SHELF, WOOD SLAT

29000061 FRONT SHELF, WOOD SLAT BRACKET

40690001 WOOD HANDLE

29000058 LONG LEG

SHORT LEG

LEG BRACE

29100070 SMOKER DOOR

29100071 FIREBOX DOOR

PARTS LIST

Quantity Key Part Number Desription

M 41540001 WHEEL

1

1 N 10000122 WHEEL AXLE

3

2

3

1

1

2

2

2

1

1

S

T

…

…

O

P

Q

R

…

…

41530000 TEMP GAUGE W/ CLIP

44830150 GREASE HOLDER

40009913 FIRE GRATE

40009914 COOKING GRATE

10000074 LEG CAP, 1 3/8", PLASTIC

55710209 HINGE KIT

14502819 COOKBOOK

42804003 ASSEMBLY INSTRUCTIONS

42030494 LFW SNAP BAG, 02204809

40010679 OUTER CARTON

G

O

K

G

L

T

A

G

T

B

D

Q

R

C

Quantity

2

1

1

1

2

2

2

4

1

1

1

1

I

J

P

M

E

N

S

F

1

• Stand smoker chamber on right end. Left end, with larger opening, should be facing upward.

• Connect long leg sections (with leg caps) to short leg sections.

•

Make sure long legs, with end caps, are

toward the top. Attach legs to smoker chamber using two

1/4-20x1-3/4” screws and two

1/4-20 flange nuts per leg assembly.

Long Leg with End Cap

Short Leg – No End Cap

Smoker

Chamber

2

• Lay unit onto its back.

• Attach leg braces on each side using four

1/4-20x1-3/4” screws and four 1/4-20 flange nuts per brace.

• When complete, return unit to its right side, as positioned in step 1.

Leg Brace

3

• Slide axle into holes at ends of short legs

(legs without end caps).

• Attach wheels onto axle rod using cotter pins. Bend cotter pin ends to prevent them from backing out of axle as shown in box A.

Check to be sure that all screws and nuts used so far are fully tightened.

Axle

A

Cotter Pin

Cotter pin

4

• Place the firebox onto the smoker chamber and align the large openings.

• Insert six

1/4-20x1/2” screws through the firebox, into the smoker chamber. Secure with six

1/4-20 flange nuts.

Fully tighten all screws and nuts.

Axle

Wheel

Firebox

5

•

Place unit in upright position.

• Attach front shelf supports to smoker chamber using one

1/4-20x1/2” screw and one

1/4-20 flange nut per support.

Front Shelf

Support

6

• Attach wood shelf slats to front shelf supports using six

#10-24x1” screws and six

#10-24 flange nuts.

Wood Shelf Slat

7

NOTE: The temperature gauge may be packed inside of the smokestack to prevent damage during shipping. If so, remove gauge before assembling smokestack to chamber.

• Remove nuts from studs on smokestack.

• Attach smokestack to right side of smoker chamber by reinstalling nuts onto studs from inside chamber.

Do not overtighten nuts.

Smokestack

8

• Insert two

1/4-20x2-1/4” carriage bolts into wood handle and place aluminum spacers onto bolts on other side of handle.

• Place the handle assembly into the holes on the front of the firebox door and secure with two

1/4-20 flange nuts. Tighten flange nuts until bolt head is flush with wood.

• Repeat on smoker chamber door.

• Insert temperature gauge into smoker chamber door and push clip onto probe until tight against door. See inset illustration for clip position.

Temperature Gauge Clip

Spacer

Wood Handle

Firebox Door

Temperature Gauge

Smoker Chamber Door

9

• Following the same procedure used on the doors, install wood handle on left side of firebox with two

1/4-20x2-1/4” carriage bolts and two

1/4-20 flange nuts.

Tighten flange nuts until bolt heads are flush with wood.

Spacer

Wood Handle

10

• Place a fire grate into the bottom of the firebox. Remaining fire grate may be placed in the bottom of the smoker chamber, if desired.

• The height of the grate can be adjusted by turning it 90 degrees.

Fire Grates

11

• Insert the longer wires at the rear of the cooking grates into the four holes in the back of the smoker chamber.

• The fronts of the cooking grates will rest on the shelf support screws.

12

• Hang the grease clip under the smoker chamber on right side.

• An empty soup can is recommended to hang from grease clip.

Cooking Grates

Grease

Clip

Before you begin . . .

Familairize yourself with the major components and controls of the unit.

Smokestack

Damper

Firebox

Firebox

Damper

Smoker

Chamber

Grilling

is a method of cooking directly over a fire, for foods such as steaks, hamburgers, and hot dogs. Cooking temperatures for grilling ranges from approximately 350° to

550°. Due to the high temperatures and direct proximity to the fire, this type of cooking requires close attention.

Barbequing

is accomplished by using indirect heat, with a temperature range from approximately 225° to 350°. Using an offset firebox design, only the heat and smoke flow through the smoker chamber, cooking the food without direct contact with the fire. This method is ideal for chicken, ribs, fish, and vegetables.

Slow Smoking

can also be done with the offset firebox design, using indirect heat and smoke. Similar to barbequing, the food is placed in the smoker chamber, with the fire in the firebox. However, slow smoking occurs in a temperature range of approximately 140° to 225°, and requires an extended cooking time. This type of cooking is ideal for turkey, ham, or sausage.

With any type of live fire cooking, allow enough time to build a fire and get the grill/smoker up to temperature.

Build a fire using either charcoal briquettes, lump charcoal, or wood chunks. Briquettes offer a very good source of heat, and are readily available in the marketplace. Most briquettes are manufactured using a combination of wood charcoal, coal powder, and a processing binder. Lump charcoal is a premium form of charcoal because it is made of only wood. Lump charcoal burns hotter and longer than briquettes, and imparts no chemical flavors to the food being cooked. For a more robust smoke flavor using briquettes or lump charcoal, try adding several wood chunks to the fire. Wood chunks are available in a variety of natural flavors, and can be used alone or in addition to charcoal. As a general rule, any hardwood that bears a fruit or nut is suitable for cooking. However, different woods have very different tastes.

Mild Flavor

Pecan

Apple

Peach

Medium Flavor Heavy Flavor

Hickory

White Oak

Cherry

Mesquite

Blackjack Oak

Red Oak

Experiment with different woods to determine your personal favorite, and always use well-seasoned wood. Green or freshcut wood can turn food black, and tastes bitter.

Prior to cooking on your grill/smoker, the following steps should be taken to season the interior steel. This will seal the inside surfaces with wood smoke and resin, helping to prevent corrosion.

First, brush all interior surfaces with vegetable oil.

Next, build a small fire on the fire grate inside the firebox, being sure not to lay coals against the walls. After the fire becomes established, close both lids and position both dampers approximately 1/4 open. Sustain this fire for at least 2 hours.

The unit is now ready for cooking!

Grilling

Position both fire grates in the smoker chamber. Build a fire on top of the fire grates using either charcoal briquettes, lump charcoal, or wood chunks. Keep the smoker chamber lid open, and both dampers open, until the fire has established itself and is ready for cooking. Spread out coals as required, insert cooking grates, and start grilling. Remember, grilling is done over the top of the fire. Use the dampers to regulate the fire and heat. Open the dampers to increase temperature; close dampers to decrease temperatures. The cooking chamber door can remain open or closed. Refer to recipes for required cooking times and temperatures.

Barbequing and Slow Smoking

Position both cooking grates in the smoker chamber. Position one fire grate in the firebox. Build a fire on this fire grate using either charcoal briquettes, lump charcoal, or wood chunks.

Keep the firebox lid open, and both dampers open until the fire is established. Then, close the firebox lid (both lids should now be closed) and you will begin to see smoke flow from the smokestack. Adjust both dampers until the desired smoker chamber temperature is achieved. Open the dampers to increase temperature; close the dampers to decrease temperatures. This process of adjusting the temperature can take several minutes. Once the proper setting is obtained, only occasional attention is required. Now, place the food in the smoker chamber. Remember, this is indirect cooking, so the fire is in the firebox, and the food is placed in the smoker chamber.

Keep both lids closed while cooking to prevent unnecessary loss of heat and smoke. Refer to recipes for required cooking times and temperatures. Add charcoal or wood chunks as necessary to maintain the fire.

Maintenance

When finished cooking, and the unit has adequately cooled, clean out all remaining ashes. Ashes collect moisture, which can lead to premature rusting and decay. Periodically coating the interior surfaces with vegetable oil will aid in the protection of your unit. Also, occasional touch up of the exterior paint will be required. Black, high-temperature spray paint is recommended. Never paint the interior of the unit.

Cooking Surface: If a bristle brush is used to clean any of the grill cooking surfaces, ensure no loose bristles remain on cooking surfaces prior to grilling. It is not recommended to clean cooking surfaces while grill is hot.

Limited Warranty

Manufacturer warrants to the original consumer-purchaser only that this product shall be free from defects in workmanship and materials after correct assembly and under normal and reasonable home use for the periods indicated below beginning on the date of purchase.

The manufacturer reserves the right to require that defective parts be returned, postage and or freight pre-paid, by the consumer, for review and examination.

90 Days LIMITED warranty

Upon consumer supplying proof of purchase as provided herein, Manufacturer will repair or replace the parts listed below which are proven defective during the applicable warranty period. Parts required to complete such repair or replacement shall be free of charge to you except for shipping costs.

The original consumer-purchaser will be responsible for all shipping charges of parts replaced under the terms of this limited warranty.

This limited warranty is applicable in the United States and Canada only, is only available to the original owner of the product and is not transferable. Manufacturer requires reasonable proof of your date of purchase. Therefore, you should retain your sales slip or invoice and register your new product immediately. Defective or missing parts subject to this limited warranty will not be replaced without registration and proof of purchase. Register online at http://www.charbroil.com or complete and return via mail the Product Registration Card located on the last page of the

Use & Care manual included with this product and retain your sales receipt for proof of purchase.

This limited warranty applies to the functionality of the product ONLY and does not cover cosmetic issues such as scratches, dents, corrosions or discoloring by heat, abrasive and chemical cleaners or any tools used in the assembly or installation of the appliance, surface rust, or the discoloration of stainless steel surfaces.

This limited warranty will not reimburse you for the cost of any inconvenience, food, personal injury or property damage.

If an original replacement part is not available, a comparable replacement part will be sent. You will be responsible for all shipping charges of parts replaced under the terms of this limited warranty.

ITEMS MANUFACTURER WILL NOT PAY FOR:

1. Service calls to your home.

2. Repairs when your product is used for other than normal, single-family household or residential use.

3. Damage resulting from accident, alteration, misuse, abuse, fire, flood, acts of God, improper installation, installation not in accordance with electrical or plumbing codes, or use of products not approved by the manufacturer.

4. Any food loss due to product failures.

5. Replacement parts or repair labor costs for units operated outside the United States or Canada.

6. Pickup and delivery of your product.

7. Repairs to parts or systems resulting from unauthorized modifications made to the product.

8. The removal and/or reinstallation of your product.

9. Shipping cost, standard or expedited, for warranty and replacement parts.

DISCLAIMER OF IMPLIED WARRANTIES; LIMITATION OF REMEDIES

Repair or replacement of defect parts is your exclusive remedy under the terms of this limited warranty. Manufacturer will not be responsible for any consequential or incidental damages arising from the breach of either this limited warranty or any applicable warranty, or for failure or damage resulting from acts of God, improper care and maintenance, grease fire, accident, alteration, replacement of parts by anyone other than

Manufacturer, misuse, transportation, commercial use, abuse, hostile environments (inclement weather, acts of nature, animal tampering), improper installation or installation not in accordance with local codes or printed manufacturer instructions.

THIS LIMITED WARRANTY IS THE SOLE EXPRESS WARRANTY GIVEN BY THE MANUFACTURER. NO PRODUCT PERFORMANCE

SPECIFICATION OR DESCRIPTION WHEREVER APPEARING IS WARRANTED BY MANUFACTURER EXCEPT TO THE EXTENT SET FORTH

IN THIS LIMITED WARRANTY. ANY IMPLIED WARRANTY PROTECTION ARISING UNDER THE LAWS OF ANY STATE, INCLUDING IMPLIED

WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR USE, IS HEREBY LIMITED IN DURATION TO THE

DURATION OF THIS LIMITED WARRANTY.

Neither dealers nor the retail establishment selling this product has any authority to make any additional warranties or to promise remedies in addition to or inconsistent with those stated above.

Manufacturer’s maximum liability, in any event, shall not exceed the documented purchase price of the product paid by the original consumer.

This warranty only applies to units purchased from an authorized retailer and or re-seller.

NOTE: Some states do not allow an exclusion or limitation of incidental or consequential damages, so some of the above limitations or exclusions may not apply to you. This limited warranty gives you specific legal rights as set for herein. You may also have other rights which vary from state to state. In the state of California only, if refinishing or replacement of the product is not commercially practicable, the retailer selling this product or the Manufacturer will refund the purchase price paid for the product, less the amount directly attributable to use by the original consumerpurchaser prior to discovery of the nonconformity. In addition, in the state of California only, you may take the product to the retail establishment selling this product in order to obtain performance under this limited warranty.

If you wish to obtain performance of any obligation under this limited warranty, you should write to:

Char-Broil Consumer Relations

P. O. Box 1240

Columbus, GA 31902-1240

Consumer returns will not be accepted unless a valid Return Authorization is first acquired by calling 1-800-241-7548 and then clearly marked on the outside of the package and the package is shipped freight/postage pre-paid to the address above.

HARDWARE LIST

Hardware is shown actual size. You may have spare hardware after assembly is complete.

Cotter Pin

Qty:2

1/4-20x2-1/4”

Carriage Bolt

Qty. 6

1/4-20x1-3/4”

Machine Screw

Qty. 12

#10-24x1”

Machine Screw

Qty. 6

1/4-20x1/2”

Hex Head

Machine Screw

Qty. 1

1/4-20x1/2”

Machine Screw

Qty. 8

#10-24x1/2”

Machine Screw

Qty. 16

1/4-20

Lock Nut

Qty. 1

1/4-20

Flange Nut

Qty. 28

#10-24

Flange Nut

Qty. 22

WARNING

MOST SURFACES ON THIS UNIT ARE HOT WHEN IN USE.

USE EXTREME CAUTION. KEEP OTHERS AWAY FROM UNIT.

ALWAYS WEAR PROTECTIVE CLOTHING TO PREVENT INJURY.

Char-Broil, LLC • Columbus, GA 31904 • Assembly Instructions © 2007

Printed in China