Charbroil 04201101 Owner's manual

Brand: Charbroil

Model: 04201101

Category: Barbecues & grills

Type: Owner's manual

42803968 (12-02-03)

THIS UNIT IS HEAVY. DO NOT assemble without helper.

Some parts may contain sharp edges - especially as noted in

manual. Wear protective gloves if necessary.

Read and follow all safety statements, warning, assembly

instructions and use & care directions before attempting to

assemble and cook.

Tools needed for assembly:

Phillips screwdriver

Adjustable wrench

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.

Smoker, BBQ and Grill

04201101

Smoker, BBQ and Grill

04201101

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

FREE OF CHARGE.

Call Our Help Line

PARTS LIST

ITEM DESCRIPTION

55700462 SMOKE CHAMBER KIT

55700463 FIREBOX KIT

55700195 WOOD SHELF KIT

55700442 AXLE KIT

55700443 WHEEL KIT

55700198 LEG BRACE KIT

55700468 SMOKESTACK KIT

55700200 SHORT LEG KIT

55700201 LONG LEG KIT

55700202 SHELF BRACKET KIT

55700203 KNOCKOUT COVER KIT

55700204 DOOR LATCH KIT

55700205 LOGO PLATE KIT

55700206 8” WOOD HANDLE KIT

55700472 BUTTERFLY DAMPER KIT

40011202 CARTON

42000035 HARDWARE BAG

42803968 ASSEMBLY INSTRUCTIONS

10000074 LEG CAPS

40009916 PORCELAIN COOKING GRATE SET

40022811 FIRE GRATE SET (2)

46030090 WOOD RACK

44830150 GREASE CAN HOLDER

• Attach one long leg and one short leg to

make two leg assemblies

Note: Short leg has two holes.

• Position wood rack between legs and

insert hooked ends of rack into holes on

insides of legs.

Note: Rack wires running front-to-back

should be on bottom, side-to-side wires on

top.

Short Leg

Long Leg

Wood Rack

Cotter Pin

Wheel

Axle

Leg Cap

Leg

Brace

• Lay unit onto its back.

• Attach leg braces on each side using four #10-

24 x 1-3/4” screws and four 10-24 flange nuts

per brace.

• Thread axle rod through both short legs.

• 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.

• Push leg caps onto long legs.

• Attach with two 1/4-20 x 2” screws and two

1/4-20 flange nuts per leg.

Fully tighten all screws and nuts.

Smoker Chamber

Smokestack Hole

Lid removed for clarity

STAND UNIT ON RIGHT END

Axle

Cotter pin

• Attach knockout cover to firebox with two

8-32 x 1/2” screws and two 8-32 keps

nuts

• Place firebox onto smoker chamber.

Fasten with six 1/4-20 x 3/4” screws,

1/4” flat washers and 1/4-20 flange nuts.

Firebox

Knockout Cover

Lids removed for clarity

Firebox

Smoker

Chamber

HAVE SOMEONE HELP YOU STAND

UNIT IN UPRIGHT POSITION.

• Attach six 10-24x1” screws and 10-24 flange nuts

in front and back of smoker chamber. These screws

will hold the porcelain grate.

Lid removed for clarity

• Fasten each shelf bracket to smoker chamber with one 1/4-20 x 1-1/4” screw and 1/4-20 flange nut.

• Attach wood slats to shelf bracket with six 10-24 x 1” screws and 10-24 flange nuts.

Shelf Bracket

Wood Slat

• 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.

Lid removed for clarity

Smokestack

• Attach handles on both the smoker chamber lid and firebox lid with two

1/4-20 x 3” screws, two washers, two spacers and two 1/4-20 flange

nuts.

• Attach logo plate using two Tennerman clips.

• Push 13/16” hole plug into lid.

Firebox Lid

Smoker Chamber Lid

Wood Handle

Logo Plate

Hole Plug

• Insert wire grates in bottom of smoker chamber.

• Position porcelain grates on support screws inside smoker chamber.

Wire Grates

Porcelain Grates

Lid removed for clarity

Grease

Clip

• Hang the grease clip under the smoker

chamber on right side.

• An empty soup can is recommended to

hang from grease clip.

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.

Limited Warranty

CHARBROIL warrants this grill/smoker for replacement or repair of parts and/or workmanship for a period of ninety (90) days .

Paint is not warranted and will require touch up.

These limited warranties are made exclusively to the original customer presenting proof of purchase. These warranties are limited to

non-commercial residential use only. Any returned goods must be shipped prepaid. These warranties do not cover normal wear and

tear or damages resulting from abuse or misuse. This warranty excludes incidental or consequential cost due to damages or losses or

property of any nature.

NOTICE: Some states do not allow the exclusion or limitation of incidental or consequential damages or limitations on how long an

implied warranty lasts, so the above limitations or exclusions may not apply to you. This warranty gives you specific legal rights and

you may also have other legal rights which may vary from state to state.

For further information, contact CHARBROIL, toll free at 1-800-232-3398.

HARDWARE LIST

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

1/4-20x2”

Machine Screw

Qty. 4

#10-24x1”

Machine Screw

Qty. 12

#10-24x1-3/4”

Machine Screw

Qty. 8

1/4-20x3/4”

Machine Screw

Qty. 6

1/4-20x3”

Machine Screw

Qty. 4

#8-32x1/2”

Machine Screw

Qty. 2

Spacer

Qty. 4

1/4-20

Flange Nut

Qty. 18

#10-24

Flange Nut

Qty. 20

Cotter Pin

Qty:2

13/16”

Hole Plug

Qty. 1

1/4”

Flat Washer

Qty. 10

#8-32

Keps Nut

Qty. 2

Tennerman Clip

Qty. 2

1/4-20x1-1/4”

Machine Screw

Qty. 2

Before you begin . . .

Familairize yourself with the major components and controls of

the unit.

Smokestack

Damper

Smoker

Chamber

Firebox

Damper

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 Medium Flavor Heavy Flavor

Pecan Hickory Mesquite

Apple White Oak Blackjack Oak

Peach Cherry Red Oak

Experiment with different woods to determine your personal

favorite, and always use well-seasoned wood. Green or fresh-

cut 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.

KEEPERS OF THE FLAME

Columbus, GA

Charbroil 04201101 Owner's manual

Brand: Charbroil

Model: 04201101

Category: Barbecues & grills

Type: Owner's manual

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Charbroil 04201101 Owner's manual

Charbroil 04201101 Owner's manual

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