Char-Broil 04201101 Smoker BBQ and Grill Installation Guide
- July 15, 2024
- Char-Broil
Table of Contents
KEEPS OF THE FLAME
Charbroil 04201101
Owner’s Manual
04201101 Smoker BBQ and Grill
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Smoker BBQ and Grill
Tools needed for assembly:
Phillips screwdriver
Adjustable wrench
Caution
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.
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.
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
1 -800 – 232 -3398
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.
-
• 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.
-
STAND UNIT ON RIGHT END
• Attach with two 1/4-20 x 2” screws and two 1/4-20 flange nuts per leg.
Fully tighten all screws and nuts
Lid removed for clarity
-
• 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. Lids removed for clarity
-
Attach six 10-24×1” screws and 10-24 flange nuts in front and back of smoker chamber. These screws will hold the porcelain grate.
HAVE SOMEONE HELP YOU STAND UNIT IN UPRIGHT POSITION.
-
• 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.
-
• 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.
-
• 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.
-
• Insert wire grates in bottom of smoker chamber.
• Position porcelain grates on support screws inside smoker chamber
-
• Hang the grease clip under the smoker chamber on right side.
• An empty soup can is recommended to hang from grease clip.
-
HARDWARE LIST
Hardware is shown actual size. You may have spare hardware after assembly is
complete. 
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.
Before you begin . . .
Familairize yourself with the major components and controls of the unit.
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 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.
KEEPERS OF THE FLAME
Columbus, GA
Documents / Resources
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Char-Broil 04201101 Smoker BBQ and
Grill
[pdf] Installation Guide
04201101 Smoker BBQ and Grill, 04201101, Smoker BBQ and Grill, BBQ and Grill,
and Grill, Grill
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References
- Repair Your Grill: Shop Replacement Parts for 24,880 Models
- Charbroil Grill Parts - Select From 3614 Models
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