Char-Broil 04201100 Charbroil Grill Owner’s Manual

: July 27, 2024
: Char-Broil

Table of Contents

Char-Broil 04201100 Charbroil Grill
PARTS LIST
INSTALLATION INSTRUCTIONS
Limited Warranty
References
Read User Manual Online (PDF format)
Download This Manual (PDF format)

Char-Broil 04201100 Charbroil Grill

PARTS LIST

ITEM DESCRIPTION
55700446 COOKING CHAMBER KIT
55700447 FIREBOX KIT
55700056 SMOKESTACK KIT
55700057 DAMPER KIT
55700058 WOOD SHELF KIT
55700059 SHELF BRACKET KIT
55700448 WOOD HANDLE KIT
55700062 LONG LEG KIT
55700063 SHORT LEG KIT
55700065 LEG BRACE KIT
55700066 SMOKE CHAMBER DOOR KIT
55700067 FIREBOX DOOR KIT
55700068 WHEEL KIT
55700069 AXLE KIT
40011207 OUTER CARTON
55700073 TEMP GAUGE KIT
42000011 HARDWARE BAG
44830150 GREASE CAN HOLDER
40009913 FIRE GRATE
40009914 COOKING GRATE
14502819 COOKBOOK
22504845 TOOLS
11502830 COVER
42803991 ASSEMBLY INSTRUCTIONS (French)
42803969 ASSEMBLY INSTRUCTIONS (English)

INSTALLATION INSTRUCTIONS

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 1/4-20×1-3/4″ screws and two 1/4-20 flange nuts per leg assembly.
Lay unit onto its back. Attach leg braces on each side using four 1/4-20×1-3/4″ screws and four 1/4-20 flange nuts per brace. When complete, return unit to its right side, as positioned in step 1.
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. Check to be sure that all screws and nuts used so far are fully tightened.
Place the firebox onto the smoker chamber and align the large openings. Insert six 1/4-20×1/2″ screws through the firebox, into the smoker chamber. Secure with six 1/4-20 flange nuts. Fully tighten all screws and nuts.
Place unit in upright position. Attach front shelf supports to smoker chamber using one 1/4-20×1/2″ screw and one 1/4-20 flange nut per support.
Attach wood shelf slats to front shelf supports using six #10-24×1″ screws and six #10-24 flange nuts.
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.
Insert two 1/4-20×2-1/4″ 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 cip onto probe until tight against door. See inset illustration for clip position.
Following the same procedure used on the doors, install wood handle on left side of firebox with two 1/4-20×2-1/4″ carriage bolts and two 1/4-20 flange nuts. Tighten flange nuts until bolt heads are flush with wood.
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.
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.
Hang the grease clip under the smoker chamber on right side. An empty soup can is recommended to hang from grease clip.

HARDWARE LIST

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 otherlegal 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

Pecan
Apple
Peach

Medium Flavor

Hickory
White Oak
Cherry

Heavy Flavor

Mesquite
Blackjack Oak
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.