Char-Broil 10201571 User manual

Product Guide
Model 10201571
Tools needed for assembly:
Phillips & Flat Head Screwdriver
Adjustable wrench
Pliers
FOR OUTDOOR USE ONLY
CAUTION:
Read and follow all safety statements, assembly
instructions, and use and care directions before
attempting to assemble and cook.
INSTALLER/ASSEMBLER:
Leave this manual with consumer.
CONSUMER:
Keep this manual for future reference.
WARNING:
Failure to follow all manufacturer’s instructions could
result in serious personal injury and/or property
damage.
CAUTION:
Some parts may contain sharp edges – especially as
noted in the manual! Wear protective gloves if
necessary.
WARNING:
CARBON MONOXIDE HAZARD
Burning charcoal indoors can kill you. It gives off
carbon monoxide, which has no odor. NEVER burn
charcoal inside homes, vehicles, or tents.
CAUTION:
THIS UNIT IS HEAVY! DO NOT attempt to
assemble without a helper.
If you have questions or need assistance during assembly, please call .
To insure your satisfaction and for follow-up service, register your appliance online at www.charbroil.com/register
1-800-241-7548
42804521 - 09/28/09
The following are trademarks registered by W.C. Bradley Co. in the U.S. Patent and Trademark Office: Char-Broil®;America's Legendary Barbeque Company®;American Gourmet®; Bandera®; BrushHawg®; CB940®;
Char-Diamonds®; Char-Broil Charcoal/Gas®; DiamondFlame®; Everybody Grills®; Everybody Outside®; FastStart®; Fireball®; Firenzy®; FlavorMaster®; Grill2Go®; Grill2Go® Express®; Grill Lovers®; H20 Smoker®;
KeepersoftheFlame®;NewBraunfelsSmokerCompany®;OklahomaJoe's®;PatioBistro®;PatioCaddie®;PatioKitchen®;PrecisionFlame®;Quantum®;SantaFe®;SearandGrill®;Sierra®;SignatureSeries®;The
BigEasy®;TheMinuteGrill®;Trentino®;WildWestTradition®;andthefollowingmarks: ®
Protected under one or more of the following U.S. Patents: 4,989,579; 5,421,319; 5,458,309; 5,579,755; 5,996,573; 6,114,666; 6,135,104; 6,209,533; 6,279,566; 6,331,108; 6,484,900; 6,526,876; 6,595,197; 6,640,799; 6,640,803; 6,729,873; 6,739,473; 6,749,424;
6,863,100;6,935,327;6,951,213; 6792,935;7,047,590;D364,535;D372,637;D373,701;D377,735; D383,035;D397,910;D405,643;D406,005;D406,009; D413,043;D413,229;D414,982;D415,388;D416,164;D416,441;D417,587;D417,588;D422,516; D423,876;
D428,303;D430,772; D435,396;D436,004; D438,059;D438,060;D438,427; D439,110; D442,505;D443,179;D443,354; D443,464;D447,384; D447,385;D447,909;D448,610; D448,614;D448,615; D448,616;D448,975;D449,492; D450,544;D451,759; D454,028;
D454,031;D455,205;D455,206; D456,202;D456,222; D456,223;D457,789; D458,520;D458,760; D458,802;D459,088; D459,148D459,149; D459,161;D459,163; D459,586;D459,943; D460,312;D460,313; D460,318;D461,359; D465,123;D465,693; D466,307;
D466,439; D466,752; D473,414; D474,371; D477,498; D477,501; D477,504; D477,506; D477,746; D478,471; D478,472; D480,914; D491,410; D494,009; D494,413; D498,523; D500,359; D504,048; D530,098; D535,000; Canada: 87,743; 87,744; 97,504; 99,355;
102,037;104,200;2,315,567;2,336,036;France:010,231;010,422;010,590;010,849;1,089,646;Germany:1,089,646;SouthKorea:384,565;China:99,127,066.5;UnitedKingdom:2,099,402;1,089,646.OtherPatentsPending. ©2008W.C.BradleyCompany
Thefollowingare trademarksofW.C.BradleyCo.: CommercialSeries™;DesignerSeries™;Grill2Go®Advantage™;Longhorn™;DoubleChef™;QuickSet™; ReadyWhenYouAre™;Hog andYardBird™;YouBringthe
Party™;SureFire™;UniversalGrillParts™ TEC™isatrademarkofTecInfraredGrills.
TM REVISION 00
®
Estimated Assembly Time: 1 Hour

DANGER
Safety Symbols
The symbols and boxes shown below explain what each heading
means. Read and follow all of the messages found throughout
the manual.
DANGER: Indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
WARNING
WARNING: Indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
CAUTION
CAUTION: Indicates a potentially hazardous situation or
unsafe practice which, if not avoided, may result in minor
or moderate injury.
CAUTION
For residential use only. Do not use for commercial
cooking.
2
This instruction manual contains important
information necessary for the proper
assembly and safe use of the appliance.
Follow all warnings and instructions when
using the appliance.
ProductRecordInformation............................1
PreparingtouseyourSmoker..........................3
LimitedWarranty.....................................6
ForYourSafety......................................2
SafetySymbols......................................2
CookingTips........................................4
SmokerMaintenance.................................5
PartsList/PartsDiagram..............................7
Assembly........................................8-21
HardwareList.......................................7
RegistrationCard...................................24
TABLE OF CONTENTS
WARNING
CALIFORNIA PROPOSITION 65
1. Combustible by-products produced when using
this product contains chemicals known to the State
of California to cause cancer, birth defects, or
other reproductive harm.
2. This product contains chemicals, including lead
and lead compounds, known to the State of
California to cause cancer, birth defects or
other reproductive harm.
Wash your hands after handling this product.
WARNING
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.
WARNING
FAILURE TO READ AND FOLLOW INSTRUCTIONS FOR
LIGHTING CHARCOAL MAY RESULT IN SERIOUS PERSONAL
INJURY AND OR PROPERTY DAMAGE.
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.
• Keep children and pets away.
• Do not move this unit during operation.
• Never substitute gasoline, kerosene or alcohol
for charcoal starter. In some states, the use of
charcoal starter is prohibited by law. In this
case, paraffin-based starter cubes can be
substituted for charcoal starter. Never use
charcoal starter fluid with an electric starter.

1. Brush all interior surfaces including grills and grates with vegetable cooking oil.
2. Build a small fire on the fire grate, being sure not to lay coals against the walls.
3. Close door. (Position butterfly damper and smokestack damper approximately at one quarter open.) This burn
should be sustained for at least two hours, the longer the better. Then, begin increasing temperature by opening the
butterfly damper and smokestack damper half-way and adding more charcoal. YourAmerican Gourmet Deluxe Smoker
is now ready for use.
Rust can appear on the inside of your smoker. Maintaining a light coat of vegetable oil on interior surfaces will aid in the
protection of your unit. Exterior surfaces of smoker may need occasional touch up. We recommend the use of a
commercially available black high temperature spray paint. NEVER PAINT THE INTERIOR OF THE UNIT!
GRILLING
Wood is recommended, however charcoal or a combination of both may be used as the fuel source for grilling, with the
fuel source placed and ignited on the fire grate. Do not build too large of a fire. We recommend starting a fire with no
more than 4 pounds of charcoal (approximately 60 briquets) and adding more as needed during cooking. After allowing
the fire to burn down, place the cooking grills in the smoker. Failure to read and follow instructions for lighting charcoal
may result in serious personal injury and/or property damage.
SMOKING AND SLOW COOKING
If using theAmerican Gourmet Deluxe Smoker as a smoker or slow cooker, remove the cooking grill from the firebox and
build your fire on top of the fire grate in the firebox. Either charcoal or wood may be used, but wood is the recommended
fuel for it’s rate of burn and the flavor it imparts to the food being cooked. Most seasoned hardwoods are good for smoking
such as hickory, mesquite, pecan, oak, and many other fruit woods. The firebox will accommodate most split fireplace size
logs (16”). Bark should be avoided or burned off first as it contains a high acid content and imparts an acrid flavor.
After allowing the fire to burn down, close the doors and control the temperature and smoke with the dampers located on
the firebox and atop the smokestack. Smoke is contained within the chambers, which will reduce burn while imparting
more smoke flavor. Do not operate the Deluxe Smoker with temperatures exceeding 450 degrees in the smoker chamber.
Place the food in the smoker chamber and monitor the temperature. Cooking and smoking are taking place using indirect
heat. There is no need to worry about a grease fire flare-up ruining the food. Do not place food within 6” of the opening
from the firebox into the smoker chamber. Ageneral rule of thumb for cooking is about 1 hour per pound for smoking
large cuts of meat. Refer to a cook book for specific cuts of meats. Limit the number of times you open the smoker
chamber door as this will allow heat to escape and extend the cooking time.
flavors to your first foods.
the finish and season the interior steel. Failure to properly follow these steps may damage the finish and/or impart metallic
Before cooking with yourAmerican Gourmet Deluxe Smoker, the following steps should be closely followed to both cure
Preparing and Using Your American Gourmet Deluxe Smoker
Grilling with Wood Chips/Wood Chunks
For a more robust smoke flavor while using charcoal briquettes or lump charcoal, try adding wood chips or
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. 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.
Our Recommendations:
Chicken - Alder, Apple, Hickory, Mesquite, Sassafras
Beef - Hickory, Mesquite, Oak, Grapevines
Pork - Fruitwoods, Hickory, Oak, Sassafras
Lamb - Fruitwoods, Mesquite
Veal - Fruitwoods, Grapevines
Seafood - Alder, Mesquite, Sassafras, Grapevines
Vegetables – Mesquite
USDA Recommended
Internal Cooking Temperatures
Ground Meat
Beef, Pork, Veal, Lamb......................................160°F
Turkey, Chicken.................................................165°F
Fresh Beef, Veal, Lamb
Medium Rare.......................................................145°F
Medium................................................................160°F
Well Done............................................................170°F
Poultry
Chicken & Turkey, whole.....................................165°F
Poultry Parts.......................................................165°F
Duck & Goose....................................................165°F
Fresh Pork
Medium..............................................................160°F
Well Done..........................................................170°F
3

THE HEAT OF THE COALS
seconds you can
hold the palm of
your hand 4 inches
above the coals temperature range (Fº) visual cues
HOT COALS 2 400 to 450 barely covered with
gray ash; deep red glow
MODERATELY HOT 375 to 450 thin coating of gray
ash; deep red glow
MODERATELY HOT COALS 4 325 to 375 significant coating of
gray ash; red glow
MODERATELY COOL COALS 5 300 to 325 thick coating of gray
ash; dull red glow
3
Building Your Fire
1.) Stack charcoal briquettes or wood into a pyramid-shaped pile on top of the charcoal grate
or ash pan. We recommend using 4 pounds (approximately 50 - 60 briquettes) to start your
fire, adding more as needed.
2.) If using lighter fluid, saturate the charcoal briquettes with lighter fluid and let it soak in for
approximately 5 minutes. If using a chimney starter, electric starter, or other type of fire
starter, light your fire according to the manufacturer's instructions.
3.) After allowing the lighter fluid to properly soak in, light the pile of briquettes in several
locations to ensure an even burn. Always light the fire with the grill lid open.
Leave lid open until briquettes are fully lit. Failure to do this could trap fumes from charcoal
lighter fluid in grill and may result in a flash fire when lid is opened.
4.) Never add charcoal lighter fluid to hot or warm coals as flashbacks may occur causing
injury.
5.) You are ready to begin cooking when the pile of briquettes ashes over and produces a red
glow (approximately 12 – 15 minutes).
6.) Depending on your cooking method, either leave the briquettes in a pile or spread evenly
across the charcoal grate using a long-handled poker.
*Always use caution when handling hot coals to prevent injury.
Know When Your Fire is Ready
Successful charcoal grilling depends on a good fire. The general rule for knowing when your coals
are ready for grilling is to make sure that 80 percent or more of the coals are ashy gray. If you
have less than that, the coals are not ready, and if all of them are glowing red hot, the fire is
probably too hot. Here are a few steps you can take to adjust the temperature of your fire:
- If it is too hot, spread the coals out a bit more, which makes the fire less intense.
- Raise or lower the adjustable charcoal grate.
- Partially close the vents in the grill, which reduces the amount of oxygen that feeds the fire.
- Use the indirect grilling method, with coals to either side of a drip pan and the food over the
pan rather than directly over the coals.
- In the event of a severe flare-up, spray the flames with water from a squirt bottle. Be
careful, spraying with water tends to blow ashes around and make a mess.
- Add briquettes 2 or 3 at a time to increase the burn time. Allow 10 minutes for coals to ash
over before adding more.
4
COOKING TIPS
TO HOT COALS

GRILL MAINTENANCE
Frequency of cleanup is determined by how much your smoker is used. Make sure coals are completely extinguished
before cleaning inside of smoker. Inside surfaces may be cleaned with a strong solution of detergent and water applied
with a scrub brush. Thoroughly rinse with water and allow to air dry before using again.
HELPFUL HINTS
• If food seems to be getting too smoky or brown before the cooking time is finished, cover it loosely with heavy duty
aluminum foil.
•Remove the ash after each use.
•Covered side dishes can be warmed in smoker chamber.
•To prevent flare-ups, brush meat lightly with oil before grilling.
•Keep a small squirt bottle of water handy for grilling flare-ups.
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.
5

LIMITED WARRANTY
6
SCOPE OF COVERAGE PERIOD OF COVERAGE TYPE OF FAILURE COVERAGE
PERFORATION, MANUFACTURING,
AND MATERIAL DEFECTS ONLY
All Parts 90 days from date of purchase*
This warranty only applies to units purchased from an authorized retailer. 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.
*Note: A dated sales reciept WILL be required for warranty service.
The original consumer-purchaser will be responsible for all shipping charges for 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 proof of your date of purchase. Therefore, you should retain your sales slip or invoice. Registering your product is not a
substitute for proof of purchase and the manufacturer is not responsible for or required to retain proof of purchase records.
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.
ITEMS MANUFACTURER WILL NOT PAY FOR:
1. Shipping cost, standard or expedited, for warranty and replacement parts
2. Service calls to your home.
3. Repairs when your product is used for other than normal, single-family household or residential use.
acts of God, improper installation or maintenance, installation not in accordance with electrical or plumbing codes, or use
of products not approved by the manufacturer.
5. Any food loss due to product failures or operating difficulties.
6. Replacement parts or repair labor costs for units operated outside the United States or Canada.
7. Pickup and delivery of your product.
8. Repairs to parts or systems resulting from unauthorized modifications made to the product.
9. The removal and/or reinstallation of your product.
DISCLAIMER OF IMPLIED WARRANTIES and LIMITATION OF REMEDIES
Repair or replacement of defective 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 implied 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 BYTHE 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 PROTECTIONARISING 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 purchase price of the
product paid by the original consumer.
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 foth 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 consumer-purchaser
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:
Consumer Relations
P. O. Box 1240
Columbus, GA 31902-1240
Consumer returns will not be accepted unless a valid Return Authorization is first acquired. Authorized returns are clearly marked on the outside of
the package with an RA number and the package is shipped freight/postage pre-paid. Consumer returns that do not meet these standards will be
refused.
LIMITED WARRANTY
WS_1 Rev02
4. Damage, failures, or operating difficulties resulting from accident, alteration, careless handling, misuse, abuse, fire, flood,
RUST is not considered a manufacturing or materials defect.

PARTS LIST
7
Key Qty Description
1 1 Right Legs
2 1 Left Legs
31
Shelf
41
Axle
52
Wheel
62
Wheel Cap
72
Leg Brace
81
Firebox Support
91
Grill Base
10 1 Front Shelf
11 2 Front Table Support
12 1 Charcoal Tray
13 1 Charcoal Grate
14 2 Charcoal Grate Adjuster
15 3 Cooking Grate
16 1 Warming Rack
17 1 Grill Lid
18 1 Smokestack Bracket
19 1 Smokestack
20 1 Smokestack Damper
21 1 Spring
22 1 Temperature Gauge
23 1 Grill Lid Handle
24 1 Firebox Lid Stop
25 1 Firebox Lid
26 1 Firebox Lid Handle
27 1 Push Handle
28 2 Firebox Cooking Grate
29 1 Firebox Door Hinge
30 1 Firebox Door
31 1 Firebox Air Shutter
32 1 Firebox Charcoal Grate
33 1 Firebox Door Latch
34 1 Firebox Base
35 1 Grease Cup Holder
…1
LOGO Plate
…1
Hardware Bag
…1
Instruction Manual, English
…1
Instruction Manual, French

2
1
ASSEMBLY
8
FIRST, GET A HELPER! This unit is heavy and requires a second person for lifting and moving. NEXT, pick a suitable
location to work. Open the carton and slit the corners so that the carton lays flat. This will give you a protective surface
during assembly.
Insert bottom shelf (item #3) into holes on the inside of the legs. Do not fully tighten screws until Step 6 is complete.
Connect right (item #1) and left legs (item #2) together (2 pairs). Front pair of legs will have 2 extra holes for the front shelf
supports as illustrated. Do not fully tighten screws until Step 6 is complete.

3
4
9
Install leg braces (item #7), with support flange towards center of grill, onto the legs using eight M6 x 15mm Phillips head bolts.
Do not fully tighten screws until Step 6 is complete.
Put axle rod (item #4) through the holes on the right legs. Put wheels (item #5) onto the axle rod (item #4) and place the
wheel caps (item #6) over the axle rod ends.
NOTE: Leg brace with two
holes for grease cup must
be mounted on right side of
grill legs.

5
6
10
Install firebox support bracket (item #8) onto the holes on the left legs using two M6 x 15mm Phillips head bolts. Do not tighten bolts
until Step 6 is completed.
Install grill base (item #9), with firebox opening towards left side, on top of the legs using four M6 x 15mm Phillips head bolts.
Install two M6 x 15mm Phillips head bolts and M6 hex nuts through grill base (item #9) and flange on leg braces (item #7)..
FULLY TIGHTEN ALL SCREWS AND NUTS AT THIS TIME.

8
7
11
Attach front shelf (item #10) to front of grill base using two M6 x 15mm Phillips head bolts. Attach table supports (item #11) with
slotted holes towards front shelf using four M6 x 15mm Phillips head bolts.
Attach push handle (item #27) onto the firebox lid (item #25) using two M6 x 15mm Phillips head bolts.

10
9
12
Attach smaller handle (item #26) to the firebox lid using two M5 x 12mm Phillips head bolts and M5 hex nuts.
Attach firebox lid stop (item #24) using one M5 x 12mm Phillips head bolt and M5 hex nut.

11
12
13
Attach air shutter (item #31) onto the firebox door (item #30) using one M6 x 15mm Phillips head bolt and M6 hex nut. Do
not over-tighten air shutter, air shutter should move freely.
Attach door latch (item #33) using one M5 x 12mm Phillips head shoulder bolt and M5 hex nut as illustrated.
Connect firebox door hinge (item #29) to the outside of the door (item #30) and firebox base (item
#34) using four M5 x 12mm Phillips head bolts and M5 hex nuts.
Attach one M6 x 15mm Phillips head shoulder bolt onto the firebox base (item #34) for the door
latch (item #33).
Note orientation of hinge.

Connect firebox lid (item #25) and firebox base (item #34) using six M6 x 15mm Phillips head
bolts.
14
13
14 Connect firebox and grill base (item #9) together using six M6 x 15mm Phillips head bolts.

15
16
Connect firebox support (item #8) with firebox base (item #34) using two M6 x 15mm Phillips head bolts and M6 hex nuts.
Install smokestack bracket (item #18) into grill lid (item #17 using two M6 x 15mm Phillips head bolts and M6 hex nuts.
15

17
18
Install smokestack (item #19) onto the smokestack bracket (item #18).
To install the temperature gauge (item #22), insert into center hole on grill lid (item #17), then turn it clockwise to upright
position.
16

19
20
Attach grill lid handle (item #23) using two M6 x 15mm Phillips head bolts and M6 hex nuts.
Install grill lid (item #17) on grill base (item #9) using two M8 x 23mm Phillips head shoulder bolts.
17

21
22
Attach the charcoal tray (item #12) to charcoal grate (item #13) by hooking tray edges onto the grate frame.
Use charcoal grate adjusters (item #14) to lower charcoal grate assembly into grill base (item #9). Rest charcoal grate
adjusters on supports in grill base (item #9).
18
END VIEW

23
24
Install the warming rack (item #16) inside the grill lid (item #17). Insert the cotter pins through the holes from the outside of
grill lid (item #17).
Align the warming rack support arm holes with the holes on the side panel of grill base (item #9). Using two M6 cap nuts,
two M6 washers, and two M6 x 15mm Phillips head shoulder bolts.
Place cooking grills (item #15) on support lips of grill base (item #9).
19

25
26
Place firebox charcoal grate (item #32) inside the bottom of firebox.
Place firebox cooking grills (item #28) inside the top of the firebox base (item #34).
20