Char-Broil 7201560 User manual

P/N 42804297 (10-02-07)
Tools needed for
assembly:
2 Adjustable Wrenches
7/16” Open-End Wrench
Flat Screwdriver
04201101
07201560
Smoker, BBQ and Grill
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.
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.
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.
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.
CAUTION
THIS UNIT IS HEAVY!
DO NOT assemble without a helper.
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.
If you have questions or need assistance during assembly, please call .
To insure your satisfaction and for follow-up service, register your grill online at www.grillregistration.com
1-800-241-7548

Key # Part Number Description Quantity
A 55710232 SILVER SMOKE CHAMBER KIT 1
B 29001712 FIREBOX TOP 1
C 55710234 FIREBOX BOTTOM KIT 1
D 55710235 WOOD SHELF KIT 1
E 55700442 AXLE KIT 1
F 55700443 WHEEL KIT 1
G 55700183 LEG BRACE KIT 2
H 55710236 SMOKESTACK KIT 1
I 55710237 SHORT LEG KIT 2
J 55700186 LONG LEG KIT 2
K 55700187 SHELF BRACKET KIT 2
L 24810036 HOLE PLUG 1
M 55710238 DOOR LATCH KIT 1
N 55710239 LOGO PLATE KIT 1
O 55710204 DELUXE HANDLE KIT, WOOD SPACERS 2
P 55700192 BUTTERFLY DAMPER KIT 2
Key # Part Number Description Quantity
Q 29101311 WIRE FIRE GRATE 3
R 40009916 GRATE, COOKING, SMOKER 2
S 40009925 GRATE, COOKING, FIREBOX 1
T 44830150 GREASE CLIP 1
U 46030090 RACK, WOOD 1
V 44810036 FIREBOX COVER PLATE 1
… 40003010 OPTIONAL TEMP GAUGE 1
… 42030350 SNAP BAG 1
… 42804297 INSTRUCTION ASSEMBLY 1
… 40053116 OUTER CARTON 1
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PARTS LIST
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.

Attach leg braces to the outside of one leg assembly using #10-24x1-3/4” screws and #10-24 flange nuts. Make sure
slotted (oval) hole is toward bottom of leg. DO NOT FULLY TIGHTEN screws until Step 6 is complete.
2
1FIRST, 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 work surface
during assembly.
TO BEGIN ASSEMBLY, build two leg assemblies by sliding the long leg sections into the short leg sections.
Long leg section
Leg brace
Short leg section
Slotted
hole
Leg brace Do not fully tighten screws
until Step 6 is complete.

3Lay the leg assembly on its side with legs braces pointing upward. Insert the wood rack hooks into leg holes and swing rack
upward, parallel to leg braces.
4With the aid of a helper, place leg holes of remaining leg assembly over wood rack hooks and rotate leg assembly until it
meets the leg braces. Make sure both short legs are at one end of the rack and both long legs at the other end. Attach to leg
braces using #10-24x1-3/4” screws and #10-24 flange nuts. DO NOT FULLY TIGHTEN screws until Step 8 is complete.
Wood rack
Short leg
Short leg
Long leg
Long leg
Do not fully tighten screws
until Step 6 is complete.

6
5Insert a cotter pin into the hole at one end of the axle and bend the ends of the pin back so that it cannot be removed. Slide
a wheel onto the axle. Slide the axle through the holes at the ends of the short legs. Slide remaining wheel onto axle and
secure with remaining cotter pin.
Axle
NOTE: Smoker chamber door not pictured
for clarity.
Stand the leg assembly on end, wheels
down. Stand the smoker chamber on its
solid end, open end up. Place leg assembly
against chamber, aligning holes in legs with
holes in chamber.Attach legs to chamber
using four 1/4-20x2” screws and 1/4-20
flange nuts. Insert screws from outside,
flange nuts inside chamber.
FULLY TIGHTEN ALL
SCREWS AND NUTS AT
THIS TIME.
Smoker chamber
Cotter pin
Cotter pin
Wheels down
Open end up

7
8
Attach Firebox TopAssembly to Firebox BottomAssembly using eight 1/4-20x3/4” hex-head
bolts as shown below.
NOTE: Smoker chamber and firebox doors not pictured for clarity.
TM TM
Diamond Fire Plate Installation - For models without Diamond Fire ignitor accessory,
part number 22504850.
TM
For models that feature the Diamond Fire ignitor accessory, supplemental instructions
are included with ignitor.
First, locate the cover plate in the hardware box.At the bottom right end of the
TM
firebox there is an opening for the Diamond Fire ignitor accessory. Install the
cover plate over the opening using two #8-32x1/2” screws and #8-32 lock nuts.
Second, align the hole pattern on the firebox with the pattern on the
smoker chamber. The firebox should be slightly offset from the smoker
chamber. Attach using six 1/4-20x3/4” hex-head bolts and flat washer
inside firebox and 1/4-20 flange nuts inside smoker chamber.
Firebox Top Assembly
Firebox Bottom Assembly
Firebox
Firebox
Cover Plate

9
10
Smokestack
Smokestack plate
NOTE: Smoker chamber door not pictured for clarity.
From inside the smoker chamber, slide the smokestack through the large hole.Align the two holes in the smokestack plate
with the holes in the chamber and secure with two 1/4-20x3/4” hex-head bolts outside the chamber and 1/4-20 flange nuts
inside.
NOTE: Firebox and smoker chamber not pictured for clarity.
Attach wood handle to smoker chamber door using two 1/4-20x4” screws, wood handle spacers, fiber washers and 1/4-20
flange nuts, as shown below. Repeat to attach handle to firebox door.
Smoker Chamber
Door
Wood Handle Spacer
Handle
Firebox
Door
Fiber Washer

11
12
NOTE: Smoker chamber door not pictured for clarity.
Install grate support screws in the four rear holes and two
front-center holes in the smoker chamber. Use six #10-24x1”
screws and #10 flange nuts.
NOTE: Smoker chamber door not pictured for clarity.
Attach shelf brackets to outer holes on front of smoker chamber
using two 1/4-20x1-1/4” hex-head bolts and 1/4-20 flange nuts.
DO NOT FULLY TIGHTEN until Step 13.
Shelf bracket
Do not fully tighten
until Step 13.

Hole plug
NOTE: Smoker chamber door not pictured for clarity.
First, attach shelf slats to the two outer holes in shelf brackets using
two #10-24x1” screws and #10-24 flange nuts per slat. DO NOT
FULLY TIGHTEN SCREWS.
Second, fully tighten hex-head bolts on shelf brackets (installed in
previous step).
Third, attach remaining shelf slat to brackets with two #10-24x1”
screws and #10-24 flange nuts. FULLY TIGHTEN ALL SHELF
SLAT SCREWS.
14
13 Attach two outer
shelf slats. Do not
tighten.
1st
Attach inner slat.
Fully tighten all
slat screws.
3rd
Tighten bracket bolts.
2nd
If you have purchased the optional 3” Temperature Gauge,
part number 40003010, remove the attached nut, insert
gauge stem into large hole in cooking chamber door and
attach nut to gauge on inside of door. DO NOT
OVERTIGHTEN NUT. Make sure text and graphics are
aligned for easy viewing.
If you do not have a temperature gauge, install the chrome
hole plug (provided) into temperature gauge hole in cooking
chamber door.
If you would like to purchase the optional 3” Temperature
Gauge, part number 40003010, call 1-800-241-7548.

16
15Hang grease clip from holes on bottom right side of smoker chamber.A 12 oz. soup or vegetable can will fit nicely into clip to
collect grease.
Grease
Clip
If logo plate is not already installed, insert logo plate pins into two holes in lower right corner of smoker chamber door. Press
logo plate clips onto pins until snug against inside of door.
Logo plate
Logo plate clip