Char-Broil 9201556 User manual

Product Guide
Model 09201556
Tools needed for assembly:
Pliers
Adjustable wrenches
(Tools not provided)
Longhorn Deluxe
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 inside 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
42804475 - 02/09/09
Model Number
Date Purchased
IMPORTANT: Fill out the product record information below.
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;D459,148 D459,149;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.Bradley Co.: CommercialSeries™;DesignerSeries™; Grill2Go®Advantage™;Longhorn™;DoubleChef™; QuickSet™; ReadyWhenYouAre™;Hog andYardBird™;YouBringthe
Party™;SureFire™;UniversalGrillParts™ TEC™isatrademarkofTecInfraredGrills.
TM REVISION 00
®
Estimated Assembly Time: 30 minutes

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 an 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
PreparingtouseyourGrill.............................3
LimitedWarranty.....................................6
ForYourSafety......................................2
SafetySymbols......................................2
GrillMaintenance....................................3
CookingTips......................................4-5
PartsList/PartsDiagram..............................7
Assembly........................................8-10
RegistrationCard...................................12
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.

PREPARING TO USE YOUR LONGHORN GRILL/SMOKER
Before cooking with your Grill, the following steps should be closely followed to both cure the finish
and season the interior steel. Failure to properly follow these steps may damage the finish and/or impart
metallic flavors to your first foods.
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 lid. Position butterflies at approximately one quarter open. This burn should be sustained for at least
two hours. Begin increasing temperature by opening the butterflies halfway and adding more charcoal. Your
Santa Fe Grill is now ready for use.
Rust can appear on the inside of your grill. Maintaining a light coat of vegetable oil on interior surfaces will aid
In the protection of your grill. Exterior surfaces of the grill may need occasional touch up. We recommend the
Use of commercially available black high temperature spray paint. NEVER PAINT THE INTERIOR OF THE
UNIT!
Charcoal is recommended, however wood or a combination of both may be used as the fuel source for grilling,
With the fuel source placed and ignited on the ash pan. 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 grill in the unit. Failure to read and follow
instructions for lighting charcoal may result in serious personal injury and or property damage.
Frequency of clean up is determined by how often the grill is used. Make sure coals are completely
extinguished before cleaning inside of unit. Thoroughly rinse with water and allow to air dry before using again.
GRILLING
Wipe out the interior of unit with cloth or paper towel.
GRILL 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.
Cooking Surface: 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.
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.
Always open lid BEFORE opening the ash door to
check fire or fuel.
Always open the ash door slowly. Never attempt to
look inside the grill while opening the ash door when
the grill is in use.
Failure to follow these instructions could result in
injury.
Unburned gas can accumulate and cause a flash fire
if the lid is not opened first.
WARNING
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

Direct and Indirect Grilling
Direct Grilling - For most grilling, the ignited coals are spread in a single layer under the food. This
is called direct grilling and is appropriate for relatively quick-cooking items such as hamburgers,
steaks and most seafood. The single layer of coals emits even, steady heat, whether the grill lid is
open or closed, and represents the way most people grill. For more control, pile some of the coals
on one side of the grill where they will emit intense heat. You can move the food around on the grill,
setting it over the very hot coals when you want to sear it or when a thick piece needs to cook a
little more quickly. You can also use the adjustable charcoal grate and dampers to control the
temperature in your grill.
Indirect Grilling/Smoking - For items that take longer to cook, you will want to use indirect grilling.
This method is for long, slow cooking in a covered grill. For indirect cooking, the coals are piled two
or three coals deep on one side of the grill, or divided and piled on two sides. This leaves an empty
space next to the coals or between them. Food cooked over indirect heat is often started over
direct heat and then moved to the cooler (empty) part of the grill for even, slow cooking. To make
the heat as even as possible, construct two piles of coals. It is common to place a metal drip pan in
the empty space beside or between the coals, which is filled with water, wine, beer, broth, or a
combination. Place the food directly over the drip pan. This injects a little extra moisture into the
cooking environment and also catches dripping juices, which makes clean-up a little easier and
reduces the possibility of flare-ups. (Remember to keep a spray bottle filled with water on hand to
extinguish any flare-ups.) Once you get used to the indirect method, you may prefer to use it for
more grilling tasks. Although it may take a little longer, it is an excellent cooking method and a sure
way to prevent the food from burning and to promote even cooking.
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, Grapevines
Beef - Hickory, Mesquite, Oak, Grapevines
Pork - Fruitwoods, Hickory, Oak, Sassafras
Lamb - Fruitwoods, Mesquite
Veal - Fruitwoods, Grapevines
Seafood - Alder, Mesquite, Sassafras, Grapevines
Vegetables – Mesquite
5
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

LIMITED WARRANTY
6
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 BY THE MANUFACTURER. NO PRODUCT PERFORMANCE
SPECIFICATION OR DESCRIPTION WHEREVERAPPEARING IS WARRANTED BY MANUFACTURER EXCEPT TO THE EXTENT SET
FORTH IN THIS LIMITED WARRANTY. ANY IMPLIED WARRANTY PROTECTION ARISING 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. 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.
SCOPE OF COVERAGE PERIOD OF COVERAGE TYPE OF FAILURE COVERAGE
PERFORATION, MANUFACTURING,
AND MATERIAL DEFECTS ONLY
All Parts 90 days from date of purchase*

Key Qty Description
A 1 Smoker Chamber
B 1 Firebox
C 3 Spring Handle Kit
D 1 Smokestack
E 1 Barn Door Latch
F 1 Butterfly Damper
G 1 Louvered Front Panel
H 1 Heat Shield
I 1 Left Cabinet Door
J 1 Right Cabinet Door
K 1 Cabinet
L 1 Front Shelf, Expanded Metal
Key Qty Description
M 1 Door Magnet
N 1 Grease Drawer
O 2 Fire Grate
P 3 Cooking Grate, Small, Cast Iron
Q 1 Cooking Grate, Large, Cast Iron
R 2 Temperature Guage
S 2 Caster Wheel
T 2 Wheel, 16"
U 1 Axle
V 1 Logo Plate Kit
--- 1 Assembly Instructions - English
--- 1 Hardware Pack
PARTS LIST
7
C
A
B
D
E
F
S
R
Q
P
O
N
K
I
J
U
T
L
V
M
G
H

ASSEMBLY
8
The expanded metal front shelf comes assembled and
is ready to attach to unit. Insert frame into bushings
2as shown.
1.Slide wheels onto axle. Push cotter pin
through holes near the ends of the axle.
Using pliers,bend cotter pins so they cannot
back out.
cotter pins
Bend ends of cotter
pin with pliers
Cotter pin
16” wheel
Front shelf assembly
After unpacking the unit, make sure you organize all parts. Discard all packing material in a safe manner.
Save this assembly instruction for future reference.
THIS UNIT IS EXTREMELY HEAVY.
Move with caution. Unit should never be left unattended without first making sure casters are locked.
Locate two
.
and two 16" wheels

9
Attach smokestack
3sliding stack into smokestack receive.r. Tighten
bolt in nut welded to smokestack
receiver to hold smokestack in vertical position.
3/8”-16 x3/4” Smokestack
The charcoal
4in the firebox when smoking and in
the cooking chamber if grilling.
There are three small cooking grates
and one larger cooking grate.
These can be used in any
configuration in the cooking
chamber.
Large
cooking
grate
Smokestack
receiver
Tighten bolt
Cooking chamber
Firebox
Charcoal
grate
Small
cooking
grate
to end of smoke chamber by
grate should be used

10
6
5Install temperature
gauges by placing the
stem through the
threaded bushing in
each cooking chamber
door. Thread and
tighten until gauge text
is in the desired
position.
Slide the grease drawer into the
Temperature gauge
side of the cabinet.
Grease drawer
opening on the left

REGTEMP REV00