Char-Broil American Gourmet 02204809 User manual

P/N 42804003 • 02204809 (12-06-07)
Tools needed for
assembly:
Adjustable Wrench
Screwdriver
04201101
02204809
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

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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.
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Key Part Number Desription Quantity
A 29000054 SMOKER CHAMBER 1
B 29000055 FIREBOX CHAMBER 1
C 29000056 SMOKE STACK ASSEMBLY 1
D 55700057 DAMPER KIT 1
E 40690000 FRONT SHELF, WOOD SLAT 3
F 29000061 FRONT SHELF, WOOD SLAT BRACKET 2
G 40690001 WOOD HANDLE 3
H 29000058 LONG LEG 2
I 29000059 SHORT LEG 2
J 29000060 LEG BRACE 2
K 29100070 SMOKER DOOR 1
L 29100071 FIREBOX DOOR 1
Key Part Number Desription Quantity
M 41540001 WHEEL 2
N 10000122 WHEEL AXLE 1
O 41530000 TEMP GAUGE W/ CLIP 1
P 44830150 GREASE HOLDER 1
Q 40009913 FIRE GRATE 2
R 40009914 COOKING GRATE 2
S 10000074 LEG CAP, 1 3/8", PLASTIC 2
T 55710209 HINGE KIT 4
… 14502819 COOKBOOK 1
… 42804003 ASSEMBLY INSTRUCTIONS 1
… 42030494 LFW SNAP BAG, 02204809 1
… 40010679 OUTER CARTON 1

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1
• 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 1/4-20x1-3/4” screws
and two 1/4-20 flange nuts per leg
assembly.
• Lay unit onto its back.
• Attach leg braces on each side using four
1/4-20x1-3/4” screws and four 1/4-20
flange nuts per brace.
• When complete, return unit to its right side,
as positioned in step 1.
Smoker
Chamber
Long Leg with End Cap
Short Leg – No End Cap
Leg Brace

3
•Slide axle into holes at ends of short legs
(legs without end caps).
•Attach wheels onto axle rod using cotter
pins. Bend cotter pin ends to prevent them
from backing out of axle as shown in boxA.
Check to be sure that all screws and nuts
used so far are fully tightened.
4
•Place the firebox onto the smoker chamber
and align the large openings.
•Insert six 1/4-20x1/2” screws through the
firebox, into the smoker chamber. Secure
with six 1/4-20 flange nuts.
Fully tighten all screws and nuts.
Axle
Wheel
Firebox
Cotter Pin
Axle
Cotter pin
A

5
•Place unit in upright position.
•Attach front shelf supports to smoker
chamber using one 1/4-20x1/2” screw and
one 1/4-20 flange nut per support.
6
•Attach wood shelf slats to front shelf
supports using six #10-24x1” screws and
six #10-24 flange nuts.
Wood Shelf Slat
Front Shelf
Support

7
8
Smokestack
•Insert two 1/4-20x2-1/4” 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 clip onto probe
until tight against door. See inset illustration
for clip position.
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.
Wood Handle
Spacer
Firebox Door
Smoker Chamber Door
Temperature Gauge
Temperature Gauge Clip

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10
•Following the same procedure used on the
doors, install wood handle on left side of
firebox with two 1/4-20x2-1/4” carriage
bolts and two 1/4-20 flange nuts.
Tighten flange nuts until bolt heads are flush
with wood.
Wood Handle
Spacer
•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.
Fire Grates

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12
•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.
Cooking Grates
•Hang the grease clip under the smoker
chamber on right side.
•An empty soup can is recommended to
hang from grease clip.
Grease
Clip

Before you begin . . .
Familairize yourself with the major components and controls of
the unit.
Smokestack
Damper
Smoker
Chamber
Firebox
Firebox
Damper
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 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.
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.