Char-Broil The Big Easy 10101550 User manual

FOR OUTDOOR USE ONLY
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
CAUTION:
Read and follow all warnings and instructions
before assembling and using the appliance.
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.
10101550• 42804468 • 12-01-09
Serial Number
Date Purchased
IMPORTANT: Fill out the product record information below.
See rating label on unit for serial number.
© 2008 Char-Broil, LLC Printed in China• Columbus, GA31902 • •Assembly Instructions © 2009
Smoker, Roaster & Grill
Product Guide
Model 10101550
EstimatedAssembly Time: 1 Hour
The following are trademarks registered by W.C. Bradley Co. in the U.S. Patent and Trademark Office: Caldera®; Charcoal2Go®; Char-Broil®; America's
Legendary Barbeque Company®;American Gourmet®; Bandera®; Brush Hawg®; CB 940®; Char-Diamonds®; Char-Broil Charcoal/Gas®; Everybody Grills®;
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® ®
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D104,200;D108,377;2,315,567;France:D010,231;D010,422;D010,590;D010,849;1,089,646;SouthKorea:384,565;UnitedKingdom:2,099,402.OtherPatentsPending. ©2009W.C.BradleyCompany
The following are trademarks of W.C. Bradley Co.: Advantage Series™; Auto-Clean™;Chef Tested™; Commercial Series™; Designer Series™;; Diamond
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SureFire™;TheMinuteGrill™;Torchfork™;UniversalGrillParts™;YouBringtheParty™ TEC™isatrademarkofTecInfraredGrills.
TM REVISION 03

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.
DANGER
If you smell gas:
1. Shut off gas to the appliance.
2. Extinguish any open flame.
3. Open lid.
4. If odor continues, keep away from the appliance
and immediately call your fire department.
Failure to follow these instructions could result in
fire or explosion, which could cause property
damage, personal injury or death.
DANGER
1. Never operate this appliance unattended.
2. Never operate this appliance within 10ft (3m) of
any structure, combustible material or other gas
cylinder.
3. Never operate this appliance within 25 ft (7.5 m)
of any flammable liquid.
4. If a fire should occur, keep away from the
appliance and immediately call your fire
department.
Failure to follow these instructions could result in
fire, explosion or burn hazard, which could cause
property damage, personal injury or death.
CAUTION
For residential use only. This appliance is not
intended for commercial use.
WARNING
Do not attempt to repair or alter the
hose/valve/regulator for any “assumed” defect. Any
modification to this assembly will void your warranty
and create the risk of a gas leak and fire. Use only
authorized replacement parts supplied by
manufacturer.
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.
Do not use this appliance on or under any
apartment or condominium balcony or deck.
ProductRecordInformation............................1
Installation Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FoodSafety ........................................4
LimitedWarranty....................................11
ForYourSafety......................................2
SafetySymbols......................................2
UseandCare ....................................5-10
PartsList/PartsDiagram.............................12
Assembly.......................................13-16
Troubleshooting..................................19-20
RegistrationCard...................................24
TABLE OF CONTENTS
Page 2

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.
Installation Safety Precautions
•Use your appliance, as purchased, only with LP (propane) gas
and the regulator/valve assembly supplied.
•The appliance installation must conform with local codes, or in
their absence of local codes, with either the National Fuel Gas
Code, ANSI Z223.1/ NFPA 54, Natural Gas and Propane
Installation Code, CSA B149.1, and Propane Storage and
Handling, CSA B149.2, Canadian Electrical Code, CSA C22.1
or the Standard for Recreational Vehicles, ANSI
A 119.2/NFPA 1192, and CSA Z240 RV Series, Recreational
Vehicle Code, as applicable.
•This appliance is not for use in or on recreational vehicles
and/or boats.
• This appliance is safety certified for use in the United States
and/or Canada only. Do not modify for use in any other
location. Modification will result in a safety hazard.
Page 3

Food Safety
Food safety is a very important part of enjoying the outdoor
cooking experience. To keep food safe from harmful bacteria,
follow these four basic steps:
Clean: Wash hands, utensils, and surfaces with hot soapy water
before and after handling raw meat and poultry.
Separate: Separate raw meats and poultry from ready-to-eat
foods to avoid cross contamination. Use a clean platter and
utensils when removing cooked foods.
Cook: Cook meat and poultry thoroughly to kill bacteria. Use a
thermometer to ensure proper internal food temperatures.
Chill: Refrigerate prepared foods and leftovers promptly.
For more information call: USDA Meat and Poultry Hotline at
1-800-535-4555 In Washington, DC [phone], 10:00 am-
4:00 pm EST.
How To Tell If Meat Is Cooked Thoroughly
•Meat and poultry cooked in the appliance often browns very
fast on the outside. Use only thawed meat and a meat
thermometer to be sure food has reached a safe internal
temperature, and cut into food to check for visual signs of
doneness.
•We recommend food to be at least 40°F before cooking in your
appliance.
•Whole poultry should reach 165° F. Juices should run clear
and flesh should not be pink.
•Beef, veal and lamb steaks, roasts and pork chops can be
cooked to 160° F.
•NEVER partially cook meat or poultry and finish cooking later.
Cook food completely to destroy harmful bacteria.
•Use a meat thermometer to ensure proper internal food
temperatures.
Storing Your Appliance
• Clean cooking basket.
• Store in dry location.
• When LP cylinder is connected to appliance, store outdoors in
a well-ventilated space and out of reach of children.
• If the regulator is disconnected from the LP cylinder, a hook is
provided to hang the regulator from the handle as shown.
• Cover appliance if stored outdoors. Choose from a variety of
covers offered by the manufacturer.
• Store indoors ONLY if LPcylinder is turned off and is
disconnected, removed from appliance and stored outdoors.
• When removing appliance from storage, follow “Cleaning the
Burner Assembly” instructions before starting.
Grease Tray
• Never use drippings directly from the grease tray to make
gravy. Use the included foil tray liner to catch drippings, then
reheat the drippings to kill bacteria. Replacement foil tray liners
and other accessories can be found at www.charbroil.com.
“For Best Results”
Place poultry into the appliance
with breast up as shown.
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
Page 4

• NEVER store a spare LP cylinder under or near the
appliance or in an enclosed area.
• Never fill a cylinder beyond 80% full.
• An over filled or improperly stored cylinder is a hazard
due to possible gas release from the safety relief valve.
This could cause an intense fire with risk of property
damage, serious injury or death.
• If you see, smell or hear gas escaping, immediately get
away from the LP cylinder/appliance and call your fire
department.
• Keep LP tank at a minimum distance of 24” (inches) away
from appliance at all times.
DANGER
USE AND CARE
LP (Liquefied Petroleum Gas)
•LP gas is nontoxic, odorless and colorless when produced. For
Your Safety, LP gas has been given an odor (similar to rotten
cabbage) so that it can be smelled.
•LP gas is highly flammable and may ignite unexpectedly when
mixed with air.
LP Cylinder Filling
•Use only licensed and experienced dealers.
•LP dealer must purge new cylinder before filling.
•Dealer should NEVER fill LP cylinder more than 80% of LP
cylinder volume. Volume of propane in cylinder will vary by
temperature.
•Afrosty regulator indicates gas overfill. Immediately close LP
cylinder valve and call local LP gas dealer for assistance.
• Do not release liquid propane (LP) gas into the atmosphere.
This is a hazardous practice.
• To remove gas from LP cylinder, contact an LP dealer or call a
local fire department for assistance. Check the telephone
directory under “Gas Companies” for nearest certified LP
dealers.
LP Cylinder Removal, Transport and Storage
• Turn OFF the control knob and LP cylinder valve.Turn coupling
nut counterclockwise by hand only - do not use tools to
disconnect. Install safety cap onto LP cylinder valve.Always
use cap and strap supplied with valve. Failure to use safety
cap as directed may result in serious personal injury
and/or property damage.
• Adisconnected LP cylinder in
storage or being transported
must have a safety cap installed (as shown).
Do not store an LP cylinder in enclosed spaces
such as a carport, garage, porch, covered
patio or other building. Never leave an LP cylinder
inside a vehicle which may become overheated
by the sun.
• Do not store an LP cylinder in an area where children play.
LP Cylinder
• The LP cylinder used with your appliance must meet the
following requirements:
•Use LP cylinders only with these required measurements: 12"
(30.5cm) (diameter) x 18" (45.7 cm) (tall) with 20 lb. (9 kg.)
capacity maximum.
• LP cylinders must be constructed and marked in accordance
with specifications for LP cylinders of the U.S. Department of
Transportation (DOT) or the National Standard of Canada,
CAN/CSA-339, Cylinders, Spheres and Tubes for
Transportation of Dangerous Goods; and commission, as
applicable. See LP cylinder collar for marking.
•LP cylinder valve must have:
• Type 1 outlet compatible with
regulator or appliance.
• Safety relief valve.
• ULlisted Overfill Protection
Device (OPD). This OPD safety
feature is identified by a unique triangular hand wheel. Use
only LP cylinders equipped with this type of valve.
• LP cylinder must be arranged for vapor withdrawal and include
collar to protect LP cylinder valve.Always keep LP cylinders in
upright position during use, transit or storage.
OPD Hand Wheel
LP Cylinder Valve
Retainer Strap
Safety
Cap
24”
Page 5

WARNING
If “growing” bubbles appear do not use or move the LP
cylinder. Contact an LP gas supplier or your fire
department!
Connecting Regulator to the LP Cylinder
1. LP cylinder must be properly secured onto . (Refer to
assembly section.)
2. Turn all control knobs to the OFF position.
3. Turn LP cylinder OFF by turning hand-wheel clockwise to a
full stop.
4. Remove the protective cap from LP cylinder valve.Always use
cap and strap supplied with valve.
appliance
Safety Relief Valve
Nipple has to be centered
into the LP cylinder valve.
OPD Hand Wheel
Type 1 outlet with
thread on outside
c k w
o
l
i
s
C
e
f
f
O
Do not use a POL transport plug
(plastic part with external threads)!
It will defeat the safety feature of
the valve.
Strap and Cap
LP Cylinder Exchange
• Many retailers that sell offer you the option of
replacing your empty LP cylinder through an exchange service.
Use only those reputable exchange companies that inspect,
precision fill, test and certify their cylinders. Exchange your
cylinder only for an OPD safety feature-equipped cylinder
as described in the "LP Cylinder" section of this manual.
•Always keep new and exchanged LP cylinders in upright
position during use, transit or storage.
•Leak test new and exchanged LP cylinders BEFORE
connecting to the appliance.
LP Cylinder Leak Test
For your safety
•Leak test must be repeated each time LP cylinder is exchanged
or refilled.
•Do not smoke during leak test.
•Do not use an open flame to check for gas leaks.
•This appliance must be leak tested outdoors in a well-ventilated
area, away from ignition sources such as gas fired or electrical
appliances. During leak test, keep appliance away from open
flames or sparks.
• Use a clean paintbrush and a 50/50 mild soap and water
solution.
• Do not use household cleaning agents. Damage to gas train
components can result.
this appliance
Brush soapy solution onto areas indicated by arrows
in figure below.
5. Hold regulator and insert nipple into LP
cylinder valve. Hand-tighten the
coupling nut, holding regulator in a
straight line with LP cylinder valve so
as not to cross-thread the connection.
•Place dust cap on cylinder valve outlet whenever the cylinder is
not in use. Only install the type of dust cap on the cylinder valve
outlet that is provided with the cylinder valve. Other types of caps
or plugs may result in leakage of propane.
Page 6

6. Turn the coupling nut clockwise and tighten to a full stop. The
regulator will seal on the back-check feature in the LP cylinder
valve, resulting in some resistance. An additional one-half to
three-quarters turn is required to complete the
connection. Tighten by hand only – do not use tools.
NOTE:
If you cannot complete the connection, disconnect regulator and
repeat steps 5 and 6. If you are still unable to complete the
connection, do not use this regulator!
Straight
Hold coupling nut and regulator
as shown for proper connection
to LP cylinder valve.
DANGER
• Do not insert any tool or foreign object into the valve
outlet or safety relief valve. You may damage the valve
and cause a leak. Leaking propane may result in
explosion, fire, severe personal injury, or death.
Leak Testing Valves, Hose and Regulator
1. Turn control knob to OFF.
2. Be sure regulator is tightly connected to LP cylinder.
3. Completely open LP cylinder valve by turning hand wheel
counterclockwise. If you hear a rushing sound, turn gas off
immediately. There is a major leak at the connection. Correct
before proceeding.
4. Brush soapy solution onto areas circled below.
5. If “growing” bubbles appear, there is a leak. Close LP
cylinder valve immediately and retighten connections. If leaks
cannot be stopped do not try to repair. Call for replacement
parts. Order new parts by giving the serial, model number and
name and part number of items needed (see parts list) to the
Grill Service Center at the number listed on front cover.
6. Always close LP cylinder valve after performing leak test by
turning hand wheel clockwise.
• This appliance is not intended to be installed in or on a
boat.
• is not intended to be installed in or on an
RV.
• Never attempt to attach this to the self-
contained LP gas system of a camper trailer or motor
home.
• Do not use until leak-tested.
• If a leak is detected at any time, STOPand call the fire
department.
• If you cannot stop a gas leak, immediately close LP
cylinder valve and call LP gas supplier or your fire
department!
This appliance
appliance
this appliance
WARNING
Page 7

24”
3 ft.
3 ft.
WARNING
CAUTION
• Putting out grease fires by closing the lid is not
possible. This appliance is well ventilated for safety
reasons.
• Do not use water on a grease fire. Personal injury
may result. If a grease fire develops, turn knobs
and LP cylinder off.
• Do not leave appliance unattended while burning
off food residue. If appliance has not been regularly
cleaned, a grease fire can occur that may damage
the product.
For Safe Use of Your appliance and to Avoid Serious
Injury:
•The use of alcohol, prescription or non-prescription
drugs may impair the consumer's ability to properly
assemble or safely operate the appliance.
•When cooking, the appliance must be on a level, stable
noncombustible surface in an area clear of combustible
material.An asphalt surface (blacktop) may not be
acceptable for this purpose.
•Do not leave appliance unattended. Keep children and
pets away from the appliance at all times.
•Do not place empty cooking vessel on the appliance
while in operation. Use caution when placing anything in
cooking vessel while the appliance is in operation.
•Do not move the appliance when in use.Allow the
cooking vessel to cool to 115°F (45°C) before moving or
storing.
•This appliance is not intended for and should never be
used as a heater.
•This appliance will be hot during and after use. Use
insulated oven mitts or gloves and long-handled
barbecue utensils for protection from hot surfaces or
splatter from cooking liquids.
•Keep appliance area clear and free from materials that
burn.
•Keep appliance area clear and free from combustible
materials, gasoline and other flammable vapors and
liquids.
•Keep fuel supply hose away from any heated surfaces.
•Use only in well-ventilated space. NEVER use
in enclosed space such as carport, garage, porch,
covered patio, or under an overhead structure of any
kind.
• Use appliance at least 3 ft. from any wall or surface.
Maintain 10 ft. clearance to objects that can catch fire or
sources of ignition such as pilot lights on water heaters,
live electrical appliances, etc.
appliance
• Apartment Dwellers:
Check with management to learn the requirements and
fire codes for using an LP gas appliance in your
apartment complex. If allowed, use outside on the ground
floor with a three (3) foot clearance from walls or rails. Do
not use on or under balconies.
• NEVER attempt to light burner with any type of
closed cover . A buildup of non-ignited gas inside a
closed appliance is hazardous.
• Never operate appliance with LP cylinder out of
correct position specified in assembly instructions.
• Always close LP cylinder valve and remove coupling
nut before moving LP cylinder from specified
operation position.
Safety Tips
•Before opening LP cylinder valve, check the coupling nut for
tightness.
•When this appliance is not in use, turn off control knob and LP
cylinder valve.
•The grease tray must be inserted into appliance and emptied
after each use.
•If you notice grease or other hot material dripping from
appliance onto valve, hose or regulator, turn off gas supply at
once. Determine the cause, correct it, then clean and inspect
valve, hose and regulator before continuing. Perform a leak
test.
•Do not store objects or materials under the appliance
enclosure that would block the flow of combustion air to the
underside of either the control panel or the firebox bowl.
•The regulator may make a humming or whistling noise during
operation. This will not affect safety or use of the appliance.
•If you have an appliance problem see the "Troubleshooting
Section".
•If the regulator frosts, turn off appliance and LPcylinder valve
immediately. This indicates a problem with the cylinder and it
should not be used on any product. Return to supplier!
• Clean grill often, preferably after each cookout. 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.
Page 8

CAUTION
If ignition does NOT occur in 5 seconds, turn the
control knob OFF, wait 5 minutes and repeat the
lighting procedure. If the burner does not ignite with
the valve open, gas will continue to flow out of the
burner and could accidently ignite with risk of injury.
Turn control knob and LP cylinder OFF when not in
use.
WARNING
Ignitor Lighting
• Do not lean over appliance while lighting.
• Read all instructions before lighting.
1. Turn ON LP gas cylinder.
2. Open lid during lighting.
3. Press and turn the control knob to HIGH.
4. Turn ROTARYIGNITOR knob rapidly.
5. If ignition does not occur in 5 seconds, turn the burner control
knob OFF, wait 5 minutes, and repeat lighting procedure.
If ignition still does not occur, follow match-lighting
instructions.
Match-Lighting
Do not lean over appliance while lighting.
1. Turn ON LP cylinder.
2. Swing match hole plate to expose match lighting hole. Place
lit match into match lighting hole of appliance as pictured
below. Make sure lit match is placed inside hole and near
burner.
3. Push in and turn control knob to HIGH. Be sure burner lights
and stays lit.
4. Once lit, swing match hole plate back to cover up match
lighting hole. Caution: Plate maybe hot.
View is from side of appliance
Match
Match
Lighting
Hole
Match
Hole
Plate
Swing Plate
to expose
Matchlighting
Hole
Control
Knob
Turning Appliance Off
• Turn control knob to position. Turn LP cylinder off by
turning hand-wheel clockwise to a full stop.
Ignitor Check
• Turn gas off at LP cylinder. Turn ignitor knob. "Click" should
be heard each time at electrode. See "Troubleshooting" if no
click or spark.
Valve Check
• Important: Make sure gas is off at LP cylinder before
checking valve. Knob locks in position. To check valve,
first push in knob and release, knob should spring back. If knob
does not spring back, replace valve assembly before using this
appliance. Turn knob to LOW position then turn back to
position. Valve should turn smoothly.
Hose Check
•Before each use, check to see if hose is cut, worn or kinked.
Replace damaged hose before using applaince. Use only
valve/hose/regulator specified by manufacturer.
General Appliance Cleaning
• Meat Thermometer: Do not immerse or soak in water. Wash
with warm soapy water and wipe dry.
• Do not mistake brown or black accumulation of grease and
smoke for paint. Interiors are not painted at the factory (and
should never be painted).Apply a strong solution of detergent
and water or use a grill cleaner with scrub brush on insides of
appliance lid and bottom. Rinse and allow to completely air dry.
Do not apply a caustic grill/oven cleaner to painted
surfaces. Ablack surface improves the appliances
performance.
• Plastic parts: Wash with warm soapy water and wipe dry.
Do not use citrisol, abrasive cleaners, degreasers or a
concentrated grill cleaner on plastic parts. Damage to and
failure of parts can result.
• Painted surfaces: Wash with mild detergent or non-abrasive
cleaner and warm soapy water. Wipe dry with a soft non-
abrasive cloth.
•
OFF
OFF
OFF
Cooking surfaces: 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.
Burner Flame Check
• Light burner. Looking through viewing hole on top of appliance,
you should see the flame height as shown below. Turn control
knob from HIGH to LOW. The Flame height should decrease
and then go out.Always check flame prior to each use. If only
low flame is seen refer to "Sudden drop or low flame" in the
Troubleshooting Section.
Normal
Hose Kinked
Hose
High Flame Low Flame High Flame
Page 9

Cleaning the Burner Assembly (Continued)
9. Clean inner burner as recommended below, shown E.
We suggest three ways to clean the burner tube. Use the one
easiest for you.
(A) Bend a stiff wire (a light weight coat hanger works well)
into a small hook. Run hook through burner tube several
times.
(B) Use a narrow bottle brush with a flexible handle (do not
use a brass wire brush), run the brush through burner
tube several times.
(C) Wear eye protection: Use an air hose to force air into
the burner tube and out the burner ports. Check each
port to make sure air comes out each hole.
10. Check burner for damage, due to normal wear and corrosion
some holes may become enlarged. If any large cracks or
holes are found replace burner.
11. Carefully replace heat shield and control panel assembly .
12. Reattach electrode wire to ignitor.
VERY IMPORTANT: Burner tube must re-engage over valve
opening. See illustration, shown F.
11. Reattach front legs. Carefully stand the unit upright.
13. Reposition inner liner, cooking basket.
Burner
(exposed)
Burner
(exposed)
Tube cleaner
(see above
recommendations)
Cooking
Basket
Cooking
Chamber
Remove Screws
Control
Panel
Assembly
Electrode
Wire
Valve engaged inside burner
tube end correctly
(Control panel and heat sheild
hidden for clarity)
Valve Burner Tube
B
CD
EF
CAUTION
SPIDER ALERT!
VALVE
CONTROL PANEL SPIDER WEBS
INSIDE VENTURI
If you notice that your the appliance is getting hard to light or
that the flame isn’t as strong as it should be, take the time to
check and clean the venturi’s.
In some areas of the country, spiders or small insects have been
known to create “flashback” problems. The spiders spin webs, build
nests and lay eggs in the the appliance’s venturi tube(s) obstructing
the flow of gas to the burner. The backed-up gas can ignite in the
venturi behind the control panel. This is known as a flashback and it
can damage your the appliance and even cause injury.
To prevent flashbacks and ensure good performance the burner and
venturi assembly should be removed from the the appliance and
cleaned before use whenever the the appliance has been idle for an
extended period.
BURNER
SPIDER AND WEBS
INSIDE BURNER
Cleaning the Burner Assembly
Follow these instructions to clean and/or replace parts of burner
assembly or if you have trouble igniting appliance.
1. Turn gas OFF at control knob and LP cylinder and
disengage regulator from cylinder.
2. Open top cover, remove cooking basket and cooking
Chamber, shown A. This will expose the burner from inside,
shown B.
3. Wire brush entire outer surface of burner to remove food
residue and dirt.
4. Clean any blocked ports with a stiff wire such as an open
paper clip.
5. Carefully lay the appliance on its back, with control panel
facing up shown C.
6. Disconnect electrode wire underneath appliance, shown C.
7. Remove screws and disengage front legs from appliance.
8. Remove screws and disengage control panel assembly and
heat shield from unit, shown D.
Remove
Front Legs
Carefully place
unit on its back. Heat Shield
Burner
Tube
A
Page 10
Please note that the burner
shown is for illustration
purposes only. The burner in
your product may be different
from the one shown.

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 OFANY 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.
SCOPE OF COVERAGE PERIOD OF COVERAGE TYPE OF FAILURE COVERAGE
PERFORATION, MANUFACTURING,
AND MATERIAL DEFECTS ONLY
All Parts 90 days from date of purchase*
Page 11

PARTS DIAGRAM
Key Qty Description
A 1 Outer Body
B 1 Inner Body
C 1 Body Top Ring
D 1 Burner
E 1 Heat Shield
F 1 Ignition Kit
G 1 Logo Plate
H 1 Cooking Chamber
I 1 Roaster Basket
J 2 Side Handles
K 3 Handle Springs
L 1 Control Panel
Key Qty Description
M 1 Ignitor Knob
N 1 Control Knob
O 1 Top Lid
P 4 LegAssembly
Q 1 Grease Tray
R2Grease Tray Rails
S 1 Hose, Valve, RegulatorAssembly
T 1 Heat Shield
U 1 Lift Hook
X. 1 Smoker BoxAssembly
V 1 Meat Thermometer
W 1 Cooking GrateAssembly
NOTE: Some grill parts shown in the assembly steps may differ slightly in appearance from
those on your particular model. However, the method of assembly remains the same.
R
S
K
AA
F
Q
N
Y
D
G
I
A
BH
JJ
C
K
L
T
U
M
Key Qty Description
Y 1 Wind Shield
Z 2 Wire Grate, Half Rack
AA 4 Burner Support
BB 1 Top Handle
CC 1
DD 1 HingeAssembly, Left
... 1 Hardware Pack
... 1 Assembly Manual, English
... 1 Assembly Manual, Spanish
HingeAssembly, Right
V
W
X
O
CC
DD
E
Z
K
BB
P
Page 12

ASSEMBLY
2
1
Tools required for assembly:
Phillips Screwdriver (Not Supplied); Small Adjustable Wrench (Not Supplied)
•Carefully turn the unit upside down.
Slide Heatshield into place over the exposed burner tube.
•
Align hole in
Heat Shield
with end of
Burner Tube
Heat Shield in Position
•While holding the Heat Shield in place, slide the Control PanelAssembly into place, taking care to ensure that
the valve engages the burner tube. shown Figure A
•Install two #10x3/8" self-tap screws through the right side of the control panel. Leave screws loose.
Make sure valve is inside burner tube.Align the heat shield as shown Figure B.
•
Hold Heat Shield in place while attaching Control Panel
NOTE:
Install these
NOTE:
Ensure that the valve engages the burner tube
Ignitor Wire
Qty: 4
#10x3/8"
Self-Tap Screw
Fig. A
Proper Valve to Burner Tube installation
(veiw from underneath control panel)
Page 13
Burner
Tube
Valve
End
Ignitor Wire
Screw hole
for leg - used
later.
screws first!
Fig. B
Secure control panel using the two remaining #10x3/8” self-tap screws. Tighten all four screws.
Screw hole
for leg - used
later.
Heat shield
Control
Panel
Carefully insert valve end into burner tube making sure valve is centered with burner tube,
after aligned correctly, loosely secure with two self-tap screws on RH side of control panel.

Ignitor
Wire
The windshield is held in place once the legs are attached.
3•The ignitor wire is factory installed to the ignitor. Pass the loose end of the wire through the
hole in the body, shown Figure A
•Place Windshield inside the bottom of the body. NOTE: Fasteners are not required for the windshield. .
Figure B
Grease Tray Rail
Windshield
Figure A
Ignitor
•Attach round end of ignitor wire to electrode.
Page 14

4•Install legs by engaging leg tabs over bottom edge of the
appliance body.
•
•Slide the grease tray into the rear of the unit.
•Once the leg is in place, attach two #10-24x1" screws
through the leg and into the appliance body.
•Repeat for the remaining legs.
When all four legs are securely installed, carefully turn the
unit upright.
Qty: 8
#10-24x1" Screw
#10-24x1/2"
Screw
5
Grease tray
rails
Grease Tray
Leg Tabs shown
in proper
position.
Qty: 4
#10-24x1/2" Screw
•Attach the side handle assemblies to the unit using two #10-24x1/2" screw per
handle.
•Install the control knobs on to the valve stem and the ignitor stem.
Control
Knob
Ignitor
Knob
Page 15
#10-24x1"
Screw

Page 16
Qty: 8
#10-24x3/8" Screw
Qty: 4
#10-24 Keps Nut
Qty: 8
Fiber Washer
7
•Attach the hinges to the lid inserting a #10-24x3/8" screw into
hinge, install a fiber washer onto screw, align lid onto screw,
install fiber washer from inside the lid, and finally secure with a
#10-24 Keps nut. Repeat for opposite hinge. Shown A.
#10-24 Keps nut
#10-24x1" Screw
Fiber Washer
Qty: 2
#10-24x1" Screw
Qty: 2
#10-24 Keps Nut
Qty: 4
Fiber Washer
•Attach the lid handle by inserting a #10-24x1" screw into handle, install a fiber washer onto screw, align handle onto lid screw
hole, install fiber washer from inside the lid, and finally secure with a #10-24 Keps nut.
•Repeat for opposite side.
•Slide the Cooking Chamber and Cooking Basket into the unit.
6
A
#10-24x3/8"
Screw
#10-24 Keps nut
Fiber
Washer
B
• Install lid by aligning the LH and RH hinges at the rear of
the unit and securing with 4 #10-24x3/8" screws as
shown B.
LH Hinge
RH Hinge

Accessory Use and Storage
Cooking
Basket
NOTE: Before cooking on your appliance for the first time, refer to the separate Cooking Guide on how to prepare the appliance for
cooking. It is recommended that you season your appliance prior to cooking.
•Once seasoning is complete, the appliance is now ready for use. The cooking chamber will continue to darken with use. This will
inhibitrustingalongwithimprovingtheperformanceoftheinfraredcookingsystem.
•The bottom of the Cooking Grate has a locating ring. Be sure that the locating ring faces down and is centered in the
cooking Chamber when using the Cooking Grate. Otherwise, the Cooking Grate could slip off the top of the
appliance.
Never use the Cooking Grate upside down!
Cooking Grate shown
in proper position.
Assembling your Half Racks into the cooking basket is very easy.
Just insert the Half Rack through the side of the cooking basket at the desired
level.
Allow the Half Rack legs to rest securely on the cooking basket wire.
Make sure the legs are OUTSIDE of the cooking basket. This prevents the
Half Racks from slipping.
Two Half Racks are included with your Smoker, Roaster, & Grill. Please visit us at
www.charbroil.com and click on the Buy Online link to purchase additional Half Rack sets.
When using the Cooking Basket, insert it into the Cooking Chamber as
shown.
All four Legs outside
of cooking basket.
Locating
Ring on bottom
of Cooking Grate
Locating
Ring
Never use the
Cooking Grate
upside down!
Note:
Cooking Grate
shown
transparent
for clarity
Page 17

Half Rack Storage
Accessory Use and Storage
Accessory storage
Accessory items such as the cooking grate, smoker box and half racks can be
stored on board the Smoker, Roaster, & Grill as shown.
Hanging hooks
Hole
Cooking Grate Storage Smoker Box Storage
Slot
Smoker Box
The Smoker Box has a clip that secures it into one of the four vent holes on
the top ring of the appliance. Insert the clip as shown. When smoking, you will
use the smoker box with the cooking basket.
Insert clip into
vent hole.
Smoker Box
shown in place.
Smoker box in place along with cooking basket
All accessories
properly stored.
Page 18

EMERGENCIES: If a gas leak cannot be stopped, or a fire occurs due to gas leakage, call the fire department.
Emergencies
Problem
Gas leaking from
cracked/cut/burned
hose.
Gas leaking from LP
cylinder.
Gas leaking from LP
cylinder valve.
Gas leaking between
LP cylinder and
regulator connection.
Fire coming through
control panel.
Grease fire or
continuous excessive
flames above cooking
surface.
Burner will not light
using ignitor.
Possible Cause
Possible Cause
• Damaged hose.
• Mechanical failure due to rusting or
mishandling.
• Failure of cylinder valve from
mishandling or mechanical failure.
• Improper installation, connection not
tight, failure of rubber seal.
• Fire in burner section of burner due to
blockage.
• Too much grease buildup in burner area.
GAS ISSUES:
• Burner not engaged with control valve.
• Obstruction in burner.
• No gas flow.
• Vapor lock at coupling nut to LP cylinder.
• Coupling nut and LP cylinder valve not
fully connected.
ELECTRICAL ISSUES:
• Electrode cracked or broken; “sparks at
crack.”
• Electrode tip not in proper position
• Wire and/or electrode covered with
cooking residue.
• Wire is loose or disconnected.
• Wire is shorting (sparking) between
ignitor and electrode.
Prevention/Solution
Prevention/Solution
• Turn off gas at LP cylinder or at source on natural gas systems. If
hose is cut or cracked, replace valve/hose/regulator. See LP
Cylinder Leak Test and Connecting Regulator to the LP Cylinder.
• Replace LP cylinder.
• Turn off LP cylinder valve. Return LP cylinder to gas supplier.
• Turn off LP cylinder valve. Remove regulator from cylinder and
visually inspect rubber seal for damage. See LP Cylinder LeakTest
and Connecting Regulator to the LP Cylinder.
• Turn off control knob and LP cylinder valve.Allow flames to die
down.After fire is out and fryer is cold, remove burner and inspect
for spider nests or rust. See Natural Hazard and Cleaning the
BurnerAssembly pages.
• Turn off control knob and LP cylinder valve.Allow flames to die
down.After cooling, clean food particles and excess grease from
inside appliance body, grease tray, and other surfaces.
• Make sure valve is positioned inside of burner .
• Ensure burner is not obstructed with spider webs or other matter.
See cleaning section of Use and Care.
• Make sure LP cylinder is not empty. If LP cylinder is not empty,
refer to “Sudden drop in gas flow.”
• Turn off knob and disconnect coupling nut from LP cylinder.
Reconnect and retry.
• Turn the coupling nut approximately one-half to three-quarters
additional turn until solid stop. Tighten by hand only - do not use
tools.
• Replace electrode.
• Tip of electrode should be pointing toward gas port opening on
burner. The distance should be 1/8” to 1/4”.Adjust if necessary.
• Clean wire and/or electrode with rubbing alcohol and clean swab.
• Reconnect wire or replace electrode/wire assembly.
• Replace ignitor wire/electrode assembly.
Troubleshooting
Page 19

Troubleshooting (continued)
Possible Cause
• Rotary knob rotates without clicking.
• Sparking between ignitor and electrode.
• See “GAS ISSUES:” on previous page.
• Match will not reach.
• Improper method of match-lighting.
• Out of gas.
• Excess flow valve on regulator tripped.
• Vapor lock at coupling nut/LP cylinder
connection.
• Low on LP gas.
• Excess flow valve tripped.
• Grease buildup.
• Excessive fat in meat.
• Excessive cooking temperature.
• Grease trapped by food buildup around
burner system.
• Burner is blocked.
• Some dealers have older fill nozzles
with worn threads.
• Vapor Lock
• Valve not properly aligned to burner
• High wind conditions
Prevention/Solution
• Replace knob.
• Inspect wire insulation and proper connection. Replace wire if
insulation is broken.
• Use long-stem match (fireplace match).
• See “Match-Lighting” section of Use and Care.
• Check for gas in LP cylinder.
• Turn off control knob, wait 30 seconds and light appliance. If flames
are still low, turn off knob and LP cylinder valve. Disconnect
regulator. Reconnect regulator and leak-test. Turn on LPcylinder
valve, wait 30 seconds and then light appliance.
• Turn off knob and LP cylinder valve. Disconnect coupling nut from
cylinder. Reconnect and retry.
• Refill LP cylinder.
• Refer to “Sudden drop in gas flow” above.
• Clean burner and inside of fryer body.
• Trim fat from meat before grilling.
• Adjust (lower) temperature accordingly.
• Turn knob to OFF. Turn gas off at LP cylinder. Let fire burn out. After
fryer cools, remove and clean all parts.
• Turn knob to OFF. Clean burner. See burner cleaning section of Use
and Care.
• The worn nozzles don’t have enough “bite” to engage the valve. Try
a second LP dealer.
• Turn off control knob and disconnect coupling nut from LP cylinder.
Reconnect and retry.
• Loosen control panel and valve. Be sure valve is centered top to
bottom and left to right in burner . Tighten all components once
proper alignment is achieved.
• Relocate the appliance to a less windy area. Use Top Cover during
cooking.
Problem
Burner will not light
using ignitor.
Burner will not match
light.
Sudden drop in gas
flow or low flame.
Flames blow out.
Flare-up.
Persistent grease fire.
Flashback...
(fire in burner ).
Unable to fill LP
cylinder.
Cooking slower than
expected
Page 20