Char-Griller Flavor Pro 7400 User manual

Flavor Pro™
Keep your receipt with
this manual for warranty.
CUSTOMER SERVICE
1-912-638-4724
[e-mail]
Model #7400
Contents of this manual are Trademarked and Copyrighted by Char-Griller | A&J Manufacturing.
Using the information contained in this manual without consent of Char-Griller and/or A&J
Manufacturing is strictly prohibited.
OM_7400_ED_ A.2
OWNER’S MANUAL
PATENTED
& PATENTS PENDING

TABLE OF CONTENTS
Safety Warnings & Warranty...............................A-1
Assembly Instructions ..................................... B-1
Product Usage .................................................. C-1
Recipes .............................................................. D-1
Accessories ....................................................... E-1
If you smell gas:
1. Shut off gas to the appliance.
2. Extinguish any open ame.
3. If odor continues, keep away from the
appliance and immediately call your gas
supplier or your re department.
1. Do not store or use gasoline or other
ammable liquids or vapors in the vicinity
of this or any other appliance.
2. An LP cylinder not connected for use
shall not be stored in the vicinity of this
or any other appliance.
For Outdoor Use Only (outside any enclosure).
Danger Warning
Warning

A-1
A propane gas cylinder is required for operation. This gas grill is not intended for
commercial use.
SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE. IF YOU ARE ASSEMBLING
THIS UNIT FOR SOMEONE ELSE, GIVE THIS MANUAL TO HIM OR HER TO SAVE FOR
FUTURE REFERENCE.
For use outdoors and in well-ventilated areas, only.
WARNING:
Improper installation, adjustment, alteration, service, or maintenance could cause injury or property
damage. Read the installation, operation, and maintenance instructions thoroughly before assembling
or servicing this equipment. Failure to follow these instructions could result in re or explosion that could
cause property damage, personal injury, or death.
DANGER:
DO NOT use gas grill for indoor cooking or heating. TOXIC fumes can accumulate and cause
asphyxiation. Do not use in or on boats or recreational vehicles.
WARNING:
Accessible parts may be very hot. Keep young children away. Read the instruction literature before
using the appliance. The use of unauthorized parts can create unsafe conditions and environment.
NOTE: The use and installation of this product must conform to local codes or, in absence of local
codes, the Natural Gas and Propane Installation Code, CSA B149.1, or the Propane Storage and
Handling Code,CSA B149.2.
IMPORTANT NOTICE: Read all instructions prior to assembly and use. Read and understand all
warnings and precautions prior to operating your grill.
READ ALL SAFETY WARNINGS AND INSTRUCTIONS CAREFULLY BEFORE
ASSEMBLING AND OPERATING YOUR GRILL
IMPORTANT SAFETY WARNINGS
WARNING: FUELS USED IN WOOD OR CHARCOAL BURNING APPLIANCES, AND THE PRODUCTS OF COMBUSTION OF SUCH FUELS, CAN EXPOSE
YOU TO CHEMICALS INCLUDING CARBON BLACK, WHICH IS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, AND CARBON MONOXIDE,
WHICH IS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM. For more information go to:
www.P65Warnings.ca.gov.
ADVERTENCIA:LOS COMBUSTIBLES USADOS EN EQUIPOS PARA QUEMAR MADERA O CARBÓN, ASÍ COMO LOS PRODUCTOS DE TAL COMBUSTIÓN,
PUEDEN EXPONERTE A SUSTANCIAS QUÍMICAS, ENTRE ELLAS EL NEGRO DE HUMO Y EL MONÓXIDO DE CARBONO, QUE EL ESTADO DE CALIFORNIA
RECONOCE COMO CAUSA, RESPECTIVAMENTE, DE CÁNCER Y DE MALFORMACIONES CONGÉNITAS Y OTROS DAÑOS AL SISTEMA REPRODUCTOR.
Para más información, visite www.P65Warnings.ca.gov
WARNING: FUELS USED IN LIQUEFIED PROPANE GAS APPLIANCES, AND THE PRODUCTS OF COMBUSTION OF SUCH FUELS, CAN EXPOSE YOU TO
CHEMICALS INCLUDING BENZENE, WHICH IS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER AND CAUSE BIRTH DEFECTS OR OTHER
REPRODUCTIVE HARM. For more information go to: www.P65Warnings.ca.gov.
ADVERTENCIA:LOS COMBUSTIBLES USADOS EN EQUIPOS PARA LICUAR GAS PROPANO, ASÍ COMO LOS PRODUCTOS DE SU COMBUSTIÓN,
PUEDEN EXPONERTE A SUSTANCIAS QUÍMICAS, ENTRE ELLAS EL BENCENO, QUE EL ESTADO DE CALIFORNIA RECONOCE COMO CAUSA DE CÁNCER
Y DE MALFORMACIONES CONGÉNITAS Y OTROS DAÑOS AL SISTEMA REPRODUCTOR. Para más información, visite www.P65Warnings.ca.gov

A-2
Read the following instructions carefully and be sure your barbecue is properly assembled, installed
and maintained. Failure to follow these instructions may result in serious bodily injury and/or property
damage. If you have any questions concerning assembly or operation, consult your dealer or LP
gas company.
• When used, always place the appliance and gas bottle on at level ground. Grill can be used with
20lb gas cylinder. Grill will perform better if propane or LPG mixtures are used. Butane can be used,
but because of the rate of the appliance the cylinder will tend to freeze and supply gas at reduced
pressures, affecting grill performance.
• DO NOT move the appliance during use.
• DO NOT attempt to disconnect any gas ttings while barbecue is in use.
• DO NOT use gas bottle if the bottle and/or valve are damaged, rusty, or dented as this may be
hazardous. Contact your supplier to have it checked.
• DO NOT lean over an open grill and be mindful of hands/ngers near the edge of the cooking area.
• Should a re occur, turn off all gas burners, close the lid, and stand back from grill until re is out.
• Should ames go out while in operation, turn off all gas valves and leave lid open. Return to grill
after ve minutes and try to relight the burners – following lighting instructions.
• Keep children and pets away from grill when in use. Some parts of the grill will become very hot.
• When cleaning the valves and burners, be careful not to stretch the valve orices or burner ports.
• Move gas hoses as far away as possible from hot surfaces and dripping hot grease.
• Gas may still be present in a cylinder that appears to be empty. Adhere to proper transportation/
storage of the cylinder at all times.
• If gas is leaking from cylinder, move away from cylinder immediately and call your gas supplier or
re department. DO NOT try to address problem yourself.
• DO NOT use a ame to check for gas leaks.
• DO check for gas leaks and any obstructions to burners before use. This is especially important
after a period of storage or non-use.
• The exible tube should be changed whenever it is damaged or cracked or by expiration date
printed on the tubing. Or, change tube every ve (5) years.
• Always connect or replace cylinder in a well-ventilated area, and never in the presence of a ame,
spark or heat source.
• Grill must be kept away from ammable materials.
• Turn off gas supply at gas container after use.
• Do not alter this grill in any manner.
• Do not touch metal parts of grill until it has completely cooled (about 45 minutes) to avoid burns,
unless you are wearing protective gear (BBQ mittens, pot holders, etc.).
• Note that parts sealed by manufacturer or its agent must not be altered.

A-3
• When assembling the grill, position the connection exible tube so that it is protected
against twisting.
• Stay away from any source of ignition when changing gas container.
• When assembling the grill, do not obstruct ventilation openings of grill’s container compartment. We
reserve the right to make minor technical adjustments to the device.
• When cooking with oil/grease, do not allow the oil/grease to exceed 350°F (177°C). Do not store or
use extra cooking oil in the vicinity of this or any other appliance.
• Never ll the cylinder beyond 80% full. Not following the above information exactly may result in a
re causing death or serious injury.
• Do not store a spare LP gas cylinder under or near this appliance.
CAUTION
• This grill is for use with propane gas only (propane gas cylinder not included).
• Never attempt to attach this grill to the self-contained propane system of a camper trailer, motor
home or house.
• Do not use gasoline, kerosene or alcohol for lighting. The LP gas supply cylinder must be
constructed and marked in accordance with the specications for propane gas cylinders of the U.S.
Department of Transportation (DOT) CFR 49.
• The gas supply cylinder must be provided with a listed overlling prevention device.
• The gas supply cylinder must be provided with a cylinder connection device compatible with the
connection for outdoor cooking appliances.
• This grill is not intended for use on recreation vehicles and/or boats.
• Do not use grill unless it is completely assembled and all parts are securely fastened and tightened.
• Keep all combustible items and surfaces at least 36 inches (91.4cm) away from grill at all times.
• DO NOT use this grill or any gas product near unprotected combustible constructions.
• Do not use in an explosive atmosphere. Keep grill area clear and free from combustible materials,
gasoline and other ammable vapors and liquids.
• Never keep a lled container in a hot car or car trunk. Heat will cause gas pressure to increase,
which may open relief valve and allow gas to escape.
• Keep grill’s valve compartment, burners and circulating air passages clean. Inspect grill before
each use.

A-4
WARNING
• This grill is for outside use only, and should not be used in a building, garage, or any other
enclosed area.
• The use of alcohol, prescription or non-prescription drugs may impair the operator’s ability to
properly assemble or safely operate the grill.
• Always open grill lid slowly and carefully as heat and steam trapped within the grill can burn
you severely.
• Always place grill on a hard, level surface far away from combustibles. An asphalt or blacktop
surface may not be acceptable for this purpose.
• Do not leave a lit grill unattended. Keep children and pets away from grill at all times.
• Do not place grill on any type of tabletop surface.
• Do not use grill in high winds.
• Disconnect the propane tank (LP tank) by rst turning off valve on top of propane tank, turn off
burner valves, then disconnect regulator from valve on propane tank by turning plastic connector
counter clockwise. Unscrew wing-bolt in bottom shelf to release the tank for removal.
DANGER
• Liquid propane (LP) gas is ammable and hazardous if handled improperly. Know its characteristics
before using any propane product.
• Propane Characteristics: ammable, explosive under pressure, heavier than air and settles in pools
and low areas.
• In its natural state, propane has no odor. For your safety, an odorant has been added.
• Contact with propane can cause freeze burns to skin.
• Never use a propane cylinder with a damaged body, valve, collar or footing.
• Dented or rusted propane cylinders may be hazardous and should be checked by your propane
gas supplier.
• Use caution when assembling and operating your grill to avoid scrapes or cuts from sharp edges.
• Do not use gasoline, kerosene, or alcohol to light charcoal. Use of any of these or similar products
could cause an explosion possibly leading to severe bodily injury.
• Use caution when moving grill to prevent strains.
• When adding charcoal and/or wood, use extreme caution.
• Never move grill when it is in use or when it contains hot coals or ashes.
• WARNING: To avoid injuries gloves or other protective articles should be used when touching the
ash pan hangers.
• Do not exceed a temperature of 650°F.

A-5
• Do not allow charcoal and/ or wood to rest on the walls of grill. Doing so will greatly reduce the life of
the grill.
• CAUTION: Exposed metal dampers on air vents and/or metal handles are hot during usage.
Again, always wear oven mitts when adjusting air ow to protect hands from burns.
• When opening lid, make sure it is pushed all the way back so it rests against the lid support
brackets. Use extreme caution as hood could fall back to a closed position and cause bodily injury.
• Close lid and all dampers to help suffocate ame.
• Always hold an open lid from the handle to prevent it from closing unexpectedly.
• Never leave coals and ashes unattended. Before grill can be left unattended, coals and ashes must
be removed. Use caution to protect yourself and property.
• Ashes left in the grill (ash tray, grease tray, Flavor Drawer™, etc.) hold moisture and may cause rust
if not cleaned out.
• Carefully place remaining coals and ashes in a noncombustible metal container and saturate
completely with water. Allow coals and water to remain in metal container 24 hours prior
to disposing.
• Make sure to empty grease tray after every use once completely cooled.
• Heat gauges maintain moisture, which will result in steam during cooking.
• Smoke will escape from other areas than smokestacks. This will not affect cooking.
• It is recommended that charcoal grill be heated up and fuel kept red hot for at least 30 minutes prior
to rst time cooking. Do not cook before briquettes have turned gray with ash.
• WARNING! Do not use spirit or petrol when lighting or relighting.
• To protect against bacteria that could cause illness, keep all meats refrigerated and thaw in
refrigerator or microwave. Keep raw meats separate from other foods, and wash everything that
comes in contact with raw meat.
• Cook meat thoroughly, and refrigerate leftovers immediately.
• Use a calibrated food thermometer and the USDA guidelines to ensure that meat, poultry, seafood,
and other cooked foods reach a safe minimum internal temperature.
• Always have a re extinguisher near at all times. Maintain and check your re extinguisher regularly.
• Non-rechargeable batteries are not to be recharged.
• D o n o t m i x d i f f e r e n t t y p e s o f b a t t e r i e s s u c h a s a l k a l i n e , c a r b o n - z i n c , o r r e c h a r g e a b l e b a t t e r i e s .
• Do not mix old and new batteries.
• Exhausted batteries are to be removed from the product.
• Batteries included.
• DO NOT DISPOSE OF BATTERIES IN FIRE. BATTERIES MAY EXPLODE OR LEAK.

A-6
(example)
*** STOP! CALL FIRST! ***
Do NOT Return Product to Store.
This grill has been made according to the highest of quality standards. If you have any questions not
addressed in this manual or if you need parts please call our Customer Service Department at 1-912-
638-4724 (USA) or email Char-Griller at: [e-mail] and have your serial number handy.
REGISTERYOUR GRILL:
To take full advantage of the Char-Griller warranty be sure to register your grill by visiting
www.CharGriller.com/Register or calling Customer Service at 1-912-638-4724.
Registration provides important protections:
1. In the extremely unlikely event of a product recall Char-Griller can easily contact you and rectify
the issue.
2. If a warrantied part is broken or missing we can send you the needed parts promptly.
NOTE: You will need your model #, serial number, and a copy of the original sales receipt
when registering.
Document Your Grill Model and Serial Numbers HERE:
(Model and Serial number are located on the back of the grill body or on the leg.)
_________________________ _________________________
(MODEL #) (SERIAL #)

A-7
WARRANTY INFORMATION
A COPY OF THE DATED PROOF OF PURCHASE (RECEIPT) IS REQUIRED WHEN REGISTERING OR
SUBMITTING A WARRANTY* CLAIM. PLEASE RETAIN A COPY OF THE RECEIPT FOR YOUR RECORDS.
Char-Griller will replace any defective part of its grillers/smokers, under warranty, as outlined below.
PLEASE READ THIS INFORMATION IN DETAIL AND IF YOU HAVE ANY QUESTIONS CONTACT CUSTOMER
SERVICE AT 912-638-4724 OR [email protected].
SURFACE RUST IS NOT CONSIDERED A MANUFACTURING OR MATERIALS DEFECT
Char-Griller grills are made of steel and if exposed to the elements rust will occur naturally. Please refer to the
section entitled, “Usage” to review how to care for your grill properly.
Surface issues such as scratches, dents, corrosion or discoloring by heat, abrasive and chemical clearers, surface
rust or the discoloration of steel surfaces are NOT covered under these warranties.
Warranties are for the replacement of defective parts only. Char-Griller is not responsible for damage resulting
from accident, alteration, misuse, abuse, hostile environments, improper installation, and installation not in
accordance with local codes of service of unit.
Excluded Under ALL Warranties
Paint; Surface Rust; Heat Damage; Incorrect Parts ordered by customer, including shipping; Worn Parts; Missing
or damaged parts not reported within two (2) months of purchase date; Defective parts not reported within one (1)
year of purchase date; Fading grill cover.
*NOTE: For warranty claims, photos and prepaid return of the item in question may be required. Misuse, abuse or
commercial use nullies all warranties.
Charcoal / Pellet / Kamado Grills
Grill - Hood AND Bottom
(excludes removable Ash Pan)
5 years from date of purchase for rust
through / burn through
Ash Pan AND Defective Parts 1 year from date of purchase
Gas Grills
Grill Hood (TOP half) AND Main Burner Tubes
(excludes Side Burner)
5 years from date of purchase for rust
through / burn through
Grill Body (BOTTOM half) AND Side Burner
AND Defective Parts
1 year from date of purchase
Dual Fuel Grills (Gas & Charcoal)
Charcoal Grill - Hood AND Bottom AND Gas
Grill Hood (TOP half) AND Main Burner Tubes
(excludes Ash Pan and Side Burner)
5 years from date of purchase for rust
through / burn through
Ash Pan AND Defective Parts AND Gas Grill
Body (BOTTOM half) AND Side Burner
1 year from date of purchase
Parts, Accessories, and Grill Covers 1 year from date of purchase
(seam tears only for covers)

B-1
7400_OM_A.2
PARTS LIST
13
4
5
6
7
8
10
11
12
2
13 14
15
16
17
18
19
20
21
22
23
24
25
26
2727
28
29
30
31
32
33
38
39
40
41
42
43
44
46
45
44
47
48
49
5150
34
35
36
37
9
52
53
56
55
45
46
54

B-2
7400_OM_A.2
PARTS LIST
Item QTY Part Name
1 1 HOOD
2 1 LOGO PLATE
3 4 HANDLE CAP
4 1 HOOD HANDLE
5 1 DRAWER HANDLE
6 4 BURNER SUPPORT
BRACKET
7 4 BURNER
8 4 ELECTRODE WITH WIRE
9 1 DRAWER FASCIA
10 1 RIGHT SIDE SHELF CAP
11 1 RIGHT SIDE SHELF
12 1 RIGHT SHELF FASCIA
13 1 GREASE CUP LID
14 1 GREASE & ASH TRAY
15 1 GREASE CUP
16 1 TANK EXCLUSION WIRE
17 1 BACK PANEL
18 1 CART FRONT BRACE
19 2 DOOR MAGNET
20 1 CART RIGHT PANEL
21 1 RIGHT DOOR
22 2 DOOR HANDLE
23 1 LEFT DOOR
24 1 BOTTOM SHELF
25 1 LOCKABLE CASTER WHEEL
26 1 SWIVEL CASTER WHEEL
27 2 FIXED CASTER WHEEL
28 1 LEFT CART PANEL
29 4 KNOB
30 4 KNOB BEZEL
Item QTY Part Name
31 1 IGNITOR
32 1 CONTROL PANEL
33 1 HOSE/VALVES/REGULATOR
ASSEMBLY
34 1 HEAT SHIELD
35 1 GRILL BODY
36 4 COOKING GRATE
37 1 WARMING RACK
38 1 LEFT SIDE SHELF FASCIA
39 1 LEFT SIDE SHELF CAP
40 1 LEFT SIDE SHELF
41 1 THERMOMETER BEZEL
42 1 THERMOMETER
43 2 ADJUSTABLE SMOKESTACK
44 2 SLIDER RAIL SUPPORT
BRACKET
45 1 LEFT INNER SLIDER RAIL
46 1 RIGHT INNER SLIDER RAIL
47 1 DRAWER
48 1 DRAWER FRONT PLATE
49 1 EMBER TRAY
50 1 EMBER TRAY LEFT
SUPPORT BRACKET
51 1 EMBER TRAY RIGHT
SUPPORT BRACKET
52 2 DOOR SUPPORT PIN
53 2 UPPER DOOR SOCKET
54 1 DOOR BRACE
55 1 TANK HOLDER
56 1 GRATE LIFTER

B-3
7400_OM_A.2
Hardware Pack:
HARDWARE AND TOOLS NEEDED
Assembly: Requires 2 people. Tools Needed: Pliers, Phillips Head Screwdriver and a
7/16” Nut Driver.
NOTE: Do Not tighten any bolts unless instructed to do so. Tightening too soon may
prohibit parts from tting together. All Hex Nuts should be on the inside of the grill
unless stated otherwise. Unpack all contents in a well cleared and padded area.
Estimated Assembly Time: 45 minutes
HEX BOLT, 1/4-20 X 1/2” 41
HEX BOLT, 1/4-20 X 1 3/4” 2
SCREW, #10-24 15
HEX NUT, 1/4-20 4
LOCK WASHER, 1/4” 28
FLAT WASHER, 1/4” 4
WING BOLT, 1/4-20 x 1/2” 4

B-4
7400_OM_A.2
ASSEMBLY
Step 1
Install Caster Wheels onto Bottom Shelf with four Lock Washers and four ½” Hex Bolts per
Caster Wheel. Position the caster wheel as shown on the picture below.
Lock Washer
Hex Bolt
Fixed Caster Wheel
Lockable
Caster Wheel
Swivel Caster
Wheel

B-5
7400_OM_A.2
Step 2
Install Left and Right Cart onto Bottom Shelf with four Lock Washers and four ½” Hex Bolts per
side cart. Then install the Back Panel onto the Left and Right Cart with ve #10-24 Screws.
Lock Washer
Hex Bolt
Left Cart
Screw
Right Cart

B-6
7400_OM_A.2
Step 3
Install Cart Front Brace onto the Left and Right Cart at the front with eight #10-24 Screws.
Screw

B-7
7400_OM_A.2
Step 4
Install the Tank Exclusion Wire inside of the cart with one ½” Hex Bolt.
Hex Bolt
Tank Exclusion Wire

B-8
7400_OM_A.2
Step 5
Install Left Door with handle to Cart. Insert Door Support Pin at the bottom of the Front Door on
the Bottom Shelf, then push in the Door Pin on top of the door and slide the door into position.
Repeat process for right door.
Door Pin
Door Pin

B-9
7400_OM_A.2
Step 6
Insert the Thermometer through the Thermometer Bezel then through the hole in Grill Hood
(from outside) and secure with a Flat Washer and a Wing Bolt.
NOTE: Thermometer hardware is included with Thermometer.
Thermometer
Thermometer Bezel
Wing Bolt
Flat Washer

B-10
7400_OM_A.2
Step 7
Place Grill Body and Hood onto Cart and secure it with four ¼-20 Hex Bolts.
Hex Bolt
Hex Bolt

B-11
7400_OM_A.2
Step 8
Install Left-Side Shelf Assembly to Grill Body.
First, loosen the top bolt on the Drawer Fascia; and
loosely install three ½” Hex Bolts into side mounting
holes on the Grill Body. Align keyhole on the Left-Side
Shelf Assembly with the Hex Bolts on the Grill Body
and push the Side Shelf down.
Secure the Side Shelf Fascia to the Side of the
Drawer Fascia with one ½” Hex Bolt.
Then tighten all Hex Bolts. Repeat the same process
for the Right-Side Shelf.
A
DETAIL A
SCALE 1 : 3
A
DETAIL A
SCALE 1 : 3
A
DETAIL A
SCALE 1 : 4
Match Holder
Hex Bolt
Left Side Shelf Fascia
Left Side Shelf Fascia
Left Side Shelf Cap
Hex Bolt
Left Side of Grill Body