Char Broil Smoker 10201597 50 User Manual

Product Manual

Model 10201597-50

IMPORTANT: Fill out the product record information below.

Model Number

Serial Number

See rating label on grill for serial number.

Date Purchased

Estimated time to complete assembly: 1 hour

FOR OUTDOOR USE ONLY

CAUTION

WARNING

Read and follow all safety statements, assembly

instructions, and use and care directions before

attempting to assemble and cook.

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.

INSTALLER/ASSEMBLER:

Leave this manual with consumer.

CONSUMER:

Keep this manual for future reference.

CAUTION

THIS UNIT IS HEAVY!

DO NOT assemble without a helper.

If you have questions or need assistance during assembly, please call 1-800-241-7548.

To insure your satisfaction and for follow-up service, register your smoker online at

www.grillregistration.com

42804691 • 04-01-10

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TABLE OF CONTENTS

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.

Product Record Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

For Your Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Installation Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Safety Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Use and Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Parts List/ Parts Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-17

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-19

Limited Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

The following are trademarks registered by W.C. Bradley Co. in the U.S. Patent and Trademark Office: Caldera®; Charcoal2Go®; Char-Broil®; American

Gourmet®; Bandera®; Brush Hawg®; CB 940®; Char-Diamonds®; Char-Broil Charcoal/Gas®; Everybody Grills®; Grill 2 Go®; Grill 2 Go® Express®; Grill

Lovers®; Infrared Grilling That’s All About U®; Keepers of the Flame®; Magneto®; New Braunfels Smoker Company®; Patio Bistro®; Patio Caddie®; Patio

Kitchen®; Pro-Sear®; RED®; Quantum®; Santa Fe®; Sear and Grill®; Sierra®; Signature Series®; Sure2Burn®; The Big Easy®; U®; Wild West Tradition®;

and the following marks:

The following are trademarks of W.C. Bradley Co.:America's Legendary Barbeque Company™; Advantage Series™; Auto-Clean™;Chef Tested™;

Commercial Series™; Designer Series™;; Diamond Flame™; Double Chef™; Everybody Outside™; FastStart™; FlavorMaster™; Front Avenue™; Grill 2

Go® Advantage™; Grill 2 Go® Ice™; Hog and Yard Bird™; H20 Smoker™; Infrared. Grilling’s Juicy Little Secret™; Incredible Taste. Infallible Results™;

Infrared Inside™; Let’s Grill Something Together™; Longhorn™;; Precision Flame™; Quick2Burn™; QuickSet™; Ready When YouAre™; Season, Set, And

Savor™; Sizzle On The Grill™; SureFire™; Torchfork™; Trentino™; Universal Grill Parts™; You Bring the Party™

Grills.

TEC™ is a trademark of Tec Infrared

Protected under one or more of the following U.S. Patents: 5,421,319; 5,458,309; 5,579,755; 5,996,573; 6,114,666; 6,135,104; 6.209,533; 6,331,108; 6,484,900; 6,595,197; 6,640,803; 6,729,873; 6,792,935; 6,951,213;

6,935,327; D405,643; D406,005; D406,009 ; D413,043; D413,229; D414,982; D415,388; D416,164; D416,441; D417,587; D417,588; D422,516; D423,274; 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; D448,614; D448,615; D448,616; D448,975; D449,492; D451,759; D454,028; D454,031; D455,205; D455,206; D456,202;

D460,312; D460,313; D461,359; D465,123; D465,693; D466,439; D477,501; D478,472; D480,914; D491,410; D494,009; D494,413; D498,523; D500,359; D504,048; D535,000; D551,489; D553,430; D562,619;

TM REVISION 07

10201597-50 • 3

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LP Cylinder

USE AND CARE

•The LP cylinder used with your grill must meet the

following requirements:

DANGER

•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.

• NEVER store a spare LP cylinder under or near the

appliance or in an enclosed area.

•LP cylinders must be constructed and marked in accordance

with specifications for LP cylinders of the U.S. Department of

Transportation (DOT) or for Canada, CAN/CSA-B339,

cylinders, spheres and tubes for transportation of dangerous

goods. Transport Canada (TC). See LP cylinder collar for

marking.

• 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.

•LP cylinder valve must have:

•Type 1 outlet compatible with

regulator or grill.

• If you see, smell or hear gas escaping, immediately get

away from the LP cylinder/appliance and call your fire

department.

•Safety relief valve.

OPD Hand Wheel

•UL listed Overfill Protection

• Keep LP tank at a minimum distance of 24” (inches) away

from appliance at all times.

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.

WARNING

DO NOT place

cylinder

within 24"of

appliance

24”

LP cylinder in upright position for vapor withdrawal

LP (Liquefied Petroleum Gas)

WARNING

Hose is a trip hazard

•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 Cylinder Removal, Transport and Storage

•Turn OFF all control knobs and LP cylinder valve. Turn coupling

nut counterclockwise by hand only - do not use tools to

disconnect. Loosen cylinder screw beneath bottom shelf, then

lift LP cylinder up and out of cart. 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.

•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.

LP Cylinder Valve

•A disconnected 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.

•A frosty 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.

Safety

Cap

•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.

Retainer Strap

•Do not store an LP cylinder in an area where children play.

4 • 10201597-50

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LP Cylinder Exchange

Connecting Regulator to the LP Cylinder

•Many retailers that sell grills 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.

1.LP cylinder must be properly secured onto grill. (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.

•Always keep new and exchanged LP cylinders in upright

position during use, transit or storage.

4.Remove the protective cap from LP cylinder valve. Always use

cap and strap supplied with valve.

•Leak test new and exchanged LP cylinders BEFORE

connecting to grill.

•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.

OPD Hand Wheel

Type 1 outlet with

thread on outside

LP Cylinder Leak Test

For your safety

•Leak test must be repeated each time LP cylinder is exchanged

or refilled.

Safety Relief Valve

•Do not smoke during leak test.

•Do not use an open flame to check for gas leaks.

•Grill 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 grill away from open flames

or sparks.

Strap and Cap

•Use a clean paintbrush and a 50/50 mild soap and water

solution. Brush soapy solution onto areas indicated by arrows

in figure below.

Do not use a POL transport plug

(plastic part with external threads)!

It will defeat the safety feature of

the valve.

Do not use household cleaning agents. Damage to gas

train components can result.

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.

Nipple has to be centered

into the LP cylinder valve.

WARNING

If “growing” bubbles appear do not use or move the LP

cylinder. Contact an LP gas supplier or your fire

department!

10201597-50 • 5

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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.

Hold coupling nut and regulator

as shown for proper connection

to LP cylinder valve.

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!

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.

WARNING

• This appliance is not intended to be installed in or on a

boat.

• This appliance is not intended to be installed in or on an

RV.

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 1-800-241-7548.

• Never attempt to attach this appliance to the self-

contained LP gas system of a camper trailer or motor

home.

• Do not use appliance until leak-tested.

6. Always close LP cylinder valve after performing leak test by

• If a leak is detected at any time, STOP and call the fire

department.

turning hand wheel clockwise.

• If you cannot stop a gas leak, immediately close LP

cylinder valve and call LP gas supplier or your fire

department!

6 • 10201597-50

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• Apartment Dwellers:

WARNING

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.

For Safe Use of Your CB600x™ 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.

• NEVER attempt to light burner with any type of

closed cover . A buildup of non-ignited gas inside a

closed appliance is hazardous.

• 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.

• 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.

• 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.

Safety Tips

• Before opening LP cylinder valve, check the coupling nut for

tightness.

• When appliance is not in use, turn off control knob and LP cylinder

valve.

• Do not move the appliance when in use. Allow the

cooking vessel to cool to 115°F (45°C) before moving or

storing.

• Smoker Chamber door should be open while attempting to light the

burner.

• The grease tray must be inserted into appliance and emptied after

each use. Do not remove grease tray until appliance has completely

cooled.

• 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.

• 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.

• The regulator may make a humming or whistling noise during

operation. This will not affect safety or use of grill.

• If you have an appliance problem see the "Troubleshooting Section".

• If the regulator frosts, turn off appliance and LP cylinder valve

immediately. This indicates a problem with the cylinder and it should

not be used on any product. Return to supplier!

• 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 appliance 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.

• 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.

• 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.

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.

24”

10201597-50 • 7

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Ignitor Lighting

• Do not lean over appliance while lighting.

1. Turn ON LP gas cylinder.

Burner Flame Check

• Light burner, rotate knob from HIGH to LOW. Looking through

the match light holes underneath the appliance, you should see

the flame height decrease when turning knob from HIGH to

LOW. Always check flame prior to each use. If only low flame

is seen refer to "Sudden drop or low flame" in the

Troubleshooting Section.

2. Open the Smoke Chamber door.

3. Press and turn the control knob to HIGH.

4. Turn ROTARY IGNITOR knob rapidly.

5. Pull out the Firebox Drawer to verify that the burner is lit.

6. 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.

Turning Appliance Off

• Turn control knob to OFF 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.

WARNING

Turn control knob and LP cylinder OFF when not in

use.

Valve Check

• Important: Make sure gas is off at LP cylinder before

checking valve. Knob locks in OFF 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 Oil-

less Fryer. Turn knob to HIGH position then turn back to OFF

position. Valve should turn smoothly.

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.

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.

Match-Lighting

Do not lean over appliance while lighting.

1. Turn ON LP cylinder.

Kinked

Hose

Normal

Hose

2. Open the Smoke Chamber door.

3. Place lit match into match lighting hole of appliance as

pictured below. Make sure lit match is placed inside hole and

near burner.

General Appliance Cleaning

• 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.

4. Push in and turn control knob to HIGH.

Be sure burner

lights and stays lit.

5. Pull out the Firebox Drawer to verify that the burner is lit.

• 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.

First - Open

the door

Match

Lighting

Hole

Firebox

Drawer

• Stainless steel surfaces: To maintain the high quality

appearance, wash with mild detergent and warm soapy water

and wipe dry with a soft cloth after each use. Baked-on grease

deposits may require the use of an abrasive plastic cleaning

pad. Use only in direction of brushed finish to avoid damage.

Do not use abrasive pad on areas with graphics.

Match

Control

Knob

• 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.

View is from side of appliance

8 • 10201597-50

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Cleaning the Burner Assembly (Continued)

7. Clean inner burner as recommended below, shown E.

We suggest three ways to clean the burner tube. Use the one

easiest for you.

CAUTION

(A) Bend a stiff wire (a light weight coat hanger works well)

into a small hook. Run hook through burner tube several

times.

SPIDER ALERT!

(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.

SPIDER AND WEBS

SHOWN

INSIDE BURNER TUBE

the burner tube and out the burner ports. Check each

port to make sure air comes out each hole.

8. 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.

If you notice that your grill 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.

9. Attach electrode to burner.

10. Carefully replace control panel assembly .

VERY IMPORTANT: Burner tube must re-engage over valve

opening. See illustration, shown F.

VALVE

11. Reverse steps for re-assembly.

SPIDER WEBS

CONTROL PANEL

INSIDE VENTURI

Rotary Ignitor

BURNER

Remove Electrode Wire

from Rotary Ignitor

Remove

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 grill’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 grill and even cause injury.

Smoker

Drawer

To prevent flashbacks and ensure good performance the burner and

venturi assembly should be removed from the grill and cleaned

before use whenever the grill has been idle for an extended period.

Remove Control

Panel screw and nuts

Cleaning the Burner Assembly

Follow these instructions to clean and/or replace parts of burner

assembly or if you have trouble igniting appliance.

Disengage Venturi

tube from Control

Valve and slide

Control Panel out.

1. Turn gas off at control knob and LP cylinder and

disengage regulator from cylinder.

2. Remove the smoker drawer and water pan, shown A.

3. Remove the Electrode Wire from the Rotary Ignitor,

shown B.

4. Remove 4 Control Panel screws and nuts. Shown C

5. Disengage Control Panel/control Valve from burner..

6. Slide Control Panel Assembly from unit, shown D.

Use Tool to

remove debris

from Venturi

Tube.

Proper Venturi Tube to Valve

Alignment shown.

(Some parts not

shown for clarity)

10201597-50 • 9

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Food Safety

Storing Your Appliance

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:

• 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 Regulator is disconnected from the LP cylinder, a hook is

provided to hang Regulator from the handle as shown.

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.

Use wire hook provided

to store regulator.

Chill: Refrigerate prepared foods and leftovers promptly.

For more information call: USDA Meat and Poultry Hotline at

1-800-535-4555 In Washington, DC (202) 720-3333, 10:00 am-

4:00 pm EST.

How To Tell If Meat Is Cooked Thoroughly

• Meat and poultry cooked on 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.

• Cover appliance if stored outdoors. Choose from a variety of

covers offered by manufacturer.

• Store indoors ONLY if LP cylinder is turned off and

disconnected, removed from appliance and stored outdoors.

• When removing appliance from storage, follow “Cleaning the

Burner Assembly” instructions before starting.

• 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.

Safety Precautions while cooking:

• Beef, veal and lamb steaks, roasts and pork chops can be

• The exterior surfaces of your CB600x™ can become extremely

hot during use. Be sure to wear insulated oven mitts or gloves

before making adjustments to the Top Damper or when

opening the Smoker door.

cooked to 160° F.

• NEVER partially cook meat or poultry and finish cooking later.

Cook food completely to destroy harmful bacteria.

Water Level

• Watch water level. Always keep water in water pan (unless you

wish to brown your food), Food can burn quickly if water

completely evaporates. When using smoker, be very careful

when adding water to the hot smoker.

Tools Required for Assembly:

#2 Phillips or Standard Flat blade Screwdriver (Not Provided)

Small Adjustable Wrench (Not Provided)

7/16” Combination Wrench (Not Provided)

10 • 10201597-50

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Setup Instructions

Using Wood Chips or Chunks

Meats that require more than 4 hours of cooking time

to reach doneness may require additional water. The

initial amount of hot water added (4 quarts) should

last 4-6 hours. After 4-6 hours, check water level and

add more hot water as necessary.

• Dried aromatic wood chips or chunks need to be saturated with

water, so that when placed in the water pan, a smoldering

smoke will result. Wood chips or chunks can be soaked too

long; however, 2 hours is adequate. As a rule of thumb, use

wood chunks for smoking 3 or more hours and wood chips

when smoking less than 3 hours. Start with 3 wood chunks or

1½ cups of wood chips.

Use a meat thermometer for measuring the internal

heat of any food. The appearance of smoked foods

resembles no other method of cooking, particularly in

light colored meats such as pork, turkey, chicken and

Cornish hens. The outside will be pinkish-red while

the inside when cooked to perfection, is often pink.

The juices from fully cooked poultry will run clear

when pierced with a fork. Fish is done when it flakes

easily when tested with a fork. Shrimp should be

resilient to the touch when done. Remove foods from

smoker before carving. To brown meats, cook for an

additional ½ hour or more with no water in water pan.

Water

Reservoir

Wood Chips

or Chunks

Spray inside door and body with nonstick vegetable

oil based spray. Place water pan onto brackets in

the smoker drawer. Using a 4 quart (one gallon)

container fill the water pan 2/3 full with hot tap water.

Do not overfill the water pan.

Performance of the smoker is dependent on ambient

temperature and wind conditions. With temperature

below 60°F and winds of 5 MPH or more, the smoker

can lose a significant amount of heat and it may not

be possible to raise internal temperature of meat high

enough to cook it in a reasonable time.

Water or Juice?

Your smoker is designed with a drawer that is used

to hold the water pan. This drawer will allow you to

keep a check on the water level in the smoker

without having to open the door. Opening the door

during cooking will allow heat to escape and will

significantly increase cooking time.

Placing water alone in the water pan is adequate;

however, it is not the only viable choice. Fruit juice,

cola, beer, wine, drained marinades and even the

water in which the wood has soaked make flavorful

sources. In addition, celery stalks, onions, carrots,

apples, peppercorns and bay leaves are just a few of

the other popular flavor sources to add to the water

pan.

You may use your smoker without water in the water

pan. However DO NOT use the smoker without the

water pan properly installed. To do so will allow

grease and drippings from the food being cooked to

drop through the unit and onto the floor or surface on

which the units sits.

Before each use, inspect the interior lid and body

surface areas for loose particle buildup. Clean away

any loose or flaking residue so it will not fall onto

food while being cooked.

Brush poultry and naturally lean meats with cooking

oil, butter or margarine before cooking.

Before cooking, coat cooking grates with oil or with a

vegetable oil based spray. Using oven mitts, carefully

place cooking grates into smoker. Larger cuts of

meat or food that cook for long periods of time

should be placed on the lower cooking grate. If you

are cooking foods with several pieces, such as racks

of ribs or Cornish hens, be sure to allow adequate

spacing for even heat circulation. Using oven mitts,

carefully insert upper cooking grate into smoker.

Smaller food items require less cooking time and

should be placed on the upper cooking grate.

After filling the smoker, close the door and leave

undisturbed until suggested minimum cooking

time.

When cooking more than one piece of meat, the

cooking time is determined by the largest piece being

cooked.

The meat bastes itself during cooking. No basting or

turning is necessary while cooking in the smoker. For

variety, marinade of barbeque sauce may be applied

before placing into the smoker.

Resist the temptation to open the door during

cooking time. Opening the door will cause a loss of

heat, which will result in longer cooking times.

10201597-50 • 11

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PARTS DIAGRAM

Key Qty Description

IGNITOR, ROTARY KIT

KNOB, IGNITOR

TEMPERATURE GAUGE

Key Qty Description

CHAR-BROIL LOGO PLATE

SMOKER CHAMBER

DOOR, SMOKER CHAMBER

FIREBOX

WIRE RACK, SMOKER CHAMBER

WIRE, ELECTRODE

---

—

HARDWARE PACK

BURNER HOUSING KIT

CONTROL PANEL KIT

LEG

ASSEMBLY INSTRUCTIONS, ENGLISH

ASSEMBLY INSTRUCTIONS, SPANISH

BURNER KIT

Hardware List

TOP GRATE, PORCELAIN

DAMPER ASSEMBLY, TOP

GRATE, COOKING

PAN, WATER

Item

Description

Qty.

#1/4 Flat washer

#10-24 Keps nut

1/4-20 Keps nut

#10-24×3/8" Screw

HOSE, VALVE, REGULATOR

HANDLE

#1/4-20 Reversible Lock Nut

#1/4-20×3/4" Combo truss head screw

#1/4-20×1/2" Hex head bolt

#1/4-20×1/2" Combo truss head screw

HANDLE SPRING

KNOB, CONTROL

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.

12 • 10201597-50

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ASSEMBLY

•

Carefully remove the door from the unit by swinging it opening and lifting it up and away from the smoker

chamber. Lay the door aside.

Place the Smoker Chamber on it’s back with the door opening facing up. CAUTION: This unit is heavy!

Place Unit on it’s back

(door opening facing up)

TOP

CAUTION: THIS UNIT IS HEAVY!

DO NOT ASSEMBLE WITHOUT A HELPER!

Swing Door open,

then lift up and

Remove the door

from its hinges

Inset A

•

Install Burner Housing to Smoker Chamber using three 1/4-20x1/2” bolts. Install all bolts hand tight, then tighten with a

#2 phillips screwdriver. (not provided)

NOTE: The venturi tube MUST face up (towards the door opening).

NOTE:

The venturi tube

MUST be installed

#1/4-20x1/2"

as shown

Qty: 3

#1/4-20x1/2"

Combo Truss

head screw

Venturi

Tube

Burner Housing

with Burner

10201597-50 • 13

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• Place Control Panel Assembly onto Smoker Chamber by placing tabs under the front edge of the Smoker Chamber. The

Control valve must engage the burner venturi tube as shown A.

• From the inside of the Smoker Chamber, Install 2 #10-24x3/8” screws through the smoker chamber and through the

Control panel Tabs as shown. Thread 1 #10-24 Keps Nut onto each screw and tighten As shown B. Install 2 #10-24x3/8”

screws through the control panel tabs and into the burner assembly housing. Thread 1 #10-24 Keps Nut onto each screw

and tighten securely. Shown B

Qty: 4

#10-24x3/8" Screw

Control

Valve

Qty: 4

#10-24 Keps Nut

#10-24x3/8" Screws

Control

Panel Tabs

NOTE: Hose not shown

for clarity

Install 1 #10-24x3/8"

Screw per side

Control Panel

Shown Installed

Control Panel

Screw Hole

Burner Assembly

Housing

• Be sure the electrode wire exits the hole UNDER the venturi tube hole. DO NOT route the wire through the same hole as

the burner venturi tube.

• Install Ignitor Wire by pushing the round connector onto the Ignitor as shown.

Rotary ignitor

Push the

Round end

of ignitor wire

onto the

Rotary Ignitor

Route wire

through

hole under the

Venturi Tube

Hole

14 • 10201597-50

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• Install legs by placing 2 - 1/4-20x1/2” Hex Head Bolt through the smoker body and through each leg as shown. Thread the

bolts into the 1/4-20 nut welded to the underside of each leg. Tighten bolts by hand. Using an adjustable wrench (not

provided), tighten each bolt securely.

• Install the leg with the rating label on the back side of the smoker body, as shown.

Qty: 8

#1/4-20x1/2"

Hex Head Bolt

Install bolts from inside

the smoker body

Leg with Rating Label

• With the assistance of a helper - stand the unit upright on its legs.

CAUTION: THIS UNIT IS HEAVY!

Stand the unit upright on its legs

CAUTION: This unit is HEAVY!

Do not attempt this step

without assistance!

10201597-50 • 15

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• Insert 1/4-20x1/2” Hex Head Bolt and flat washer through the top smoker body, in the center of the damper holes as shown.(A)

• Insert the damper as shown. (B)

• Place the 1/4” flat washer onto bolt and thread the 1/4-20 nut on to the bolt. Tighten the nut sufficiently to allow the damper to move. (B)

• Damper is shown properly installed in figure C.

• Install the side handles with 1/4-20X3/4” screws and 1/4-20 Keps nuts as shown (D)

• NOTE: If the handle springs are not installed on the handle rod, Install them per inset E.

Insert 1/4-20X1/2” bolt

and flat washer into bolt hole

Qty: 4

#1/4-20 Keps Nut

Qty: 1

#1/4-20x1/2"

Hex Head Bolt

Qty: 2

#1/4 Flat

Washer

Qty: 1

#1/4-20 Nut

Qty: 4

#1/4-20x3/4”

Combo truss

head screw

Insert damper handle through

damper hole as shown

1/4-20X3/4” screws

Spring

1/4-20 Keps nuts

Handle Rod

Damper shown

installed

CAUTION: THE DAMPER HANDLE

WILL BE HOT WHILE COOKING!

WEAR AN INSULATED OVEN MITT

WHEN MAKING ADJUSTMENTS!

Install Side Handles with 1/4-20X3/4”

bolts and 1/4-20 Keps nuts as shown.

• Install Drawer Handle using 2 - 1/4-20x 3/4”screws and 2 1/4-20 Keps nuts. Tighten securely.

• Place the Water Pan onto the drawer rack as shown.

• Slide the Drawer, with Water Pan, into the Smoker body.

Water Pan Frame

Qty: 2

#1/4-20 Keps Nut

Qty: 2

#1/4-20x3/4"

Combo truss

head screw

Smoker Drawer

Water Pan

1/4-20 Keps nuts

1/4-20x3/4” bolts

Smoker Drawer

16 • 10201597-50

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• Insert the 3 Cooking Grates into the smoker body.

• Slip the edge of the Top Grate under the Damper Handle (A), Then carefully align the grate so that the wire ends fit into the holes in the

Smoker Body top.(B)

• Carefully place the door back onto the Smoker Body hinges.

Top Grate

Cooking Grates (3)

• Remove wingnut from Thermometer, insert Thermometer through the hole in the door from the front, reinstall the wingnut

to the Thermometer.

Thermometer

Wing Nut

10201597-50 • 17

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EMERGENCIES: If a gas leak cannot be stopped, or a fire occurs due to gas leakage, call the fire department.

Emergencies

Possible Cause

Prevention/Solution

Gas leaking from

cracked/cut/burned

hose.

• Damaged hose.

• 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.

Gas leaking from LP

cylinder.

• Mechanical failure due to rusting or

mishandling.

• Replace LP cylinder.

Gas leaking from LP

cylinder valve.

• Failure of cylinder valve from

mishandling or mechanical failure.

• Turn off LP cylinder valve. Return LP cylinder to gas supplier.

Gas leaking between

LP cylinder and

regulator connection.

• Improper installation, connection not

tight, failure of rubber seal.

• Turn off LP cylinder valve. Remove regulator from cylinder and

visually inspect rubber seal for damage. See LP Cylinder Leak Test

and Connecting Regulator to the LP Cylinder.

Fire coming through

control panel.

• Fire in burner tube section of burner due

to blockage.

• 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

Burner Assembly pages.

Grease fire or

• Too much grease buildup in burner area.

• Turn off control knobs and LP cylinder valve. Allow flames to die

down. After cooling, clean food particles and excess grease from

inside fryer body, grease tray, and other surfaces.

continuous excessive

flames above cooking

surface.

Troubleshooting

Problem

Possible Cause

Prevention/Solution

GAS ISSUES:

• Burner not engaged with control valve.

Burner will not light

using ignitor.

• Make sure valve is positioned inside of burner tube.

• Obstruction in burner.

• Ensure burner tube is not obstructed with spider webs or other

matter. See cleaning section of Use and Care.

• No gas flow.

• Make sure LP cylinder is not empty. If LP cylinder is not empty,

refer to “Sudden drop in gas flow.”

• Vapor lock at coupling nut to LP cylinder.

• Turn off knob and disconnect coupling nut from LP cylinder.

Reconnect and retry.

• Coupling nut and LP cylinder valve not

fully connected.

• Turn the coupling nut approximately one-half to three-quarters

additional turn until solid stop. Tighten by hand only - do not use

tools.

ELECTRICAL ISSUES:

• Electrode cracked or broken; “sparks at

crack.”

• Replace electrode.

• Electrode tip not in proper position

• Tip of electrode should be pointing toward gas port opening on

burner. The distance should be 1/8” to 1/4”. Adjust if necessary.

• Wire and/or electrode covered with

cooking residue.

• Clean wire and/or electrode with rubbing alcohol and clean swab.

• Wire is loose or disconnected.

• Reconnect wire or replace electrode/wire assembly.

• Replace ignitor wire/electrode assembly.

• Wire is shorting (sparking) between

ignitor and electrode.

18 • 10201597-50

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Troubleshooting (continued)

Problem

Possible Cause

Prevention/Solution

Burner will not light

using ignitor.

• Rotary knob rotates without clicking.

• Sparking between ignitor and electrode.

• Replace knob.

• Inspect wire insulation and proper connection. Replace wire if

insulation is broken.

• See “GAS ISSUES:” on previous page.

• Match will not reach.

Burner will not match

light.

• Use long-stem match (fireplace match).

• Improper method of match-lighting.

• See “Match-Lighting” section of Use and Care.

Sudden drop in gas

flow or low flame.

• Out of gas.

• Check for gas in LP cylinder.

• Excess flow valve tripped.

• Turn off knob, wait 30 seconds and light fryer. If flames are still low,

turn off knob and LP cylinder valve. Disconnect regulator.

Reconnect regulator and leak-test. Turn on LP cylinder valve, wait

30 seconds and then light fryer.

• Vapor lock at coupling nut/LP cylinder

connection.

• Turn off knob and LP cylinder valve. Disconnect coupling nut from

cylinder. Reconnect and retry.

Flames blow out.

Flare-up.

• Low on LP gas.

• Refill LP cylinder.

• Excess flow valve tripped.

• Refer to “Sudden drop in gas flow” above.

• Grease buildup.

• Clean burner and inside of fryer body.

• Trim fat from meat before grilling.

• Adjust (lower) temperature accordingly.

• Excessive fat in meat.

• Excessive cooking temperature.

Persistent grease fire.

• Grease trapped by food buildup around

burner system.

• Turn knob to OFF. Turn gas off at LP cylinder. Let fire burn out. After

fryer cools, remove and clean all parts.

Flashback...

(fire in burner tube).

• Burner and/or burner tube is blocked.

• Turn knob to OFF. Clean burner and/or burner tube. See burner

cleaning section of Use and Care.

Unable to fill LP

cylinder.

• Some dealers have older fill nozzles

with worn threads.

• The worn nozzles don’t have enough “bite” to engage the valve. Try

a second LP dealer.

• High wind conditions

• Vapor Lock

• Relocate cooker to a less windy area

Cooking slower than

expected

• Turn off knob and disconnect coupling nut from LP cylinder.

Reconnect and retry.

• Valve not properly aligned to burner

• Loosen control panel and valve. Be sure valve is centered top to

bottom and left to right in burner tube. Tighten all components

once proper alignment is achieved.

10201597-50 • 19

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LIMITED WARRANTY

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.

SCOPE OF COVERAGE

PERIOD OF COVERAGE

TYPE OF FAILURE COVERAGE

PERFORATION, MANUFACTURING,

AND MATERIAL DEFECTS ONLY

90 Days

All Parts

*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. RUST is not considered a manufacturing or materials defect.

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.

4. Damage, failures, or operating difficulties resulting from accident, alteration, careless handling, misuse, abuse, fire, flood,

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. In the event of parts availability issues,

the manufacturer reserves the right to substitute like or similar parts that are equally functional.

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 WHEREVER APPEARING 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 Rev03

20 • 10201597-50