Char-Broil 7201560 User manual

P/N 42804297 (10-02-07)

Tools needed for

assembly:

2 Adjustable Wrenches

7/16” Open-End Wrench

Flat Screwdriver

04201101

07201560

Smoker, BBQ and Grill

CAUTION

Some parts may contain sharp edges. Wear

protective gloves if necessary.

Read and follow all safety statements, warnings,

assembly instructions and use & care directions

before attempting to assemble and cook.

WARNING

CARBON MONOXIDE HAZARD

Burning charcoal inside can kill you. It gives off

carbon monoxide, which has no odor. NEVER burn

charcoal inside homes, vehicles or tents.

NEVER LEAVE FIRE UNATTENDED!

Do not allow small children near flame. Hot embers

can fly out in breezy conditions. Adequate fire

extinguishing material should be readily available.

WARNING

CALIFORNIA PROPOSITION 65

1. This product is produced with or contains

chemicals known to the State of California to

cause cancer, birth defects, or other reproductive

harm.

2. This product contains chemicals, including lead

and lead compounds, known to the State of

California to cause cancer, birth defects or other

reproductive harm.

Wash your hands after handling this product.

CAUTION

THIS UNIT IS HEAVY!

DO NOT assemble without a helper.

WARNING

All surfaces can be hot during use. Use protection

as required to prevent burning.

Do not use this unit on or near combustible surfaces

or structures such as wood decks, dry leaves or

grass, vinyl or wood siding, etc.

SEE OWNERS MANUAL FOR IMPORTANT SAFETY

INFORMATION.

If you have questions or need assistance during assembly, please call .

To insure your satisfaction and for follow-up service, register your grill online at www.grillregistration.com

1-800-241-7548

Key # Part Number Description Quantity

A 55710232 SILVER SMOKE CHAMBER KIT 1

B 29001712 FIREBOX TOP 1

C 55710234 FIREBOX BOTTOM KIT 1

D 55710235 WOOD SHELF KIT 1

E 55700442 AXLE KIT 1

F 55700443 WHEEL KIT 1

G 55700183 LEG BRACE KIT 2

H 55710236 SMOKESTACK KIT 1

I 55710237 SHORT LEG KIT 2

J 55700186 LONG LEG KIT 2

K 55700187 SHELF BRACKET KIT 2

L 24810036 HOLE PLUG 1

M 55710238 DOOR LATCH KIT 1

N 55710239 LOGO PLATE KIT 1

O 55710204 DELUXE HANDLE KIT, WOOD SPACERS 2

P 55700192 BUTTERFLY DAMPER KIT 2

Key # Part Number Description Quantity

Q 29101311 WIRE FIRE GRATE 3

R 40009916 GRATE, COOKING, SMOKER 2

S 40009925 GRATE, COOKING, FIREBOX 1

T 44830150 GREASE CLIP 1

U 46030090 RACK, WOOD 1

V 44810036 FIREBOX COVER PLATE 1

… 40003010 OPTIONAL TEMP GAUGE 1

… 42030350 SNAP BAG 1

… 42804297 INSTRUCTION ASSEMBLY 1

… 40053116 OUTER CARTON 1

PARTS LIST

STOP!

Missing a part?

No need to go back to the store!

The store where you made your purchase

does not stock parts for this item. If you

need parts, whether they are missing or

damaged, call the Customer Service toll

free Help Line.

Call us and we will gladly ship

the part you need.

Call Grill Service Center for Help and Parts

• If you need assistance with your product or warranty

parts call 1-800-241-7548. Hours of Service

Center Operation are 8:00 A.M. To 6:00 P.M. EST

Monday - Friday.

• To order non-warranty replacement parts or

accessories please visit us on the web at

www.charbroil. com or call

1-800-241-7548 and one of our friendly and

knowledgeable agents will be glad to assist you.

Attach leg braces to the outside of one leg assembly using #10-24x1-3/4” screws and #10-24 flange nuts. Make sure

slotted (oval) hole is toward bottom of leg. DO NOT FULLY TIGHTEN screws until Step 6 is complete.

1FIRST, GET A HELPER! This unit is heavy and requires a second person for lifting and moving. NEXT, pick a suitable

location to work. Open the carton and slit the corners so that the carton lays flat. This will give you a protective work surface

during assembly.

TO BEGIN ASSEMBLY, build two leg assemblies by sliding the long leg sections into the short leg sections.

Long leg section

Leg brace

Short leg section

Slotted

hole

Leg brace Do not fully tighten screws

until Step 6 is complete.

3Lay the leg assembly on its side with legs braces pointing upward. Insert the wood rack hooks into leg holes and swing rack

upward, parallel to leg braces.

4With the aid of a helper, place leg holes of remaining leg assembly over wood rack hooks and rotate leg assembly until it

meets the leg braces. Make sure both short legs are at one end of the rack and both long legs at the other end. Attach to leg

braces using #10-24x1-3/4” screws and #10-24 flange nuts. DO NOT FULLY TIGHTEN screws until Step 8 is complete.

Wood rack

Short leg

Long leg

Do not fully tighten screws

until Step 6 is complete.

5Insert a cotter pin into the hole at one end of the axle and bend the ends of the pin back so that it cannot be removed. Slide

a wheel onto the axle. Slide the axle through the holes at the ends of the short legs. Slide remaining wheel onto axle and

secure with remaining cotter pin.

Axle

NOTE: Smoker chamber door not pictured

for clarity.

Stand the leg assembly on end, wheels

down. Stand the smoker chamber on its

solid end, open end up. Place leg assembly

against chamber, aligning holes in legs with

holes in chamber.Attach legs to chamber

using four 1/4-20x2” screws and 1/4-20

flange nuts. Insert screws from outside,

flange nuts inside chamber.

FULLY TIGHTEN ALL

SCREWS AND NUTS AT

THIS TIME.

Smoker chamber

Cotter pin

Wheels down

Open end up

Attach Firebox TopAssembly to Firebox BottomAssembly using eight 1/4-20x3/4” hex-head

bolts as shown below.

NOTE: Smoker chamber and firebox doors not pictured for clarity.

TM TM

Diamond Fire Plate Installation - For models without Diamond Fire ignitor accessory,

part number 22504850.

For models that feature the Diamond Fire ignitor accessory, supplemental instructions

are included with ignitor.

First, locate the cover plate in the hardware box.At the bottom right end of the

firebox there is an opening for the Diamond Fire ignitor accessory. Install the

cover plate over the opening using two #8-32x1/2” screws and #8-32 lock nuts.

Second, align the hole pattern on the firebox with the pattern on the

smoker chamber. The firebox should be slightly offset from the smoker

chamber. Attach using six 1/4-20x3/4” hex-head bolts and flat washer

inside firebox and 1/4-20 flange nuts inside smoker chamber.

Firebox Top Assembly

Firebox Bottom Assembly

Firebox

Cover Plate

Smokestack

Smokestack plate

NOTE: Smoker chamber door not pictured for clarity.

From inside the smoker chamber, slide the smokestack through the large hole.Align the two holes in the smokestack plate

with the holes in the chamber and secure with two 1/4-20x3/4” hex-head bolts outside the chamber and 1/4-20 flange nuts

inside.

NOTE: Firebox and smoker chamber not pictured for clarity.

Attach wood handle to smoker chamber door using two 1/4-20x4” screws, wood handle spacers, fiber washers and 1/4-20

flange nuts, as shown below. Repeat to attach handle to firebox door.

Smoker Chamber

Door

Wood Handle Spacer

Handle

Firebox

Door

Fiber Washer

NOTE: Smoker chamber door not pictured for clarity.

Install grate support screws in the four rear holes and two

front-center holes in the smoker chamber. Use six #10-24x1”

screws and #10 flange nuts.

NOTE: Smoker chamber door not pictured for clarity.

Attach shelf brackets to outer holes on front of smoker chamber

using two 1/4-20x1-1/4” hex-head bolts and 1/4-20 flange nuts.

DO NOT FULLY TIGHTEN until Step 13.

Shelf bracket

Do not fully tighten

until Step 13.

Hole plug

NOTE: Smoker chamber door not pictured for clarity.

First, attach shelf slats to the two outer holes in shelf brackets using

two #10-24x1” screws and #10-24 flange nuts per slat. DO NOT

FULLY TIGHTEN SCREWS.

Second, fully tighten hex-head bolts on shelf brackets (installed in

previous step).

Third, attach remaining shelf slat to brackets with two #10-24x1”

screws and #10-24 flange nuts. FULLY TIGHTEN ALL SHELF

SLAT SCREWS.

13 Attach two outer

shelf slats. Do not

tighten.

1st

Attach inner slat.

Fully tighten all

slat screws.

3rd

Tighten bracket bolts.

2nd

If you have purchased the optional 3” Temperature Gauge,

part number 40003010, remove the attached nut, insert

gauge stem into large hole in cooking chamber door and

attach nut to gauge on inside of door. DO NOT

OVERTIGHTEN NUT. Make sure text and graphics are

aligned for easy viewing.

If you do not have a temperature gauge, install the chrome

hole plug (provided) into temperature gauge hole in cooking

chamber door.

If you would like to purchase the optional 3” Temperature

Gauge, part number 40003010, call 1-800-241-7548.

15Hang grease clip from holes on bottom right side of smoker chamber.A 12 oz. soup or vegetable can will fit nicely into clip to

collect grease.

Grease

Clip

If logo plate is not already installed, insert logo plate pins into two holes in lower right corner of smoker chamber door. Press

logo plate clips onto pins until snug against inside of door.

Logo plate

Logo plate clip

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