Char-Broil 10201595 User Manual

American Gourmet

Smoker, BBQ and Grill

Product Guide
Model 10201595

Tools needed for assembly:

Phillips Screwdriver
Flat Head Screwdriver
Two adjustable wrenches
Hammer

IMPORTANT: Fill out the product record information below.

Serial Number

Date Purchased

Estimated Assembly Time: 1 Hour

FOR OUTDOOR USE ONLY

CAUTION:

Read and follow all safety statements, assembly instructions,
and use and care directions before attempting to assemble
and cook.

INSTALLER/ASSEMBLER:

Leave this manual with consumer.

CONSUMER:

Keep this manual for future reference.

WARNING:

CARBON MONOXIDE HAZARD

Burning charcoal inside can kill you. It gives off carbon

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.

CAUTION:

THIS UNIT IS HEAVY! DO NOT attempt to
assemble without a helper.

monoxide, which has no odor. NEVER burn charcoal inside
homes, vehicles, or tents.

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®; Everybody Outside®; FastStart®; Grill 2 Go®; Grill 2 Go® Express®; Grill Lovers®; Infrared Grilling
That’s All About U®; Keepers of the Flame®; 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®; Trentino®; U®; Wild West Tradition®; and the following marks:

® ®

The following are trademarks of W.C. Bradley Co.: Advantage Series™; Auto-Clean™;Chef Tested™; Commercial Series™; Designer Series™;; Diamond Flame™; Double Chef™; Fireball™; Firenzy™;

FlavorMaster™;Front Avenue™; Grill 2 Go® Advantage™; Hog and Yard Bird™; H20 Smoker™; Infrared. Grilling’s Juicy Little Secret™; Incredible Taste. Infallible Results™; Infrared Inside™; Insure™; Let’s
Grill Something Together™; Lev-Alert™; Longhorn™; Magneto™; Precision Flame™; Quick2Burn™; QuickSet™; Ready When You Are™; Season, Set, And Savor™; Sizzle On The Grill™; Signature
Series™; SureFire™; The Minute Grill™;Torchfork™; Universal Grill Parts™; You Bring the Party™ TEC™ is a trademark of Tec Infrared Grills.

Protected under one or more of the following U.S. Patents: 5,421,319; 5,458,309; 5,579,755; 5,996,573; 6,135,104; 6,279,566; 6,331,108; 6,484,900; 6,526,876; 6,595,197; 6,640,799; 6,640,803; 6,729,873; 6,739,473; 6,749,424; 6,792,935; 6,951,213;
7,047,590; 7,516,693; D364,535; D372,637; D373,701; D377,735; D383,035; D397,910; 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; D447,384; D447,385; D447,909; D448,610; D448,614; D448,615; D448,616; D448,975; D449,492; D450,544; D451,759;
D454,028; D454,031; D455,205; D455,206; D456,202; D456,222; D456,223; D457,789; D458,520; D458,760; D458,802; D459,088; D459,148 D459,149; D459,161; D459,163; D459,586; D459,943; D460,312; D460,313; D460,318; D461,359; D465,123;
D465,693; D466,307; D466,439; D466,752; D473,414; D474,371; D477,498; D477,501; D477,504; D477,506; D477,746; D478,471; D478,472; D480,914; D491,410; D494,009; D494,413; D498,523; D500,359; D504,048; D530,098; D535,000;
Canada:D97,504;D99,355; D102,037; D104,200;D108,377; 2,315,567; France:D010,231;D010,422;D010,590;D010,849; 1,089,646; South Korea: 384,565; United Kingdom: 2,099,402. Other Patents Pending. © 2009 W.C. Bradley Company

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 appliance online at www.charbroil.com/register

42804518 - 11/18/09

TABLE OF CONTENTS

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

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

Preparing to use your Grill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

WARNING

FAILURE TO READ AND FOLLOW INSTRUCTIONS FOR
LIGHTING CHARCOAL MAY RESULT IN SERIOUS PERSONAL
INJURY AND OR PROPERTY DAMAGE.

Smoker Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Cooking Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Limited Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Parts List/ Parts Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13

Hardware List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Registration Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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.

WARNING

• Most surfaces on this unit are hot when in use.
Use extreme caution. Keep others away from
unit. Always wear protective clothing to prevent
injury.

• Keep children and pets away.

• Do not move this unit during operation.

• Never substitute gasoline, kerosene or alcohol
for charcoal starter. In some states, the use of
charcoal starter is prohibited by law. In this
case, paraffin-based starter cubes can be
substituted for charcoal starter. Never use
charcoal starter fluid with an electric starter.

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.

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

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.

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.

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.

CAUTION

For residential use only. Do not use for commercial
cooking.

Page 2

Preparing and Using Your American Gourmet Smoker

Before cooking with your American Gourmet Smoker, the following steps should be closely followed to both cure
the finish and season the interior steel. Failure to properly follow these steps may damage the finish and/or impart metallic

flavors to your first foods.

Brush all interior surfaces including grills and grates with vegetable cooking oil.

1.

2. Build a small fire on the fire grate, being sure not to lay coals against the walls.

3. Close door. (Position butterfly damper and smokestack damper approximately at one quarter open.) This burn
should be sustained for at least two hours, the longer the better. Then, begin increasing temperature by opening the
butterfly damper and smokestack damper half-way and adding more charcoal. Your American Gourmet Smoker
is now ready for use.

Rust can appear on the inside of your smoker. Maintaining a light coat of vegetable oil on interior surfaces will aid in the
protection of your unit. Exterior surfaces of smoker may need occasional touch up. We recommend the use of a
commercially available black high temperature spray paint. NEVER PAINT THE INTERIOR OF THE UNIT !

GRILLING

Wood is recommended, however charcoal or a combination of both may be used as the fuel source for grilling, with the
fuel source placed and ignited on the fire grate. Do not build too large of a fire. We recommend starting a fire with no
more than 2 pounds of charcoal (approximately 20 briquettes). After allowing the fire to burn down, place the cooking grates
in the smoker. Failure to read and follow instructions for lighting charcoal may result in serious personal injury and/or property
damage.

SMOKING AND SLOW COOKING

If using the American Gourmet Smoker as a smoker or slow cooker, remove the cooking grill from the firebox and
build your fire on top of the fire grate in the firebox. Either charcoal or wood may be used, but wood is the recommended
fuel for it’s rate of burn and the flavor it imparts to the food being cooked. Most seasoned hardwoods are good for smoking
such as hickory, mesquite, pecan, oak, and many other fruit woods. The firebox will accommodate most split fireplace size
logs (16”). Bark should be avoided or burned off first as it contains a high acid content and imparts an acrid flavor.

After allowing the fire to burn down, close the doors and control the temperature and smoke with the dampers located on
the firebox and atop the smokestack. Smoke is contained within the chambers, which will reduce burn while imparting
more smoke flavor. Do not operate the Smoker with temperatures exceeding 450 degrees in the smoker chamber.
Place the food in the smoker chamber and monitor the temperature. Cooking and smoking are taking place using indirect
heat. There is no need to worry about a grease fire flare-up ruining the food. Do not place food within 6” of the opening
from the firebox into the smoker chamber. A general rule of thumb for cooking is about 1 hour per pound for smoking
large cuts of meat. Refer to a cook book for specific cuts of meats. Limit the number of times you open the smoker
chamber door as this will allow heat to escape and extend the cooking time.

Grilling with Wood Chips/Wood Chunks

For a more robust smoke flavor while using charcoal briquettes or lump charcoal, try adding wood chips or
several wood chunks to the fire. Wood chunks are available in a variety of natural flavors, and can be used
alone or in addition to charcoal. As a general rule, any hardwood that bears a fruit or nut is suitable for
cooking. However, different woods have very different tastes. Experiment with different woods to determine
your personal favorite, and always use well-seasoned wood. Green or fresh-cut wood can turn food black,
and tastes bitter.

USDA Recommended

Our Recommendations:

Chicken - Alder, Apple, Hickory, Mesquite, Sassafras
Beef - Hickory, Mesquite, Oak, Grapevines
Pork - Fruitwoods, Hickory, Oak, Sassafras
Lamb - Fruitwoods, Mesquite
Veal - Fruitwoods, Grapevines
Seafood - Alder, Mesquite, Sassafras, Grapevines
Vegetables – Mesquite

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 3

COOKING TIPS

Building Your Fire

1.) Stack charcoal briquettes or wood into a pyramid-shaped pile on top of the charcoal grate
or ash pan. We recommend using 2 pounds (approximately 20 briquettes) to start your fire.

2.) If using lighter fluid, saturate the charcoal briquettes with lighter fluid and let it soak in for
approximately 5 minutes. If using a chimney starter, electric starter, or other type of fire
starter, light your fire according to the manufacturer's instructions.

3.) After allowing the lighter fluid to properly soak in, light the pile of briquettes in several
locations to ensure an even burn. Always light the fire with the grill lid open.

Leave lid open until briquettes are fully lit. Failure to do this could trap fumes from charcoal

lighter fluid in grill and may result in a flash fire when lid is opened.

4.) Never add charcoal lighter fluid to hot or warm coals as flashbacks may occur causing
injury.

5.) You are ready to begin cooking when the pile of briquettes ashes over and produces a red

glow (approximately 12 – 15 minutes).

6.) Depending on your cooking method, either leave the briquettes in a pile or spread evenly

across the charcoal grate using a long-handled poker.

*Always use caution when handling hot coals to prevent injury.

Know When Your Fire is Ready

Successful charcoal grilling depends on a good fire. The general rule for knowing when your coals
are ready for grilling is to make sure that 80 percent or more of the coals are ashy gray. If you
have less than that, the coals are not ready, and if all of them are glowing red hot, the fire is
probably too hot. Here are a few steps you can take to adjust the temperature of your fire:

- If it is too hot, spread the coals out a bit more, which makes the fire less intense.

- Raise or lower the adjustable charcoal grate.

- Partially close the vents in the grill, which reduces the amount of oxygen that feeds the fire.

- Use the indirect grilling method, with coals to either side of a drip pan and the food over the
pan rather than directly over the coals.

- In the event of a severe flare-up, spray the flames with water from a squirt bottle. Be
careful, spraying with water tends to blow ashes around and make a mess.

- Add briquettes 2 or 3 at a time to increase the burn time. Allow 10 minutes for coals to ash
over before adding more.

Page 4

THE HEAT OF THE COALS

seconds you can
hold the palm of

your hand 4 inches

above the coals temperature range (Fº) visual cues

HOT COALS 2 400 to 450 barely covered with

gray ash; deep red glow

MODERATELY HOT

TO HOT COALS

MODERATELY HOT COALS 4 325 to 375 significant coating of

MODERATELY COOL COALS 5 300 to 325 thick coating of gray

3

375 to 450 thin coating of gray

ash; deep red glow

gray ash; red glow

ash; dull red glow

GRILL MAINTENANCE

Frequency of cleanup is determined by how much your smoker is used. Make sure coals are completely extinguished
before cleaning inside of smoker. Inside surfaces may be cleaned with a strong solution of detergent and water applied
with a scrub brush. Thoroughly rinse with water and allow to air dry before using again.

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.

HELPFUL HINTS

• If food seems to be getting too smoky or brown before the cooking time is finished, cover it loosely with heavy duty
aluminum foil.

•Remove the ash after each use.

•Covered side dishes can be warmed in smoker chamber.

•To prevent flare-ups, brush meat lightly with oil before grilling.

•Keep a small squirt bottle of water handy for grilling flare-ups.

Page 5