Char-Griller Pro Deluxe XL, 2735 - Charcoal Grill Manual

ASSEMBLY INSTRUCTIONS

Read all instructions carefully before assembly and use. Read and understand all warnings and precautions before operating your grill.

PARTS LIST

HARDWARE AND TOOLS NEEDED

Assembly: Get another person to help. Tools Needed: Hammer, Pliers, and a 7/16" Nut Driver.

NOTE: Do Not tighten any bolts unless instructed to do so. Tightening too soon may prohibit parts from fitting 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.

Step 1: Assemble Long Legs, Short Legs, and Leg Braces

Assemble Long Legs, Short Legs, and Leg Braces as shown below then secure the Leg Braces to one set of the Long Legs and Short Lets with four 1-3/4" Hex Bolts and four Hex Nuts.

Step 2: Install Bottom Wire Shelf

Install Bottom Wire Shelf by placing the four corner hooks inside the hole on each leg, then rotate the leg assemblies up and secure the leg braces to the other side of the Long Leg and Short Leg set using four 1-3/4" Hex Bolts and four Hex Nuts.

Step 3: Lay the cart assembly down

Lay the cart assembly down with the Long Legs on the floor. To install the Axle and Wheels, snap the Hub Cap onto one end of the Axle and insert a Large Cotter Pin. Slide on a 2/5" washer and a wheel, and fit the Axle through the axle hole in the cart. On the other end, slide on the other Wheel, 2/5" Washer, Cotter Pin, and finally the Hub Cap. The parts should be in this order:
Hub Cap – Pin – Washer – Wheel – CART – Wheel – Washer – Pin - Hub Cap

Step 4: Attach the Grill Body to the previously assembled Cart

Attach the Grill Body to the previously assembled Cart using four 1-3/4" Hex Bolts and four Hex Nuts. The Bolts must go through the Leg and Grill Body, then add Hex Nut inside the Grill Body and tighten.

Step 5: Attach Damper Circle to the side of the Grill Body

Attach Damper Circle to the side of the Grill Body with one ¾" Hex Bolt, two Flat Washers, one Lock Washer, and one Hex Flange Nut.

Step 6: Attach the Grill Hood to the Grill Body

Attach the Grill Hood to the Grill Body using the two Hinge Pins and two Small Cotter Pins provided.

Step 7: Attach Side Shelf to Grill Body

Attach Side Shelf to Grill Body with four 3/4" long Hex Bolts and four Hex Nuts.

Step 8: Attach Front Shelf to the Left Bracket and Right bracket

Attach Front Shelf to the Left Bracket and Right bracket using two ½" Hex Bolts per side, then attach to Grill Body with four ½" long Hex Bolts and four Hex Nuts.

Step 9: Insert Smokestack Assembly

From the inside of the Grill Hood, insert Smokestack Assembly through the hole on the Grill Hood. Secure in place using two ½" Hex Bolts and two Hex Nuts.

Step 10: Insert the Thermometer

Insert the Thermometer through the Thermometer Bezel then through the hole in Grill Hood (from outside) Flat Washer and secure with Wing Nut. Insert the Hood Handle through the Handle Bezel and Grill Hood (from outside) and then through Lock Washers and secure with Wing Nuts as shown.

Step 11: To install the Warming Rack

To install the Warming Rack, first attach two 2" long Hex Bolts and two Hex Nuts on Grill Hood and attach two ¾" long Hex Bolts and two Hex Nuts onto Grill Body, as shown below. Then position the Warming Rack onto the Hex Bolts and add two nuts to secure it in place.

Step 12: Install the Grease Cup Holder

Install the Grease Cup Holder underneath the Grill Body.

Step 13: Place Ash Pan and Ash Pan Hangers

Place Ash Pan and Ash Pan Hangers onto Grill Body.

Step 14: Place Cooking Grates and install Utensil Hooks

Place Cooking Grates onto Grill Body and install Utensil Hooks underneath the Side Shelf at the front of the Grill.

Step 15: Tighten all nuts and bolts

Tighten all nuts and bolts securely.

Fully Assembled

OPERATING INSTRUCTIONS

Setting Up

Set grill up on solid, flat surface with adequate wind shelter. Do not move grill while hot, and do not leave unattended during operation.

This appliance is designed for use outdoors, away from any flammable materials. It is important that there are no overhead obstructions and that there is a minimum distance of 12 feet (366 cm) from the side or rear of the appliance. It is important that the ventilation openings of the appliance are not obstructed. The barbecue must be used on a level, stable surface. The appliance should be protected from direct drafts and positioned or protected against direct penetration by any trickling water (e.g. rain).

PLEASE NOTE: NO RETURNS ON USED GRILLS.

Seasoning and Preparing the Grill

BEFORE YOU USE YOUR GRILL FOR THE FIRST TIME YOU MUST SEASON THE CAST IRON COOKING GRATE(S).

Cure grill prior to your initial use to protect the interior and exterior finish, cooking grates, and to prevent unnatural flavors to your first meals.

1. Lightly coat ALL INTERIOR SURFACES (including grills, grates, and inside of barrel.) with vegetable oil (spray vegetable oil is easiest but do not use near hot coals or fire).
2. Build a medium sized fire on the fire grate. Always put charcoal on top of the fire grate and not directly into the bottom of the grill.
3. After coals ash over, spread out coals, replace cooking grates, close lid and heat at approximately 250 F for two hours.
4. Remove grates from the grill with oven mitts, allow to cool, then re-coat grates and return to grill at approximately 200° F for two hours.
5. You can lightly coat the exterior of the grill body (while warm) with vegetable oil. This will extend the life of the finish, much like waxing a car. Your grill is now ready for use.

NOTE: Grill will drip oil during this process and for several uses afterwards. This is normal.

NEVER EXCEED 400°F BECAUSE THIS WILL DAMAGE THE FINISH AND CONTRIBUTE TO RUST. PAINT IS NOT WARRANTED AND WILL REQUIRE TOUCH-UP. THIS UNIT IS NOT WARRANTED AGAINST RUST.

Lighting Instructions

1. To start a charcoal fire, stack 50-60 briquettes in a pyramid and saturate with lighter fluid.
   NOTE: Do not use gasoline, kerosene or alcohol for lighting charcoal. Use of any of these or similar products could cause an explosion possibly leading to severe bodily injury.
2. Light coals in several places
3. After briquettes ash over or turn gray, spread them out and start cooking
4. If one end burns faster, use tongs to move coals from one end to the other for even heat.

Grill Operation & Tips

• Control heat with amount and type of fuel, Dual dampers, and adjustable fire grate. Adjust grate one end at a time. Wood burns hotter than coals. More airflow is more heat.
• To reduce flare-ups, cook with lid in the down position.
• Add water soaked hardwood chips for a smoked flavor.
• Ashes left in bottom too long hold moisture and will rust through any thickness of steel. This grill is made of steel and cast iron, which WILL RUST, ESPECIALLY IF NOT PROPERLY CARED FOR.
• Do not use self-starting charcoal as it will give unnatural flavor. Burn lighter fluid completely before closing lid.
• After each use, coat vegetable oil on the interior grates and bare metal while warm to reduce rust
• On the EXTERIOR, remove dust with wire brush and touch up with a high heat paint, available at most hardware/auto stores.
• You may place a coffee can on bottom shelf under the hole in the grill to catch drippings.
• Heat guage may obtain moisture, which will steam out during cooking. Gauge can be removed and calibrated in oven.
• You may fill unwanted holes with Nuts & Bolts (Not Provided).

NOTE: Smoke may escape from areas other than the smokestack. This should not affect cooking.

Finishing Up

When your are finished grilling you can shut down your grill by closing both dampers and allowing the fire to suffocate. Be patient. This may take an hour or more.

Emptying the Ashes & Ash Pan: ONLY EMPTY ASHES WHILE GRILL IS NOT IS USE.

After the fire is completely extinguished you should wait several hours before emptying the ashes to ensure they are not still hot and a burn hazard.

1. Knock any ashes that did not fall into the ash pan from the fire grate. (If there are pieces of partially burned charcoal on the fire grate you can save them for next time. They are still good).
2. Tap the sides of the fire bowl to knock loose any ash that is on the sides.
3. Unclip the ash pan from the bottom of the grill and slide out towards the front.
4. Give the ash pan a few firm taps to loosen any ash that may be stuck.
5. Place the ashes in a metal container and cover with water to ensure there are no lit coals then you can dispose of the ashes.

Charcoal is porous and holds moisture. DO NOT leave charcoal in your grill while you are not using it. Charcoal and ashes left inside the ash pan may reduce the life of your grill.

For pricing or to order accessories visit: www.CharGriller.com

IF YOU HAVE ANY QUESTIONS CONTACT CUSTOMER SERVICE AT
912-638-4724
OR
SERVICE@CHARGRILLER.COM.

IMPORTANT SAFETY WARNINGS

READ ALL SAFETY WARNINGS AND INSTRUCTIONS CAREFULLY BEFORE ASSEMBLING AND OPERATING YOUR GRILL

Read the following instructions carefully and be sure your appliance 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, call 912-638-4724.

• Grill is for use outdoors and in well-ventilated areas, only.
• 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.
• Do not leave a lit grill unattended. Keep children and pets away from grill at all times.
• Use caution when moving grill to prevent strains.
• Keep grill at least 15 feet from any combustible material (decks, buildings, fences, trees, bushes, etc).
• 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.
• Do not place grill near flammable liquids, gases, or where flammable vapors may be present.
• Use caution since flames can flare-up when fresh air suddenly comes in contact with fire.
• When opening the lid, keep hands, face, and body safe from hot steam and flame flare-ups.
• WARNING: To avoid injuries gloves or other protective articles should be used when touching the ash pan hangers.
• Do not exceed a temperature of 400°F.
• Do not allow charcoal and/ or wood to rest on the walls of grill. Doing so will greatly reduce the life of the grill.
• Always wear oven mitts to protect hands from burns. Avoid touching hot surfaces.
• 
  Exposed metal dampers on air vents and/or metal handles are hot during usage. Again, always wear oven mitts when adjusting air flow to protect hands from burns.

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.

• 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 flame.
• 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.
• 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.
• 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 fire extinguisher near at all times. Maintain and check your fire extinguisher regularly.

THESE WARNINGS ALSO APPLY TO THE SIDE FIRE BOX.

REGISTER YOUR 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.

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 that are 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: Service@CharGriller.com and have your serial number handy.

Document Your Grill Model and Serial Numbers, see HERE:

(Model and Serial number are located on the back of the grill body or on the leg.)

Documents / Resources

References

• Char-Griller BBQ Grills and Smokers
• http://www.p65warnings.ca.gov

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