06201343 04201101 Hondo Jr. Smoker For Outdoor Use Only CAUTION WARNING THIS UNIT IS HEAVY! 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 OWNER’S MANUAL FOR IMPORTANT SAFETY INFORMATION. DO NOT assemble without a helper. CAUTION Some parts may contain sharp edges – especially as noted in manual. Wear protective gloves if necessary. WARNING NEVER LEAVE FIRE UNATTENDED! CAUTION Read and follow all safety statements, warnings, assembly instructions and use & care directions before attempting to assemble. WARNING All surfaces can be hot during use. Use protection as required to prevent burning. Do not allow small children near flame. Hot embers can fly out in breezy conditions. Adequate fire extinguishing material should be readily available. 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. 42804225 (12-19-06) STOP! Call Our Help Line 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. PARTS LIST Call us and we will gladly ship the part you need ITEM DESCRIPTION 55710221 Cooking Chamber Kit 55710222 Firebox Kit 55700056 Smokestack Kit 55700057 Damper Kit 55710223 Wire Shelf Kit 55700060 Wood Handle Kit 55700062 Long Leg Kit 55700063 Short Leg Kit 55700065 Leg Brace Kit 55700066 Smoke Chamber Door Kit 55700067 Firebox Door Kit 55700068 Wheel Kit 55700069 Axle Kit 55710210 Temperature Gauge Kit 42000011 Hardware Bag 44830150 Grease Can Holder 40009913 Fire Grate 40009914 Cooking Grate 42804225 Assembly Instructions 1 Long Leg with End Cap • Stand smoker chamber on right end. Left end, with larger opening, should be facing upward. • Connect long leg sections (with leg caps) to short leg sections. • Make sure long legs, with end caps, are toward the top. Attach legs to smoker chamber using two 1/4-20x1-3/4” screws and two 1/4-20 flange nuts per leg assembly. Smoker Chamber Short Leg – No End Cap 2 • Lay unit onto its back. • Attach leg braces on each side using four 1/4-20x1-3/4” screws and four 1/4-20 flange nuts per brace. • When complete, return unit to its right side, as positioned in step 1. Leg Brace 3 • Press a cotter pin through hole on one end of the axle, Bend with pliers so it won’t back out. Then slide a wheel onto the axle. • Slide axle into holes at ends of short legs (legs without end caps). • Slide remaining wheel onto axle. Press remaining cotter pin through axle, and bend with pliers. Check to be sure that all screws and nuts used so far are fully tightened. Bend Cotter Pin Cotter Pin Cotter Pin Wheel Axle 4 • Place the firebox onto the smoker chamber and align the large openings. • Insert six 1/4-20x1/2” screws through the firebox, into the smoker chamber. Secure with six 1/4-20 flange nuts. Fully tighten all screws and nuts. Firebox 5 Smokestack NOTE: The temperature gauge may be packed inside of the smokestack to prevent damage during shipping. If so, remove gauge before assembling smokestack to chamber. 1/4-20 Flange Nut • Attach smokestack to right side of smoker chamber by securing two 1/4-20 flange nuts onto studs from inside chamber. Do not overtighten nuts. 6 Temperature Gauge • Assemble handle by sliding spring through handle rod until spring is in the middle of handle rod as shown in inset. Temperature Gauge Nut • Place the handle assembly into the holes on the front of the firebox door and secure with two 1/4-20 flange nuts. Smoker Chamber Door • Repeat on smoker chamber door. • Insert temperature gauge into smoker chamber door and secure with nut provided on back side until probe is tight against door. Spring Firebox Door Handle Rod 1/4-20 Flange Nut Handle 8 • Following the same procedure used on the doors (Step 6) to assemble handle, install handle on left side of firebox with two 1/420 flange nuts. Do not overtighten nuts. 1/4-20 Flange Nut Handle 9 • Place a fire grate into the bottom of the firebox. Remaining two fire grates may be placed in the bottom of the smoker chamber, if desired. • The height of the grate can be adjusted by turning it 90 degrees. Fire Grates 10 • Assemble Front Shelf by inserting wire ends into two holes on front of Smoker Chamber. After inserting the wire ends into the holes, tilt the shelf fully upright and push ends all the way into holes and then bring the shelf down to the horizontal position. 11 • Insert the longer wires at the rear of the cooking grates into the four holes in the back of the smoker chamber. • The fronts of the cooking grates will rest on the front shelf wires installed previous step. s g Grate Cookin 12 • Hang the grease clip under the smoker chamber on right side. • An empty soup can is recommended to hang from grease clip. Grease Clip HARDWARE LIST Hardware is shown actual size. You may have spare hardware after assembly is complete. 1/4-20x2-1/4” 1/4-20x1-3/4” Carriage Bolt Machine Screw Qty. 6 Qty. 12 #10-24x1” 1/4-20x1/2” 1/4-20x1/2” Machine Screw Hex Head Machine Screw Qty. 6 Machine Screw Qty. 8 Qty. 1 #10-24x1/2” Machine Screw Qty. 16 1/4-20 Lock Nut Qty. 1 1/4-20 Flange Nut Qty. 28 #10-24 Flange Nut Qty. 22 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. Before you begin . . . Familairize yourself with the major components and controls of the unit. Smoker Chamber Firebox Smokestack Damper Grilling is a method of cooking directly over a fire, for foods such as steaks, hamburgers, and hot dogs. Cooking temperatures for grilling ranges from approximately 350° to 550°. Due to the high temperatures and direct proximity to the fire, this type of cooking requires close attention. Barbequing is accomplished by using indirect heat, with a temperature range from approximately 225° to 350°. Using an offset firebox design, only the heat and smoke flow through the smoker chamber, cooking the food without direct contact with the fire. This method is ideal for chicken, ribs, fish, and vegetables. Slow Smoking can also be done with the offset firebox Firebox Damper design, using indirect heat and smoke. Similar to barbequing, the food is placed in the smoker chamber, with the fire in the firebox. However, slow smoking occurs in a temperature range of approximately 140° to 225°, and requires an extended cooking time. This type of cooking is ideal for turkey, ham, or sausage. With any type of live fire cooking, allow enough time to build a fire and get the grill/smoker up to temperature. Build a fire using either charcoal briquettes, lump charcoal, or wood chunks. Briquettes offer a very good source of heat, and are readily available in the marketplace. Most briquettes are manufactured using a combination of wood charcoal, coal powder, and a processing binder. Lump charcoal is a premium form of charcoal because it is made of only wood. Lump charcoal burns hotter and longer than briquettes, and imparts no chemical flavors to the food being cooked. For a more robust smoke flavor using briquettes or lump charcoal, try adding 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. Mild Flavor Medium Flavor Heavy Flavor Pecan Hickory Mesquite Apple White Oak Blackjack Oak Peach Cherry Red Oak Experiment with different woods to determine your personal favorite, and always use well-seasoned wood. Green or freshcut wood can turn food black, and tastes bitter. Prior to cooking on your grill/smoker, the following steps should be taken to season the interior steel. This will seal the inside surfaces with wood smoke and resin, helping to prevent corrosion. First, brush all interior surfaces with vegetable oil. Next, build a small fire on the fire grate inside the firebox, being sure not to lay coals against the walls. After the fire becomes established, close both lids and position both dampers approximately 1/4 open. Sustain this fire for at least 2 hours. The unit is now ready for cooking! Grilling Position both fire grates in the smoker chamber. Build a fire on top of the fire grates using either charcoal briquettes, lump charcoal, or wood chunks. Keep the smoker chamber lid open, and both dampers open, until the fire has established itself and is ready for cooking. Spread out coals as required, insert cooking grates, and start grilling. Remember, grilling is done over the top of the fire. Use the dampers to regulate the fire and heat. Open the dampers to increase temperature; close dampers to decrease temperatures. The cooking chamber door can remain open or closed. Refer to recipes for required cooking times and temperatures. Barbequing and Slow Smoking Position both cooking grates in the smoker chamber. Position one fire grate in the firebox. Build a fire on this fire grate using either charcoal briquettes, lump charcoal, or wood chunks. Keep the firebox lid open, and both dampers open until the fire is established. Then, close the firebox lid (both lids should now be closed) and you will begin to see smoke flow from the smokestack. Adjust both dampers until the desired smoker chamber temperature is achieved. Open the dampers to increase temperature; close the dampers to decrease temperatures. This process of adjusting the temperature can take several minutes. Once the proper setting is obtained, only occasional attention is required. Now, place the food in the smoker chamber. Remember, this is indirect cooking, so the fire is in the firebox, and the food is placed in the smoker chamber. Keep both lids closed while cooking to prevent unnecessary loss of heat and smoke. Refer to recipes for required cooking times and temperatures. Add charcoal or wood chunks as necessary to maintain the fire. Maintenance When finished cooking, and the unit has adequately cooled, clean out all remaining ashes. Ashes collect moisture, which can lead to premature rusting and decay. Periodically coating the interior surfaces with vegetable oil will aid in the protection of your unit. Also, occasional touch up of the exterior paint will be required. Black, high-temperature spray paint is recommended. Never paint the interior of the unit. LIMITED WARRANTY 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. 90 Day LIMITED Warranty Upon consumer supplying proof of purchase as provided herein, Manufacturer will repair or replace the parts listed below which are proven defective during the applicable warranty period. Parts required to complete such repair or replacement shall be free of charge to you except for shipping costs. The original consumerpurchaser will be responsible for all shipping charges of 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 reasonable proof of your date of purchase. Therefore, you should retain your sales slip or invoice and register your new product immediately. Defective or missing parts subject to this limited warranty will not be replaced without registration or proof of purchase. Register online at www.charbroil.com or complete and return via mail the Product Registration Card located on the last page of the Use & Care manual included with this product and retain your sales receipt for proof of purchase. This limited warranty applies to the functionality of the product ONLY and does not cover cosmetic issues such as scratches, dents, corrosion 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. The warranty for your grill covers manufacturing defects. Surface rust, corrosion, or powder paint chipping on metal parts that does not affect the structural integrity of the product is not considered a defect in workmanship or material and is not covered by this warranty. This limited warranty will not reimburse you for the cost of any inconvenience, food, personal injury or property damage. If an original replacement part is not available, a comparable replacement part will be sent. You will be responsible for all shipping charges of parts replaced under the terms of this limited warranty. ITEMS MANUFACTURER WILL NOT PAY FOR: 1. Service calls to your home. 2. Repairs when your product is used for other than normal, single-family household or residential use. 3. Damage resulting from accident, alteration, misuse, abuse, fire, flood, acts of God, improper installation, installation not in accordance with electrical or plumbing codes, or use of products not approved by the manufacturer. 4. Any food loss due to product failures. 5. Replacement parts or repair labor costs for units operated outside the United States or Canada. 6. Pickup and delivery of your product. 7. Repairs to parts or systems resulting from unauthorized modifications made to the product. 8. The removal and/or reinstallation of your product. 9. Shipping cost, standard or expedited, for warranty and replacement parts. DISCLAIMER OF IMPLIED WARRANTIES; LIMITATION OF REMEDIES Repair or replacement of defective parts is your exclusive remedy under the terms of this limited warranty. 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 documented purchase price of the product paid by the original consumer. This warranty only applies to units purchased from an authorized retailer and or re-seller. 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 for 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: Char-Broil Consumer Relations P. O. Box 1240 Columbus, GA 31902-1240 Consumer returns will not be accepted unless a valid Return Authorization is first acquired by calling 1-800-232-3398 and then clearly marked on the outside of the package and the package is shipped freight/postage pre-paid to the address above. Certified Grill Parts And Accessories®, Char-Broil and Design®, Char-Broil (Gas Grill Briquettes)®, Char-Diamonds®, Cooking Zone and Design®, Diamond Flame®, Executive Chef®, Faststart®, Flare Fighter®, FlavorMaster®, Gas Grill Silouette and Design®, H2O Smoker®, Lava Flame®, MasterFlame®, MasterFlame Precision Cooking System®, PowerSpark®, Quantum®, VIP®, PrecisionFlame and Design®, Sierra®, and TruFlame® are registered Trademarks of the W.C. Bradley Company. Thermos® is a registered trademark of the Thermos Company and its affiliates. Artisan Collection by Char-Broil ™, C3 and Design™, Char-Broil and Design™, Flame Design™, FlavorTents™, Grill 2 Go™, Grillin’ Stick™, Keeper of the Flame™, Keepers of the Flame™, Natural Grip™, Outdoor Cooking Collection and Design™, Patio Bistro™, PrecisionFlame™, Pro-Check™, QuickSet Grills and Design™, SmokerTents™, The Big Easy™, The Minute Grill™, The Edge™, The Tuscan Collection™, and The Urban Grill™ are Trademarks of the W.C. Bradley Company. Universal Grill Parts and Design™ is a trademark of the Thermos Company and its affiliates. TEC™ is a registered trademark of TEC INFRA-RED GRILLS. US patents pending. Protected under one or more of the following U.S. Patents: 4,598,692; 4,624,240; 4,747,391; 4,747,391; 4,817,583; 4,924,846; 4,989,579; 5,003,960; 5,076,256; 5,076,257; 5,090,398; 5,109,834; 5,224,676; 5,277,106; 5,421,319; 5,441,226; 5,452,707; 5,458,309; 5,566,606; 5,566,606; 5,579,755; 5,582,094; 5,613,486; 5,649,475; 5,706,797; 5,711,663; 5,765,543; 5,931,149; 5,996,573; 6,095,132; 6,135,104; 6,173,644B1; 6,279,566; 6,397,731; 6,418,923; 6,439,222; 6,523,461; D282,619; D339,714; D341,292; D343,337; D358,059; D361,466; D364,535; D372,637; D373,701; D377,735; D383,035; D397,910; D405,643; D405,643; D406,005; D406,009; D413,043; D413,229; D413,229; D414,982; D415,388; D416,164; D416,441; D416,441; D417,587; D422,516; D423,274; D423,876; D428,303; D435,396; D436,004; D438,059; D438,060; D438,427; D439,110; D442,505; D443,179; D443,354; D447,384; D447,385; D447,909; D448,610; D448,614; D448,615; D448,616; D448,975; D449,492; D451,759; D456,202S; D460,313, D461,359 and D504,048. Canada: 87743; 87744; 92607; 92608 and 1,316,424. Other Patents Pending. Assembly instructions © 2006. Please register your product online at: www.grillregistration.com (If you register online, you do not need to send in this registration card.) PLEASE FILL OUT THIS CARD AND RETURN IT WITHIN 10 DAYS OF PURCHASE. FAILURE TO RETURN MAY AFFECT YOUR WARRANTY COVERAGE. FOR WARRANTY SERVICE PROOF OF PURCHASE WILL BE REQUIRED. PLEASE KEEP YOUR SALES RECEIPT. THIS WARRANTY IS NON-TRANSFERABLE. LLENE ESTA TARJETA Y DEVUELVALA DENTRO DE LOS 10 DIAS DE LA COMPRA. SI NO LA DEVUELVE, PUEDE VERSE AFECTADA SU COBERTURA DE GARANTIA. PARA EL SERVICIO DE GARANTIA ES NECESARIO QUE PRESENTE SU COMPROBANTE DE COMPRA. CONSERVE LA FACTURA. ESTA GARANTIA ES INTRANSFERIBLE. VEUILLEZ COMPLETER CETTE CARTE ET LA RETOURNER DANS LES 10 JOURS SUIVANT L’ACHAT. LA COUVERTURE DE VOTRE GARANTIE POURRAIT EN ETRE AFFECTEE SI VOUS NE LE FAITES PAS. POUR OBTENIR LE SERVICE SOUS GARANTIE, UNE PREUVE D’ACHAT DOIT ETRE PRESENTEE. VEUILLEZ CONSERVER VOTRE FACTURE. LA PRESENTE GARANTIE N’EST PAS TRANSFERABLE. 1 First Name/Nombre/Prénom Initial/Inicial/Initiale Last Name/Apellido/Nom de famille Apt Number/NO de apart./NO d’appt. Address (number and street)/Dirección (número y calle)/Adresse (numéro et rue) State/Estado/Province City/Ciudad/Ville Zip Code/Código zip/Code postal Address/Dirección de correo electrónico/Adresse électronique 2 E-mail If you voluntarily provide us with your email address, you give us permission to use your email address to send you offers that may interest you. Si nos informa voluntariamente su dirección de correo electrónico, nos da permiso para usarlo a fin de enviarle ofertas que pueden interesarle. Si vous choisissez de nous fournir votre adresse électronique, vous nous donnez la permission de l’utiliser pour vous faire part d’offres spéciales susceptibles de vous intéresser. (Example: your name @ your host.com) (Ejemplo: su nombre@su host.com) (Exemple : votre nom@votre hôte.com) 3 Phone Number/Número telefónico/Numéro de téléphone 6 Date of Purchase/Fecha de compra/Date de l’achat 4 7 Store Name/Nombre de la tienda/Nom du magasin IMPORTANT!/¡IMPORTANTE!/IMPORTANT! Write Serial Number and Model Number in spaces below. Escriba en los espacios de abajo el número de serie y el número de modelo. Inscrivez le numéro de série et le numéro de modèle dans les espaces ci-dessous. 8 Purchase Price/Precio de compra/Prix d’achat $ 5 Your Gender/Sexo/Sexe : 9 Which product are your registering? ¿Qué producto está registrando? Quel produit enregistrez-vous? 1. Gas Grill/Parrilla a gas/Gril au gaz 2. Electric Grill/Parrilla eléctrica/Gril électrique 3. Smoker/Ahumador/Fumoir 4. Charcoal Grill/Parrilla a carbón/Barbecue au charbon 5. Charcoal Smoker/Ahumador a carbón/Fumoir au charbon 6. Outdoor Fireplace/Chimenea para exteriores/Foyer extérieur 7. Cooker/Fryer / Cocina/freidora / Cuiseur/Friteuse 8. Other/Otro/Autre 1. Male/Masculino/Masculin .00 2. Female/Femenino/Féminin Mail to: / Envíelo a: Consumer Warranty Service P. O. Box 1240 Columbus, GA 31902-1240 Thank you for completing this questionnaire. Your answers will help us and other companies reach you with offers that may interest you. If you prefer not to receive these offers, please check here . Gracias por completar este cuestionario. Sus respuestas nos ayudarán, a nosotros y a otras compañías, a llegar a usted con ofertas que puedan resultarle de interés. Si prefiere no recibir estas ofertas, por favor marque aquí . Merci d’avoir bien voulu remplir ce questionnaire. Vos réponses nous aideront et aideront d’autres compagnies à vous communiquer des offres spéciales susceptibles de vous intéresser. Si vous préférez ne pas recevoir d’informations concernant ces offres spéciales, veuillez cocher ici .