Product Guide
Model 10201630
Longhorn Smoker
Tools needed for assembly:
Pliers
Adjustable wrenches
IMPORTANT: Fill out the product record information below.
Serial Number
Date Purchased
Estimated Assembly Time: 1 Hour
FOR OUTDOOR USE ONLY
WARNING:
CAUTION:
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.
INSTALLER/ASSEMBLER:
CAUTION:
Some parts may contain sharp edges – especially as
noted in the manual! Wear protective gloves if
necessary.
Leave this manual with consumer.
CONSUMER:
Keep this manual for future reference.
WARNING:
CARBON MONOXIDE HAZARD
Burning charcoal indoors can kill you. It gives off carbon
monoxide, which has no odor. NEVER burn charcoal inside
homes, vehicles, or tents.
CAUTION:
THIS UNIT IS HEAVY! DO NOT attempt to
assemble without a helper.
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’sAllAbout 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 WestTradition®; 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 YouAre™; 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 ofTec 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. ©
2009W.C.BradleyCompany
TM REVISION 04
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
42804551 - 12/15/09
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Preparing and Using Your Smoker
Before cooking with your 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 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 4 pounds of charcoal (approximately 50-60 briquettes) and adding more as needed during cooking. After allowing
the fire to burn down, place the cooking grills 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 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.
Our Recommendations:
Chicken - Alder, Apple, Hickory, Mesquite, Sassafras
Beef - Hickory, Mesquite, Oak, Grapevines
USDA Recommended
Internal Cooking Temperatures
Ground Meat
Beef, Pork, Veal, Lamb......................................160°F
Turkey, Chicken.................................................165°F
Pork - Fruitwoods, Hickory, Oak, Sassafras
Lamb - Fruitwoods, Mesquite
Veal - Fruitwoods, Grapevines
Seafood - Alder, Mesquite, Sassafras, Grapevines
Fresh Beef, Veal, Lamb
Medium Rare.......................................................145°F
Medium................................................................160°F
Vegetables – Mesquite
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
3
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COOKING TIPS
Building Your Fire
1.)
2.)
3.)
Stack charcoal briquettes or wood into a pyramid-shaped pile on top of the charcoal grate
or ash pan. We recommend using 4 pounds (approximately 50 - 60 briquettes) to start your
fire, adding more as needed.
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.
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.
Never add charcoal lighter fluid to hot or warm coals as flashbacks may occur causing
injury.
You are ready to begin cooking when the pile of briquettes ashes over and produces a red
glow (approximately 12 – 15 minutes).
Depending on your cooking method, either leave the briquettes in a pile or spread evenly
across the charcoal grate using a long-handled poker.
4.)
5.)
6.)
*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.
THE HEAT OF THE COALS
seconds you can
hold the palm of
your hand 4 inches
above the coals
temperature range (Fº)
400 to 450
visual cues
HOT COALS
2
3
barely covered with
gray ash; deep red glow
MODERATELY HOT
TO HOT COALS
375 to 450
thin coating of gray
ash; deep red glow
MODERATELY HOT COALS
4
325 to 375
significant coating of
gray ash; red glow
MODERATELY COOL COALS 5
300 to 325
thick coating of gray
ash; dull red glow
4
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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.
HARDWARE LIST
Hardware is shown actual size. You may have spare hardware after assembly is complete.
3/8-16x1”
3/8-16x3/4”
1/4-20x3/4”
Hex-Head Bolt
Hex-Head Bolt
Hex-Head Bolt
3/8-16 Hex Nut
1/4-20 Lock Nut
Qty. 8
(4 already installed)
Qty. 9
(8 already installed)
Qty. 2
(1 already installed)
Qty. 8
(Already installed)
Qty. 2
(1 already installed)
1/4” Flat Washer
Qty. 4
(2 already installed)
Hitch Pin
Qty. 6
1/2”Flat Washer
Qty. 4
3/8” Lock Washer
Qty. 8
(Already installed)
WARNING
MOST SURFACES ON THIS UNITARE HOT WHEN IN USE.
USE EXTREME CAUTION. KEEP OTHERS AWAY FROM UNIT.
ALWAYS WEAR PROTECTIVE CLOTHING TO PREVENT INJURY.
5
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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
90 days from date of purchase*
PERFORATION, MANUFACTURING,
AND MATERIAL DEFECTS ONLY
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. 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 Rev02
6
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PARTS LIST
Key Qty Description
Key Qty Description
A
B
C
D
E
F
G
H
I
3
1
1
2
1
1
1
2
2
2
Wire Fire Grate
K
L
1
1
1
2
2
1
1
1
1
1
Front Shelf Assembly
Butterfly Damper Assembly
Temperature Gauge
Handle Rod
Firebox Door Latch
Large Porcelain Cooking Grate
Small Porcelain Cooking Grate
Smoke Chamber Assembly
Firebox Assembly
M
N
O
P
Handle Barrel Spring
Wood Rack
Smokestack Assembly
Short Leg Assembly
Long Leg Assembly
Q
---
---
—
Ash Pan
Hardware Pack
Assembly Instructions, English
Assembly Instructions, Spanish
J
Wheel Assembly
M
F
C
Q
D
G
D
I
B
K
E
H
A
O
A
LJ
LJ
A
N
P
L
7
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ASSEMBLY
Cut box strapping and remove top of box. Lay sides of carton on ground next to carton bottom. Remove parts from inside of unit.
One person should hold the unit steady at the firebox end while another removes the support pieces from the carton.
1
Smoke Chamber
Firebox
With one person on smoke chamber end, one person on firebox end, and one person holding both doors closed, roll the unit
onto cardboard that was placed on the ground next to the unit. Unit should now be resting on its smoke chamber handle
brackets with the leg posts pointing upward.
2
Leg posts
pointing upward
Smoke chamber
handle brackets
8
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On each short leg, slide one 1/2” flat washer onto axle, followed by a wheel, then another 1/2” flat washer. Slide a hitch pin
into the hole at the end of the axle.
3
Hitch pin
Wheel
1/2” Flat washer
1/2” Flat washer
Axle
Short leg
Hitch pin
Slide short legs onto posts closest to
firebox, with wheels facing outward. Slide
long legs onto posts at opposite end. Secure
legs to posts using one 3/8-16x1” hex-head
bolt per leg.
Long leg
4
3/8-16x1”
Hex-head bolt
NOTE: Do not fully tighten bolts. Tighten just
enough so that leg will not slide off post.
Bolts will be fully tightened when assembly
is complete.
Short leg
Firebox
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Have one person hold wood rack in position shown while another attaches rack to legs using four 3/8-16x1” hex-head bolts.
Fully tighten these four bolts.
5
Wood rack
MAKE SURE THAT LEG BOLTS ARE TIGHT ENOUGH SO THAT LEGS WON’T SLIP OFF OF POSTS. Using three people,
roll the unit over the handle brackets and stand it up onto its legs. Once standing, fully tighten the four leg bolts.
6
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7
Smokestack
Attach smokestack to end of smoke
chamber by sliding stack into smokestack
receiver. While holding the smokestack in a
vertical position, tighten the 3/8-16x3/4”
hex-head bolt in the nut that is welded to
the smokestack receiver.
Smokestack receiver
Smoke chamber
To attach damper to firebox side door, place one 1/4” flat washer onto one 1/4-20x3/4” hex-head bolt. Insert the bolt into the
center hole of the firebox side door, from the outside. Place the handle of the damper through the lower opening in the door
from the inside and place the center hole in the damper over the bolt. Place another 1/4” flat washer onto the bolt and secure
with a 1/4” lock nut. Do not over-tighten lock nut. Damper should be able to move freely. Slide door latch behind door catch to
keep firebox door closed.
8
Firebox
Side door
Door latch
Damper
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Handle Assembly . . . While holding handle in position between handle brackets, slide rod into one bracket, through handle, and
out through other bracket. Secure at each end of rod with hitch pins. Repeat process to assemble firebox handle.
9
Handle bracket
Hitch pin
Handle
Handle rod
Attach front shelf by sliding ends of shelf frame into brackets welded to smoke chamber.
10
SS Front shelf
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Temperature gauge
Place two of the smaller wire grates in the bottom of the smoke chamber and one in the bottom of the firebox.
Place the larger porcelain grates into the smoke chamber and firebox as shown below.
12
Porcelain Grates
Porcelain Grate
NOTE: Doors not shown for clarity
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Slide ash pan into ash
pan guides.
13
Ash pan guides
Ash pan
14
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REGTEMP REV00
20
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