Hondo Jr. Smoker
Product Guide
Model 10201598
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
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:
Leave this manual with consumer.
CAUTION:
Some parts may contain sharp edges – especially as
noted in the manual! Wear protective gloves if
necessary.
CONSUMER:
Keep this manual for future reference.
CAUTION:
THIS UNIT IS HEAVY! DO NOT attempt to
assemble without a helper.
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.
The following are trademarks registered by W.C. Bradley Co. in the U.S. Patent andTrademark 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™;FrontAvenue™; 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 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;D459,148D459,149;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;SouthKorea:384,565;UnitedKingdom:2,099,402.OtherPatents Pending. ©2009W.C.BradleyCompany
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
42804542 - 03/26/10
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Preparing and Using Your Hondo Jr. Smoker
Before cooking with your Hondo Jr. 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 Hondo Jr. 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 Hondo Jr. 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
Internal Cooking Temperatures
Ground Meat
Beef - Hickory, Mesquite, Oak, Grapevines
Beef, Pork, Veal, Lamb......................................160°F
Pork - Fruitwoods, Hickory, Oak, Sassafras
Turkey, Chicken.................................................165°F
Lamb - Fruitwoods, Mesquite
Veal - Fruitwoods, Grapevines
Fresh Beef, Veal, Lamb
Medium Rare.......................................................145°F
Seafood - Alder, Mesquite, Sassafras, Grapevines
Vegetables – Mesquite
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
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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.
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.
2.)
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.
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
Page 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.
Page 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. In the event of parts availability issues,
the manufacturer reserves the right to substitute like or similar parts that are equally functional.
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 Rev03
Page 6
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PARTS LIST
Key Qty Description
Key Qty Description
1
1
1
1
1
2
2
2
1
3
1
1
1
1
1
1
1
Smoker Chamber Lid Assembly
Temperature Gauge with Wingnut
Smoke Stack Assembly
Logo Plate Kit
17
18
19
20
21
22
23
24
25
26
27
—
—
1
2
1
2
2
2
2
1
2
1
2
1
1
Firebox Cook Grate
Wheel
2
3
Firebox Bottom
Leg Support Tube
Leg With End Cap
Leg For Wheel
4
5
Handle Assembly
6
Hinge Kit
7
Smoker Chamber Cook Grate
Grease Cup Clip
Leg Brace
8
Firebox Door
9
Smoker Chamber Fire Grate
Axle
Hinge for Firebox Door
Damper Door
10
11
12
13
14
15
16
Side Shelf Assembly
Shelf Support
End Cap for Legs
Hardware Pack
Assembly Instructions, English
Smoker Chamber Bottom
Firebox Lid
Handle Rod
Handle Barrel Spring
Page 7
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ASSEMBLY
FIRST, 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 surface
1during assembly.
• Attach leg supports to smoker chamber
using two 1/4-20 X 1-3/4” screws and two
1/4-20 flange nuts on each side.
1/4-20 Flange Nut
Finger tighten screws and nuts until after
next step.
Smoker
Chamber
Leg
Supports
1/4-20 X 1-3/4
Screws
2
Right
Legs
with Holes
Left
Legs
with Caps
• Lay unit on smoker chamber.
• Insert legs into leg supports making sure
holes align and the legs with caps are at
the chamber side opening.
• Attach leg brace on each side using four
1/4-20 X 1-3/4” screws and four 1/4-20
flange nuts per brace.
1/4-20
Flange
Nut
1/4-20 X 1-3/4
Screws
Finger tighten all screws and nuts in this
step until all are in place. Once all in
place, then fully tighten all screws and
nuts. Go back and fully tighten screws
and nuts in step 1.
Leg
Brace
Leg
Brace
Leg
Supports
Page 8
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3
Hitch Pin
Hitch Pin
• Slide axle into holes at ends of legs (legs
without end caps).
Wheel
Axle
Wheel
• Attach wheels onto axle rod using hitch
pins. Hitch pins insert through hole in axle
as shown in box A.
Check to be sure that all screws and nuts
used so far are fully tightened.
Legs with
holes
Hitch Pin
Axle
Figure B
4
• Pre-assemble the Firebox Lid and the Firebox
Bottom using eight #6-32 X 3/8 Screws as
shown in figure A.
• Place the firebox onto the smoker chamber and
align the large openings.
• Insert eight #10-24 X 1/2” screws through the
smoker chamber, into the firebox. Secure with
eight #10-24 flange nuts as shown in figure B.
Firebox
Fully tighten all screws and nuts.
Figure A
Firebox Lid
Eight
#6-32 X 3/8
Screws
Eight
#10-24
Flange
Nut
Smoker
Chamber
Eight
#10-24 X 1/2
Screws
Firebox Bottom
Page 9
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Hinge Pin
• Place unit in upright position.
• Attach small hinge half to smoker chamber using two #10-24
X 1/2” screws and two #10-24 flange nuts for each hinge half.
Install screws from inside the smoker chamber.
5
• Attach large hinge half to smoker chamber lid using two #10-
24 X 1/2” screws and two #10-24 flange nuts for each hinge
half. Install screws from inside the smoker chamber lid.
• Insert top hinge in between bottom hinge and secure using
one hinge pin and one hitch pin for each hinge set.
Finger tighten all screws and nuts in this step until all are
in place. Once all are in place, close the lid and fully
tighten all screws and nuts.
Hitch Pin
Smoker
Chamber
Lid
Large Hinge Half
Small Hinge Half
Nuts
Smoker
Chamber
Screws
• Insert smoke stack through smoker
chamber lid, aligning holes.
6
• Attach using two #10-24 X 1/2” screws and
two #10-24 flange nuts.
Fully tighten all screws and nuts.
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.
NOTE: Lid side wall shown
transparent for clarity
Screw
Smoke Stack
Nut
on inside of
Lid
Page 10
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7
• Insert two #10-24 X 3-1/2” screws into handle and place
spacers and fiber washer onto screws on other side of handle.
• Place the handle assembly into the holes on the front of the
smoker chamber door and secure with to #10-24 flange nuts.
Tighten flange nuts until bolt head is flush with handle.
Screw
Handle
Spacer
• Repeat on firebox door.
Fiber
Washer
• Assemble spring handle by sliding spring through handle rod
until spring is in the middle of handle rod as shown in inset.
• Insert spring handle through holes on the side of firebox and
secure with two 1/4-20 flange nuts.
Fully tighten all screws and nuts.
Nut
Spring
Spring
Handle
Nut
Firebox
Handle Rod
8
• Remove wing nut from temperature gauge.
• Insert temperature gauge though smoker chamber lid hole
above handle securing it from the underside with the wing
nut removed aligning the gauge settings before fully
tightening.
Temperature
Gauge
Logo Plate
• Insert logo plate though smoker chamber lid holes to the
right of the handle, securing it from the underside of the lid
with two logo clips.
Wing
Screw
Logo Clips
Page 11
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9
• Attach shelf support to side of smoker chamber with
one #10-24 X 1/2” machine screw where screw is going
through inside of chamber through hole of support and
secured with one #10-24 flange nut.
Holding
Bracket
• Lay side shelf on top of other end of shelf support so
that it fits inside holding bracket.
• Secure side shelf to smoker chamber using two #10-24
X 1/2”screws and two #10-24 flanged nuts.
Fully tighten all screws and nuts.
Screw
through inside
Smoker Chamber
Shelf
Support
Nut
Smoker
Chamber
Lid
Smoker
Chamber
Smoker
Chamber
Screw
Nut
Fire Grate
10
• Place a fire grate into the bottom of the
firebox. Remaining 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.
Firebox
Smoker
Chamber
Page 12
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Smoker Chamber
Cook Grates
11
• Place two Smoker Chamber Cooking
Grates into the smoker chamber.
• Place the Firebox Cook Grate into the
Firebox.
Firebox
Cook Grate
Smoker
Chamber
Firebox
12
• Hang the grease clip under the smoker
chamber on right side.
• An empty soup can is recommended to
hang from grease clip.
The assembly is completed.
Page 13
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HARDWARE LIST
You may have spare hardware after assembly is complete.
Hardware not shown actual size.
Hair Pin Clip
Qty. 4
Logo
Clip
1/4-20
Flange Nut
Qty. 14
Fiber Washer
Qty. 4
#10-24
Flange Nut
Qty. 25
Hinge Pin
Qty. 2
Qty. 2
#10-24 X 3-1/2”
Machine Screw
Qty. 4
#6-32 X 3/8”
Machine Screw
Qty. 8
Handle
Spacer
Qty. 4
1/4-20 X 1-3/4”
Machine Screw
Qty. 12
#10-24 x 1/2”
Machine
Screw
Qty. 21
Page 14
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Warranty Registration Department
P.O. Box 1240
Columbus, GA 31902-1240
REGTEMP REV02
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