Outdoor Gourmet 155541 Owner's manual

Please keep this instruction manual for future reference
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(Made in China)
Alamo Smoker
Assembly Instructions & User’s Manual
ITEM# 155541

Table of Contents
Safety Warnings………………………………………..........................…………………………………...................................................2
Exploded View…………………………………………................……………….....................................................................................4
Parts and Tools...................................................................................................................................................................................5
Assembly Instructions.........................................................................................................................................................................7
Preparation For Use & Lighting Instructions......................................................................................................................................16
Proper Care & Maintenance.............................................................................................................................................................. 23
Warranty Information......................................................................................................................................................................... 24
Note: Before beginning assembly of product, make sure all parts are present.
Compare parts with package content list and hardware contents. If any part is missing or
damaged do not attempt to assemble the unit. Contact customer service for replacement
parts.
Operating Instructions........................................................................................................................................................................18
After Use Safety.................................................................................................................................................................................23
1

Safety Warnings
IMPORTANT SAFETY WARNINGS
WE WANT YOU TO ASSEMBLE AND USE YOUR GRILL AS SAFELY AS POSSIBLE.
THE PURPOSE OF THIS SAFETY ALERT SYMBOL IS TO ATTRACT YOUR ATTENTION TO POSSIBLE HAZARDS
WHEN YOU SEE THE SAFETY ALERT SYMBOL, PAY CLOSE ATTENTION TO THE INFORMATION WHICH
FOLLOWS!
READ ALL SAFETY WARNINGS AND INSTRUCTIONS CAREFULLY
BEFORE ASSEMBLING AND OPERATING YOUR GRILL.
• Only use this grill on a hard, level, non-combustible, stable surface (concrete, ground, etc.) capable of supporting the
weight of the grill. Never use on wooden or other surface that could burn.
• Proper clearance of 10 feet between the grill and combustible material (bushes, trees, wooden decks, fences,
buildings, etc.) or construction should be maintained at all times when grill is in use. Do not place grill under a roof
overhang or other enclosed area.
• For outdoor use only. Do not operate grill indoors or in an enclosed area.
• For household use only. Do not use this grill for other than its intended purpose.
• We recommend the use of a Charcoal Chimney Starter to avoid the dangers associated with charcoal lighting fluid.
If you choose to use charcoal lighting fluid, only use lighting fluid approved for lighting charcoal. Carefully read
manufacturer’s warnings and instructions on the charcoal lighting fluid and charcoal prior to the use of their product.
Store charcoal lighting fluid safely away from grill.
• When using charcoal lighting fluid, allow charcoal to burn with grill lid and door open until covered with a light ash
(approximately 20 minutes). This will allow charcoal lighting fluid to burn off. Failure to do this could trap fumes from
charcoal lighting fluid in grill and may result in a flash fire or explosion when lid is opened.
• 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.
• Never add charcoal lighting fluid to hot or even warm coals as flashback may occur causing severe burns.
• Place grill in an area where children and pets cannot come into contact with unit. Close supervision is necessary
when grill is in use.
• Do not leave grill unattended when in use.
• When adding charcoal and/or wood, use extreme caution and follow instructions in “Adding Charcoal/Wood During
Cooking” section of this manual.
• Do not store or use grill near gasoline or other flammable liquids, gases or where flammable vapors may be present.
• Do not store lighter fluid or other flammable liquids or material under the grill.
Grill is hot when in use. To avoid burns:
• DO NOT attempt to move the grill.
• Brace grill so the unit does not accidentally move.
• Wear protective gloves or oven mitts.
• DO NOT touch any hot grill surfaces.
• DO NOT wear loose clothing or allow hair to come in contact with grill.
WARNING
AS YOU ASSEMBLE AND USE YOUR GRILL.
2

Safety Warnings
• Check grease level in grease cup often and empty or change when 3/4 full. Use extreme caution as the smoker, grease
cup and its contents will be hot.
• When grilling, grease from meat may drip into the charcoal and cause a grease fire. If this should happen close lid to
suffocate the flame. Do not use water to extinguish grease fires.
• 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 a safe distance from hot steam and flame flare-ups.
• Do not exceed a temperature of 450°F. Do not allow charcoal and/or wood to rest on the walls of firebox. Doing so will
greatly reduce the life of the metal and finish of your grill.
• Use caution when assembling and operating your grill to avoid scrapes or cuts from sharp edges of metal parts. Use
caution when reaching into or under grill.
• When opening lid, make sure it is pushed all the way open. If lid is not fully open, it could fall back to a closed position
and cause bodily injury.
• In windy weather, place grill in an outdoor area that is protected from the wind.
• Close lid, door and smoke stack to suffocate flame.
• Never leave coals and ashes in grill unattended. Before grill can be left unattended, remaining coals and ashes must
be removed from grill. Use caution to protect yourself and property. Carefully place remaining coals and ashes in a
non-combustible metal container and saturate completely with water. Allow coals and water to remain in metal
container 24 hours prior to disposing.
• Extinguished coals and ashes should be placed a safe distance from all structures and combustible materials.
• With a garden hose, completely wet the surface beneath and around grill to extinguish any ashes, coals or embers
which may have fallen during the cooking or cleaning process.
• After each use, clean the grill thoroughly and apply a light coat of vegetable oil to interior to prevent rusting. Cover the
grill to protect it from excessive rusting.
• Use caution when lifting or moving grill to prevent strains and back injuries.
• We advise that a fire extinguisher be on hand. Refer to your local authority to determine proper size and type of fire
extinguisher.
• Store the grill out of reach of children and in a dry location when not in use.
• Do not attempt to service grill other than normal maintenance as explained in “After-Use Safety” and “Proper Care &
Maintenance” sections of this manual.
• Remove all stickers and labels before first use.
• Properly dispose of all packaging material.
USE CAUTION AND COMMON SENSE WHEN OPERATING YOUR GRILL.
FAILURE TO ADHERE TO SAFETY WARNING AND GUIDELINES IN THIS MANUAL COULD RESULT
IN BODILY INJURY OR PROPERTY DAMAGE.
SAVE THIS MANUAL FOR FUTURE REFERENCE.
WARNING
3

22
Exploded View
4
WARNING:
!
This product can expose you to chemicals including soot, which is known in 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.
3
29
28
30
18
5
27
24
23
26
22
7
21 19 20
4
1
2
10
12
11
13
8
9
15
14
6
16
25
17

Part List
Cooking Grates
Charcoal Grates
Temperature Gauge
Smoking Chamber Lid
Front Table
Bottle Opener
Bottle Shelf
Firebox Lid
Grease Bucket Hook
Short Legs
Long Legs
Front Table Brackets
Wheel Axle
Side Handle
Firebox Base
Firebox Support
Firebox Top
Firebox Lid Handle
Firebox Charcoal Grate
1
2
3
4
6
7
8
9
10
11
12
13
14
3
3
1
1
1
1
2
1
1
1
1
1
1
Part # Description Picture Qty
19
21
22
23
24
25
26
27
28
30
1
1
2
2
1
1
1
1
Part # Description Picture Qty
5
Wheels
5 Smoking Chamber 1
16 1
17
Firebox Cooking Grates
1
18
1
20 2
2
1
Smoke Stack
Smoke Stack Spacer
Smoke Stack Damper
Firebox Lid Stop
29 1
Ash Door
15 1
Air Vent
Air Vent Handle
Door Latch

Hardware
Hardware # Description
M6 x 12 Bolt 38AA
Picture Qty
M5 x 12 Bolt 2 BB
2CC
M6 Nut 27DD
1EE
2FF
4
GG
M6 Lock Nut (Silver)
Tools Required
Phillips Head Screwdriver
(Not included)
Adjustable Wrench
(Not included)
6
M6 x 14 Bolt
M10 Lock Nut
M5 Nut
HH M6 x 14 Stepped Bolt 1
II M5 x 12 Stepped Bolt 1
M6 Nut (stainless steel)
JJ 2

Remove the lid (#4) from the smoking chamber (#5) by removing
bolt and sliding the hinge pins on the lid out of the hinge holes on
the smoking chamber. Set bolt aside for step 22.
Step 1
Place the grill body assembly on its end. Make sure that another
person is holding the grill body assembly steady.
Attach one long leg (#23) to the grill body assembly left side (smoke
stack side) with (4) M6 x 12 bolts (AA) and (4) M6 nuts (DD).
Attach one short leg (#20) to grill body assembly right side (firebox
side) with (4) M6 x 12 botls (AA) and (4) M6 nuts (DD).
Note: Keep the bolts and nuts loose.They can be tightened after
the wagon wheels and bottom shelf are assembled.
Step 2
AA M6 x 12 Bolt
Hardware Used
8pcs
r. Lay
bly area.
Step 1
Step 2
Assembly Instructions
7
Choose a good, cleared assembly area and get a friend to help you put your smoker together. Lay cardboard down to protect
smoker finish and assembly area.
DD M6 Nut 8pcs
Insert the bottom shelf (#22) into mounted legs.
Attach remaining two legs by inserting the hooks of the wire rack
through the holes in the legs, and then attaching to the cooking
chamber with (8) M6 x 12 bolts (AA) and (8) M6 nuts (DD).
Make sure that the wheel legs (short legs (#20)) is on the side of the
off-set firebox with the firebox hole (left side). Tighten all legs bolts.
Step 3 Step 3
AA M6 x 12 Bolt
Hardware Used
8pcs
DD M6 Nut 8pcs
Bolt
5
4
Short leg
Long leg
20
23
AA
DD
5
20
23
22 DD
AA

Assembly Instructions
Attach wheels (#21) to short legs (#20) with wheel axle
(#19) and lock by (2) M10 lock nuts (FF).
Step 4
FF M10 Lock Nut
Hardware Used
2pcs
Step 4
8
19
20
FF
Step 5
Hardware Used
DD M6 Nut 4pcs
Attach smoke stack (#28) and stack spacer (#30) to the
smoking chamber (#5) with (4) M6 nuts (DD).
Insure that the spacer (#30) is in between the smoke
stack (#28) and smoking chamber (#5).
Remove cap nut and washers from smoke stack.
Place smoke stack damper (#29) over the bolt at the top
of the smoke stack. Then place the washers over the bolt
and tighten with cap nut.
Attach side handle (#18) to the smoking chamber with (2)
M6 x 14 bolts (CC) and (2) M6 nuts (JJ).
Attach bottle opener (#27) to smoking chamber with (2)
M5 x 12 bolts (BB) and (2) M5 nuts (GG).
Step 5
Cap nut
Washers
29
28
30
18
27
5
DD
CC
JJ
BB
GG
CC M6 x 14 Bolt 2pcs
JJ M6 Nut (s/s) 2pcs
BB M5 x 12 Bolt 2pcs
GG M5 Nut 2pcs
21
Turn the grill body to be horizontal.

Assembly Instructions
Attach front table brackets (#24) to smoking chamber with (4)
M6 x 12 bolts (AA) and (4) M6 nuts (DD).
Step 6 Step 6
9
AA M6 x 12 Bolt
Hardware Used
4pcs
DD M6 Nut 4pcs AA
DD
24
Attach firebox support (#6) to short legs (#20) with
(2) M6 x 12 bolts (AA).
Step 7
Hardware Used
Step 7
AA M6 x 12 Bolt 2pcs AA
6
20
Attach firebox lid stop (#11) to firebox top (#13) with (1) M6 x 12 bolt
(AA)and (1) M6 nut (DD).
Step 8
AA M6 x 12 Bolt
Hardware Used
1pc
Step 8
DD M6 Nut 1pc
DD
11
AA
13

Assembly Instructions
Step 9
Hardware Used
AA M6 x 12 Bolt 6pcs
Step 9
10
Insert (2) M6 x 12 bolts half way inby the firebox opening as shown.
5.0MM Approx
Step 11
Hardware Used
AA M6 x 12 Bolt 2pcs
Step 11
AA
Align the holes on the firebox base (#14) to firebox top (#13) with
(6) M6 x 12 bolts (AA).
13
AA
14
Screw (1) M6 x 14 stepped bolt into the firebox base (#14) as
shown.
Step 10 Step 10
HH
14
Hardware Used
HH 1pc
M6 x 14 Stepped Bolt

Assembly Instructions
Attach firebox assembly to smoking chamber by aligning the
holes on the smoking chamber to the (2) M6 x 12 bolts and
slide into place as shown.
Step 12
Attach firebox to cooking chamber with (4) M6 x 12 bolts (AA).
Tighten all firebox bolts securely.
Step 13
Hardware Used
Step 12
Step 13
11
AA M6 x 12 Bolt 4pcs
Attach firebox to firebox support with (2) M6 x 12 bolts (AA) and
(2) M6 nuts (DD).
Step 14
Hardware Used
Step 14
AA M6 x 12 Bolt 2pcs
DD M6 Nut 2pcs
M6 x 12 Bolt
AA
AA DD

Assembly Instructions
12
Attach firebox lid handle (#10) to firebox lid (#12) with the
M6 nuts removed above.
Step 15 Step 15
10
12
M6 Nuts
Remove the pre-assembly M6 nuts from the welded bolts on
firebox lid handle (#10).
Insert air vent handle (#25) into air vent (#16) and locking by (1)
M5 nut (GG).
Step 16
Step 16
Hardware Used
GG M5 Nut 1pc 25
16
GG
Attach doorlatch (#17) to ash door (#15) with (1) M5 x 12 stepped
bolt (II)and (1) M5 nut (GG).
Step 17 Step 17
II M5 x 12
Stepped Bolt
Hardware Used
1pc
GG M5 Nut 1pc
II
GG
17
15

Assembly Instructions
13
Attach air vent assembly to ash door assembly with (1) M6 x 12
bolt (AA) and (1) M6 lock nut (EE) as shown.
Step 18 Step 18
AA
EE
AA
Hardware Used
1pc
EE M6 Lock Nut 1pc
M6 x 12 Bolt
Step 19 Step 19
Attach ash door assembly to firebox base by sliding the hinge
pins into the hinge holes on the firebox base as shown.
26
Step 20
Insert grease bucket hook (#26)through the hole inside the
smoking chamber on the left side to hang under the smoking
chamber.
Step 20

Assembly Instructions
14
Step 21
Insert front table (#7) hinge pins into the front table brackets (#24)
assembled on smoking chamber as shown.
Step 21
24
7
Attach smoking chamber lid (#4) by sliding the hinge pins into
the lid hinge holes on the smoking chamber (#5 ) as shown.
Secure with the hinge bolt remov ed on Step 1.
Step 2 2 Step 2 2
Bolt
Step 23
Remove washer and nut from temperature gauge (#3).
Install temperature gauge (#3) into lid (#4) by the washer
Step 23
4
3
washer nut
and nut as shown.
5
4

Assembly Instructions
15
Place three charcoal grates (#2) into the smoking chamber.
Place three cooking grates (#1) over the charcoal grates.
Place firebox charcoal grate (#9) into the firebox.
Place two firebox cooking grates (#8) over the charcoal grate.
Step 24 Step 24
2
8
9
1
Alamo Smoker
(Assembled)

16
PLACE THE GRILL OUTDOORS ON A HARD, LEVEL, NON-COMBUSTIBLE SURFACE AWAY FROM ROOF OVERHANG OR ANY
COMBUSTIBLE MATERIAL. NEVER USE ON WOODEN OR OTHER SURFACES THAT COULD BURN. PLACE THE GRILL AWAY FROM OPEN
WINDOWS OR DOORS TO PREVENT SMOKE FROM ENTERING YOUR HOUSE. IN WINDY WEATHER, PLACE THE GRILL IN AN OUTDOOR
AREA THAT IS PROTECTED FROM THE WIND.
READ ALL SAFETY WARNINGS AND INSTRUCTIONS CAREFULLY BEFORE OPERATING YOUR GRILL.
Prior to your first use of the Smoker, follow the instructions below carefully to cure
your grill. Curing your grill will minimize damage to the exterior finish as well as rid
the grill of paint odor that can impart unnatural flavors to the first meal prepared on
your Smoker.
IMPORTANT: To protect your grill from excessive rust, the unit must be
properly cured and covered at all times when not in use.
Step 1
Lightly coat all interior surfaces of the grill including cooking grills with
vegetable oil or vegetable oil spray. Do not coat charcoal grates or ash tray.
Step 2
Step 3
Follow the instructions below carefully to build a fire. You may use charcoal
and/or wood as fuel in the grill (see “Adding Charcoal/Wood During Cooking”
section of this manual).
NOTE: We recommend using charcoal that has been pre-treated with lighter
r.
WARNING: , material or
charcoal that has been pre-trea
the grill.
If using a Charcoal Chimney Starter, follow all manufacturer’s warnings and
instructions regarding the use of their product. Start with 5pounds of charcoal in
charcoal to cook with once the curing process has been completed.
NOTICE: To avoid heat damage to the paint, do not use more than 2 .5
pounds
of charcoal/wood in the firebox. Light the charcoal/wood with the
lid open and do not close the lid until flames have gone out (5-10
minutes). When cooking, adjust air shutter to minimize flames in
the firebox. Closing the air shutter will lower the flames and cooking
temperature.
Step 4
, stand back and carefully light
charcoal and allow to burn until covered with a light ash (approximately 20 minutes).
When charcoal is burning strong, carefully place hot coals in center of charcoal
grates.
NOTE: To extend the life of your grill, make sure that hot coals and wood do
not touch the walls of grill.
Curing Your Grill
Preparation For Use & Lighting Instructions
Place a dripping bucket (not included) in the grease bucket hook. The dripping bucket
(not included) must be placed under the grease hole at all times.
cooking chamber and 2.5 pounds of charcoal in rebox. This should be enough

300
250
200
150
100
50
350
400
450
500
S
M
O
K
I
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G
B
A
R
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B
-
Q
G
R
I
L
L
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G
300
250
200
150
100
50
350
400
450
500
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°F
°F
IF USING CHARCOAL CHIMNEY STARTER, PROCEED TO STEP 8.
, follow all manufacturer’s warnings and instructions regarding
the use of their product. Start with pounds of charcoal in cooking chamber and 2.5
1” to 2” and smokestack damper halfway.
Step 5
r.
Step 6
With grill lids open, stand back and carefully light charcoal and allow to burn
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WARNING: ffonrubyletelpmocotdewollaebtsumdiulfgnithgillaocrahC
prior to closing grill lid (approximately 20 minutes). Failure to
do this could trap fumes from charcoal lighting fluid in grill and
may result in a flash-fire or explosion when lid is opened.
WARNING: Keep hot coals away from the firebox air shutter to prevent
coals from falling out.
IF USING LIGHTER FLUID, PROCEED TO STEP 8
If using pre-treated charcoal, follow all manufacturer’s warnings and instructions
regarding the use of their product. Start with pounds of charcoal in cooking chamber
approximately 1” to 2” and smokestack damper halfway.
Step 7
charcoal and allow to burn until covered with a light ash (approximately 20 minutes).
Step 8
With coals burning strong, close the lids and door. Allow the temperature to
reach 250° F. Maintain this temperature for 2 hours.
Step 9
Increase the temperature to approximately 400° F. This can be achieved by
opening the firebox air shutter and smokestack damper and adding more
charcoal and/or wood (see “Adding Charcoal/Wood During Cooking” section
of this manual). Maintain this temperature for 1 hour then allow unit to cool
completely.
NOTE: Never exceed 450° F range in cooking chamber. It is important that
the painted exterior of the smoker is not scraped or rubbed during the
curing process.
YOUR SMOKER IS NOW CURED AND
READY FOR USE.
Preparation For Use & Lighting Instructions
I
5
5
and 2.5 pounds of charcoal in firebox. This should be enough charcoal to
17

Smoking
PLACE THE GRILL OUTDOORS ON A HARD, LEVEL, NON-COMBUSTIBLE SURFACE AWAY FROM ROOF OVERHANG OR ANY
COMBUSTIBLE MATERIAL. NEVER USE ON WOODEN OR OTHER SURFACES THAT COULD BURN. PLACE THE GRILL AWAY FROM OPEN
WINDOWS OR DOORS TO PREVENT SMOKE FROM ENTERING YOUR HOUSE. IN WINDY WEATHER, PLACE THE GRILL IN AN OUTDOOR
AREA THAT IS PROTECTED FROM THE WIND.
READ ALL SAFETY WARNINGS AND INSTRUCTIONS CAREFULLY BEFORE OPERATING YOUR GRILL.
Step 1
as fuel in the Smoker (see “Adding Charcoal/Wood During Cooking” section of this
manual).
Step 2
NOTE: We recommend using charcoal that has been pre-treated
WARNING:
grill.
If using a Charcoal Chimney Starter, follow all manufacturer’s warnings and
instructions regarding the use of their product. Start with 2.5 pounds of charcoal on
NOTICE: To avoid heat damage to the paint, do not use more than 2.5 pounds
of charcoal/wood in the firebox. Light the charcoal/wood with the
lid open and do not close the lid until flames have gone out (5-10
minutes). When cooking, adjust air shutter to minimize flames in
the firebox. Closing the air shutter will lower the flames and cooking
temperature.
Step 3
, stand back and carefully light
charcoal and allow to burn until covered with a light ash (approximately 20 minutes).
charcoal grate.
WARNING:
falling out.
NOTE: To extend the life of your grill, make sure that hot coals and wood do not
touch the walls of grill.
IF USING CHARCOAL CHIMNEY STARTER, PROCEED TO STEP 7
material for lighting charcoal. Follow all manufacturer’s warnings and instructions
regarding the use of their product. Place 2.5 pounds of charcoal on charcoal grate in
Step 4
r.
Step 5
charcoal and allow to burn until covered with a light ash (approximately 20 minutes).
Operating Instructions
18
Place a dripping bucket in the grease bucket hook. The dripping bucket must be
placed under the grease hole at all times.

Smoke Cooking Tips
WARNING: pletely burn
(approximately 20 minutes). Failure to do this could trap fumes
NOTE: To extend the life of your grill, make sure that hot coals and wood do
not touch the walls of smoker.
IF USING LIGHTER FLUID, PROCEED TO STEP 7
If using pre-treated charcoal, follow all manufacturer’s warnings and instructions
regarding the use of their product.
halfway.
Step 6
charcoal and allow to burn until covered with a light ash (approximately 20
minutes). When charcoal is burning strong, carefully place hot coals in center of
charcoal grate.
Step 7
With coals burning well, carefully add wood chunks using long cooking tongs
(see “Flavoring Wood” and “Adding Charcoal/Wood During Cooking” sections of
this manual.)
Step 8
Place food on cooking grills in cooking chamber and close both lids.
Step 9
The ideal smoking temperature is between °F and 200°F. For large cuts of
meat, allow approximately one hour of cooking time per pound of meat. Always
use a meat thermometer to ensure food is fully cooked before removing
from grill.
Step 10
Allow grill to cool completely, then follow instructions in the “After-Use Safety”
and “Proper Care & Maintenance” sections of this manual.
During the smoking process, avoid the temptation to open lid to check food.
Opening the lid allows heat and smoke to escape, making additional cooking
time necessary.
Food c own faster. Rotate food midway
through the cooking cycle. If food is excessively bro avored with
smoke, wra . This will
allow food to continue cooking without further bro avoring.
at, you may want to try water
smoking to keep the food moist. Fill water pan in cooking chamber with water or
marinade until 2/3 full.
CAUTION: Always use oven mitts/gloves to protect your hands. Liquid in water
pan will be extremely hot and can scald or burn. Always allow liquid
to cool completely before handling. Do not allow liquid to completely
evaporate from water pan.
CAUTION: Charcoal grate must be set at lowest level. Never raise or lower
charcoal grate when water smoking as hot water may splash onto
coals creating a burst of hot steam and coals.
Operating Instructions
19
140
Start with 2.5 pounds of charcoal in firebox.