Hark HK0536 User manual

HARK CHUBBY
OFFSET SMOKER
Owner’s Manual
ASSEMBLY, CARE & SAFETY INSTRUCTIONS
Product Code: HK0527
MODEL: HK0536
FOR OUTDOOR USE ONLY

3
HARK CHUBBY OFFSET SMOKER
Warranty Details
The product is guaranteed to be free from defects in workmanship and parts for a period of 12 months from the
date of purchase. Defects that occur within this warranty period, under normal use and care, will be repaired,
replaced or refunded at our discretion.
Exposure of the product to the elements should be minimised. Once the unit has cooled and is cleaned, store the
product under cover. Polyester / vinyl barbecue covers are an optional accessory that are recommended and can
be purchased from your local HARK retail dealer.
• This warranty does not cover units that have been altered or modied.
• This warranty does not cover unauthorised repairs during the warranty period.
• This warranty does not cover commercial use of the product.
• This warranty does not cover damage due to normal wear and tear, misuse, abuse, accidents or improper
maintenance.
• This warranty does not cover surface scratches, dents, chips, corrosion, discolouring caused by heat or heat
damage or caused by abrasive or chemical cleaners.
• This warranty does not cover corrosion or rust caused by exposure to the elements, grease res, insects,
weather or hail. (Rust can be removed by a scrub pad and then the surface coated with cooking oil or
touched up with high heat resistant paint).
CONDITIONS OF WARRANTY
• The appliance is delivered to the HARK distributor’s service department or authorised service agent and
freight charges both ways are paid by the owner. No liability is accepted for loss or damage during transit.
• The appliance is installed by a qualied person and operated and maintained in accordance with the
instructions supplied. Repairs or service must be carried out by an authorised person.
• Installation must conform to the applicable Gas, Electrical and Building standards laid down by the local
codes for your country or region.
• No alterations or repairs have been carried out without obtaining the distributors prior consent. Such repair or
any replacement does not extend the warranty period.
• Proof of purchase together must be provided to verify purchase date and establish the warranty period. Only
the original purchaser is covered under this warranty.
• The warranty period is calculated from the date of purchase only.
• Parts installed from other manufacturers’ products will void this warranty.
The benets conferred by this warranty are in addition to all rights and remedies in respect of the product that the
consumer has under the Competition and Consumer Act 2010 and similar state and territory laws.
Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled
to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or
damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality
and the failure does not amount to a major failure.
After Sales Support
Telephone: [phone]
[phone]
Email: [email protected]
YEAR
WARRANTY

4
READ ALL INSTRUCTIONS, WARNINGS & SAFEGUARDS PRIOR TO ASSEMBLY & OPERATION.
FAILURE TO DO SO MAY RESULT IN PROPERTY DAMAGE OR PERSONAL INJURY.
DANGER DANGER
- The HARK®Chubby Smoker is for OUTDOOR
USE ONLY.
- Never operate the smoker unattended.
- The use of alcohol, prescription or non
prescription drugs may impair your ability to
properly assemble or safely operate the smoker.
- Never operate this smoker within 7.5 metres (25
feet) of any flammable liquids.
- Keep the area clear of all flammable liquids,
combustible material including but not limited
to wood, dry plants and including grass, brush,
paper and canvas.
- Use this smoker only on a level, stable non-
combustible surface like brick, concrete or dirt.
Do not use smoker on or around any surface that
will burn or melt, such as on wooden decks, dry
grass, wood rails, vinyl or plastic.
- Never use inside an enclosed area such as screen
patios, garages, buildings and tents. Keep a
minimum clearance of 3 metres (10 feet) from all
sides of the smoker to all overhead construction
and 1 metre (3 feet) from any walls or rails.
- Never operate this smoker under any overhead
roof covering, awning or overhang.
- Keep your hands, hair and face away from any
naked flame. Do not lean over or into the firebox
or grill when lighting or operating the smoker. This
smoker has an open flame. Be careful of loose
clothing and hair that could catch fire during
operation.
- Use caution since flames can flare-up when fresh
air comes into contact with fire. Take caution
opening doors.
- Use caution when opening doors. Make sure the
door is pushed all the way open and resting on
the back stop. If not fully open it could fall back
to closed position and cause an injury.
- Always wear shoes and protective clothing during
operation of this smoker.
- Never use this smoker as a heater.
- The smoker is HOT while in use and after use.
Always wear protective gloves or mitts when
operating the smoker. Avoid touching hot
surfaces at all times.
- Keep CHILDREN AND PETS away from the
smoker at all times. Do not allow anyone to
conduct activities around the smoker during or
following its use until the unit has cooled.
- Never move the smoker when it is in use. Allow
the smoker to cool before moving or storing it.
- Never leave hot coals or ashes in the smoker
unattended. Always wait for the grill to cool
before removing hot coals or ashes and dispose
of them in a non-combustible metal container
and then dose with water to extinguish fully. Wear
protective gloves to do this.
- Never use in or on recreational vehicles and/or
boats.
- Never use this product for anything other than its
intended purposes. This smoker is not intended
for commercial use.
- Accessories and cookware not supplied by Hark®
are not recommended. Never use glassware,
plastic or ceramic cookware in the smoker.
- Do not modify the Chubby Smoker. Any changes
to the smoker will void the warranty.
- Do not use in windy conditions or days of a Total
Fire Ban.
- Do not exceed a temperature of 260 ºC (500 ºF).
Do not allow charcoal and or wood to rest on the
walls of the firebox or cooking chamber. Doing so
will greatly reduce the life of the metal finish.
- Only build the fire on top of the wire charcoal
grates.
- The smoker is extremely heavy. Use caution when
moving or lifting to prevent strains or injuries.
- Always ensure the bucket is in place under the
grease hole. Empty it regularly.
OUTDOOR USE ONLY
SAVE AND FILE THESE INSTRUCTIONS FOR FUTURE REFERENCE

5
A. PARTS LIST
NO. Name
1 Shelf Bracket R
2 Warming Shelf
3 Shelf Bracket L
4 Cooking Grills (3)
5Large Bafe
6Small Bafe (3)
7 Charcoal Grates (3)
8 Temperature Gauge
9 Smoke Stack Damper
10 Door
11 Cooking Chamber
12 Sealing Gasket
13 Smoke Stack
NO. Name
14 Side Handle
15 Hole Covers (2)
16 Beer Bottle Opener
17 Front Shelf Bracket L
18 Front Shelf Bracket R
19 Grease Bucket Holder
20 Bucket
21 Long Legs (2)
22 Wheel Legs Short (2)
23 Wheel Axle
24 Wheels (2)
25 Firebox Bracket
26 Air Damper
NO. Name
27 Air Damper Handle
28 Ash Tray Handle
29 Ash Tray
30 Firebox Base
31 Bottom Wire Rack
32 Front Shelf
33 Air Damper
34 Firebox Top
35 Firebox Door
36 Firebox Door Handle
37 Firebox Door Stop
38 Firebox Charcoal Grate
39 Firebox Cooking Grills (2)

6
B. HARDWARE PACK
Name QTY
M6-15mm Bolts
58
M6 Nuts
34
Flat Washers
16
M6 Lock Nuts
5
M12
2
M5
2
Ø6 Washers
2
M5-12mm Bolts
4

7
C. ASSEMBLY INSTRUCTIONS
STEP 1
STEP 2
STEP 3
g. 1
—Remove hinge locking screw from
left hand hinge of Cooking Chamber
Door (10) and slide door off the
hinge pins.
—Stand the Cooking Chamber (11) on
the firebox end fig. 2.
—Fit the Bottom Wire Rack (31) to
the Wheel Legs Short (22), inserting
the location pins on the rack into
the hole at the bottom of the Wheel
Legs Short (22) and attach the legs
to the base of the Cooking Chamber
(11) using 8xM6-15mm bolts, 8 flat
washers and 8xM6 nuts.
—Fit the Long Legs (21) to the Bottom
Wire Rack (31) by inserting the
location pins on the Bottom Wire
Rack (31) into the holes on the
bottom of the Long Legs (21). Bolt
the legs to the Cooking Chamber
(11) using 8xM6-15mm bolts, 8-Flat
washers and 8xM6 nuts.
g. 2
step
step
step
step
M6*15 8PCS
M6 8PCS
FLAT SPACER 8PCS
step
step
step
step
M6*15 8PCS
M6 8PCS
FLAT SPACER 8PCS
g. 3

8
STEP 4
STEP 5
STEP 6
—Insert the Wheel Axle (23) through
the holes in the Wheel Legs Short
(22) and fit the Wheels (24) onto the
Wheel Axle (23) and secure with
2xM12 lock nuts.
—Attach the Smoke Stack (13) to the
end of the Cooking Chamber (11) by
fitting the Sealing Gasket (12) and
using 4xM6-15mm bolts and 4xM6
nuts.
—Attach Side Handle (14) to the same
end of the Cooking Chamber (11)
using 4xM6-15mm bolts and 4xM6
nuts as per fig. 5.
—Attach the Smoke Stack Damper (9)
to the Smoke Stack (13) using the
dome nut and spring supplied with
the Smoke Stack (13).
g. 4
g. 5
g. 6
M12 2PCS
M6*15 8PCS
M6 8PCS

9
g. 7
g. 8
g. 9
STEP 7
STEP 8
STEP 9
—This step requires 2 people to lift the
smoker and place it onto its legs. Try
to minimise stress to the legs.
—Through the hole in the bottom of
the Cooking Chamber (11) insert the
Grease Bucket Holder (19) so that it
hangs under the Cooking Chamber
(11).
—Fit the Firebox Bracket (25) to the
Wheel Legs Short (22) using 2xM6-
15mm bolts.
—On the Firebox Top (34) fit the
Firebox Door Stop (37) into the slot
near the opening and bolt to door
using 1xM6-15 bolt & 1xM6 nut.
M6*15 1PC
M6 1PC
M6*15 2PCS

10
STEP 10
STEP 11
STEP 12
—Turn the Firebox Top (34) upside
down and fit the Firebox Base (30) to
it using 6xM6-15mm bolts.
—Turn the firebox unit over so that it is
sitting as per fig. 11. Screw 2xM6-
15mm bolts into the holes at the
side of the elliptical cut out leaving a
space of 5mm between the head of
the bolt and the side of the firebox
unit.
M6*15 6PCS
M6*15 2PCS
M6*15 4PCS
g. 12b
g. 10
g. 11
g. 12a

11
STEP 13
STEP 14
—At the end of the Cooking Chamber
(11) with the elliptical hole, fit the
Firebox unit locating the 2xM6 bolt
heads through the keyhole slots and
resting against the Firebox Bracket
(25) as per fig. 12a.
—Secure using 4xM6-15mm bolts into
the Cooking Chamber (11) as per
fig.12b.
—Use 2xM6-15 bolts & 2xM6 nuts into
the Firebox Bracket (25) fig.12c.
M6*15 4PCS
—Fit 2 Shelf Brackets R and L (1 & 3) to the Cooking Chamber (11) using 4xM6-15mm bolts.
M6*15 2PCS
M6 2PCS
g. 12c
g. 13a g. 13b
g. 14
M6*15 1PC
M5*12 2PCS
—Attach the Beer Bottle Opener (16)
to the handle side of the Cooking
Chamber (11) using 2xM5-12mm
bolts. Attach Hole Cover (15) to the
side of the Cooking Chamber (11)
with 1xM6-15 bolt.

12
STEP 15
STEP 16
STEP 17
M6*15 4PCS
M6 LOCK 4PCS
M6*15 1PC
M6*15 4PCS
M6 4PCS
g. 15
g. 16
g. 17
—Fit Hole Covers (15) to either side of
the cooking chamber using 1xM6-
15mm bolt. These holes can be used
to thread temp probes through in
to the cooking chamber to monitor
meat temperatures.
—Fit the Air Damper (33) with 4xM6-
15mm bolts and 4xM6 Lock nuts.
—Fit the Front Shelf Brackets (17,18)
onto the Cooking Chamber (11)
using 4xM6-15 bolts & 4xM6 nuts.
—Ensure that the Front Shelf Brackets
(17,18) are in the open position
shown in fig. 17.

13
STEP 18
STEP 19
STEP 20
g. 18
—Fit the Thermometer Gauge (8)
into the Cooking Chamber Door
(10). Secure with the nuts already
provided inside the door.
M6*15 2PCS
M6 2PCS
Ø6 2PCS
g. 19
—Fit Firebox Door Handle (36) to
Firebox Door (35) using 2xM6-15mm
bolts 2xØ6 washers and 2xM6 nuts.
g. 20
—Fit Cooking Chamber (11) door
assembly onto the Cooking
Chamber (11) and secure with
the hinge locking screw fig. 20
(supplied).

14
STEP 21
STEP 22
STEP 23
M6*15 1PC
M6 1PC
M6 LOCK 1PC
M5*12 2PCs
M5 2PCs
Lock Nut M6 1PC
g. 21
g. 22
g. 23
—Fit the Air Damper (26) to the Ash
Tray (29) with 1xM6-15 bolt and
1xM6 nut. Then secure with 1xM6
lock nut.
—Fit the Ash Tray Handle (28) to the
Ash Tray (29) with 2xM5-12mm bolts
and 2xM5 nuts.
—Fit firebox door assembly onto
the firebox unit and secure with
the hinge locking screw fig. 21
(supplied).

15
STEP 24
STEP 25
g. 24
g. 25
—Slide the Ash Tray (29) into the
Firebox Base (30).
—Fit the 3 Charcoal Grates into the
bottom of the Cooking Chamber as
shown in fig. 25.
—Fit baffles above the Charcoal
Grates in the Cooking Chamber.
—Fit 3 Cooking Grills into the Cooking
Chamber above the baffles.
—Fit the large Warming Shelf and the
small Front Shelf into the Cooking
Chamber.
—Fit the Firebox Charcoal Grates into
the bottom of the Firebox unit.
—Fit the 2 firebox Cooking Grills above
the firebox Charcoal Grates in the
firebox unit.

16
STEP 26
STEP 27
g. 26
g. 27
Assembly of your Hark Chubby Oset Smoker is now complete.
g. 27 shows how the assembled unit should look.
—Hang the Bucket (20) using the
Grease Bucket Holder (19).

17
D. PREPARING CHUBBY OFFSET FOR USE
Before cooking, the following steps should be followed to both cure the finish and season the
interior steel. Failure to follow these steps may damage the finish.
Coat all the interior of the firebox and cooking chamber with vegetable oil (do not coat the
cooking grills). The oil may be any vegetable type and can be applied with a towel, rag or basting
brush. An aerosol spray can is ideal and will be the easiest and fastest way to coat the interior.
NOTE: DO NOT APPLY OIL TO THE PAINTED SURFACE OUTSIDE THE SMOKER.
—Build a small fire in the fire box (refer to our Lighting Your Fire section). The Smoke Stack
Damper (9) and Firebox Damper (33) should be ½ open. Allow the temperature to gradually
rise to no more than 150ºC.
—Close all doors and burn for at least two hours. The longer and the more gradually heat rises,
the better.
—Care should be taken not to scrape or rub any surface during the curing process.
—After you have burned your fire for 2 hours or more, you will notice a shiny black coating
developing on the inside of your smoker. This is a protective resin that comes from the
burning wood. This resin will help seal the inside of the smoker for many fantastic cooks
ahead.
—It is advisable to repeat this process on a yearly basis to help prolong the life of your smoker.
—Ensure that you hang the Bucket (20) from the Grease Bucket Holder (19) under the Cooking
Chamber (11) (STEP 27). The bucket must be placed under the grease hole at all times and
will need to be checked regularly to ensure it is not full. Always wait until the smoker has fully
cooled before emptying the grease.
—Your Hark Chubby Offset Smoker is now ready for use.
WARNING
DO NOT APPLY OIL TO THE EXTERNAL PAINTED SURFACE OF THE SMOKER.
DO NOT APPLY OIL TO THE CHARCOAL GRATES, COOKING GRILLS OR ASH
TRAY.

18
ECARE OF YOUR CHUBBY OFFSET SMOKER
ASH AND RUSTING
The Chubby Offset Smoker’s heavy duty steel construction will help extend the smoker’s life
span.
The inside of the smoker should be treated like a cast iron skillet by applying cooking oil to any
rust should it appear (remembering not to coat the cooking grills). Remove ash after each use
and oil interior as required by the frequency of use.
Most rusting is caused after cooking with a fire that’s too hot. Inadequate maintenance and
protection from the weather also causes unnecessary rusting. What some people describe as
burnt out damage is really rust-out. The primary cause of rust damage is the failure to remove
ash after each use. Letting ash sit on the lower charcoal grates and in the bottom of the Chubby
Offset Smoker, will eventually cause rust as it will get wet and hold moisture over time. Ash
contains corrosive elements that will rust through any thickness of steel.
It is advised that you clean out any ash or coal remains after every cook. Always allow the smoker
and the ash to thoroughly cool before cleaning and never dispose of hot ashes in a rubbish bin.
Use a protective grill cover to prolong life and store your Chubby Offset Smoker in a covered
area.
GENERAL CLEANING
Only when fully cooled should you commence cleaning the smoker. Clean the porcelain coated
steel cooking grills after each use by removing them from the smoker and cleaning them with
warm, soapy water and a non-abrasive scourer.
To prevent rusting from developing inside the smoker, re-season with vegetable oil on a regular
basis (excluding the cooking grill).
It is also important to regularly check the bucket under the grease hole to check if it needs to be
emptied.
WARNING
NEVER USE THE SMOKER WITHOUT THE BUCKET POSITIONED UNDER
THE GREASE HOLE.
WARNING
NEVER HOSE OUT THE SMOKER WITH WATER.

19
F. LIGHTING YOUR FIRE
Lighting your re directly on the charcoal grates
—Remember, patience is a virtue! Cooking with charcoal and wood is more complicated than
using gas but you will get a much better result. Always allow plenty of time to prepare the fire
prior to cooking.
—Allow 30-45 minutes for the fire to start properly before cooking. To start a charcoal fire using
lump charcoal or briquettes, place two or three firelighters on the charcoal grates where you
plan to build your fire. Then pile the charcoal on top in a pyramid formation.
—Light the firelighters and let the charcoal burn. Once the coals have a light coating of grey
ash, you are ready to cook. Do not disturb the coals in this initial lighting process. They will
not look like they are lighting but you need to wait at least 45 minutes for this to occur.
—Have the Firebox or Cooking Chamber door open when you are lighting the fire to allow as
much air in as possible.
—If using wood to start your fire, start off with small pieces that are no longer than 30cm in
length. Make sure they are dry and able to burn. Light using firelighters or paper and as the
fire burns add larger pieces of wood to increase the fire.
—Always wear protective BBQ mitts when lighting your fire.
Lighting your re using a charcoal starter
—Fill the charcoal starter with charcoal or briquettes.
—Place three firelighters on your charcoal grate where you plan to build your fire.
—Light the firelighters and then place the charcoal starter over the fire.
—Have the Firebox or Cooking Chamber door open when you are lighting the fire to allow as
much air in as possible.
—Once the coals have a light coating of grey ash you are ready to cook. Do not disturb the coals
in this initial lighting process.
—Always wear protective BBQ mitts when lighting your fire.
WARNING
DO NOT USE SMOKER WITHOUT THE ASH TRAY IN PLACE.
DO NOT REMOVE THE ASH TRAY WHILE IT CONTAINS HOT COALS OR HOT ASH.
PLEASE NOTE: One common mistake when using an oset smoker is to build the re
too big. The Hark Chubby Oset is very ecient and only requires a small re to maintain
adequate smoking temperatures. The unit only needs a few handfuls of charcoal to
achieve a consistent smoking temperature. You are better to start the re small and then
gradually add fuel as you need it.

20
G. DIFFERENT TYPES OF COOKING METHODS
Direct Grilling
—Direct cooking is a high heat method and is best used for searing steaks, hamburgers,
sausages, chicken fillets, fish and vegetables.
—You may use either the Firebox or the Cooking Chamber to grill your food. Both of these areas
have charcoal grates and cooking grills. This will give you great capacity if you need to cater
for large crowds of people.
—To set your Chubby Offset Smoker for direct grilling, spread the charcoal across the bottom of
the charcoal grate, then place the cooking grills on top so that you are able to place the food
directly above the coals.
—To spread the coals you will need a small shovel or some long handled tongs and should use a
BBQ mitt to avoid any burns. Be careful, the coals will be extremely hot.
—You can get better heat control if you spread your coals into three temperature zones on the
charcoal grate.
a. Hot Zone – Double layer of coals. Used for initially searing the food to seal in all the juices.
b. Medium Zone – Single layer of coals. Used for cooking the food.
c. Cool Zone – No Coals. Used for warming or resting the food if it starts to burn.
Smoking or Slow Cooking
For smoking or slow cooking the fire is built in the Firebox and the food is cooked slowly in the
Cooking Chamber. The smoke and heat will pass indirectly through the opening between the
Firebox and the Cooking Chamber and will smoke-cook the food. This process adds great flavour
to food and although takes longer, is well worth the wait.
Temperatures for smoke-cooking range between 100ºC – 125ºC.
When smoking foods, always build the fire in the Firebox on top of the charcoal grate. When using
wood, seasoned hardwoods are recommended, such as Mesquite, Pecan, Hickory, Oak and any
of the fruit woods. Almost any wood can be used but never use pine or use treated, painted or
stained wood in your smoker. These woods will give off toxic fumes and taint your food. Any bark
should be removed or burned off prior to adding food as it contains a high acid content and can
impart an acrid flavour. Avoid burning pine cones too as they are highly flammable.
Hark recommends the use of “Cowboy” brand of 100% natural wood chips and wood chunks.
WARNING
REMOVE ALL FAT FROM THE BOTTOM OF THE COOKING CHAMBER BEFORE
DIRECT GRILLING.