Char-Broil Patio Caddie 464445004 User manual

4644450-04 1
464445004
ASSEMBLY MANUAL
FOR OUTDOOR HOUSEHOLD USE ONLY. DO
NOT USE INDOORS OR FOR COMMERCIAL
COOKING
INSTALLER/ASSEMBLER: Leave these
instructions with consumer.
CONSUMER: eep this manual for future
reference.
Failure to follow all manufacturer's instructions
could result in serious personal injury and/or
property damage.
Read and follow all safety statements, Assembly
Instructions and Use and Care directions before
attempting to assemble and cook.
Some parts may contain sharp edges.
Wear protective gloves if necessary.
Visit us on the web at: www.charbroil.com
464445004 / 0 - 4165320 (12-10-03)
FOR YOUR SAFETY
1. Do not store or use gasoline or other
flammable vapors and li uids in the
vicinity of this or any other appliance.
2. A Fuel bottle not connected for use shall
not be stored in the vicinity of this or any
other appliance.
FOR YOUR SAFETY
If You smell gas:
1. Shut off gas to the appliance.
2. Extinguish any open flame.
3. Open lid.
4. If odor continues, immediately call your
gas supplier.

24644450-04
Safety Symbols
The symbols and boxes shown below explain what each heading means Read
and follow all of the messages found throughout the manual
Indicates an imminently hazardous situation which, if not avoided,
will result in death or serious injury
Be alert to the possibility of serious bodily injury if the instructions
are not followed Be sure to read and carefully follow all of the
messages
Indicates a potentially hazardous situation which, if not avoided,
may result in minor or moderate injury
Installation Safety Precautions
 Warning: accessible parts may be very hot, wear protective gloves
when handling hot parts Keep young children away Beware of
heat escaping when lifting lid
This barbecue is designed for use with LP (Butane/propane) gas The
valve supplied must be used Replacement parts must be those specified
by the manufacturer
Barbecue installation must conform with local codes Barbecue is not to be
installed in or on recreational vehicles and/or boats
 Keep any electrical cords and/or fuel supply hoses away from any hot
surfaces
 Do not modify for use in any other location Modification will result in a safety
hazard
 Check the seals on the gas container and regulator before connecting a new
gas container to the appliance
 Injectors have been stamped for size Never remove injectors from valves
Any modification of the appliance may be dangerous
This product is subject to patents pending in the U.S. and other countries.
Installation Safety Precautions
For safe use of your Barbecue and to avoid serious injury:
 Do not let children operate or play near Barbecue
 Keep Barbecue area clear and free from materials that burn
 Do not block holes in bottom or back of Barbecue
 Check burner flames regularly
 Use Barbecue only in well-ventilated space NEVER use in enclosed
space such as carport, garage, porch, covered patio, or under a
surface that can catch fire
Do not use charcoal in a gas Barbecue
Use Barbecue at least 1M from any wall or
surface Maintain 3M clearance to
objects that can catch fire or sources
of ignition such as pilot lights, live
electrical appliances, etc
 Apartment Dwellers:
Check with management to learn the requirements and fire codes for
using a Gas Barbecue in an apartment If allowed use outside on the
ground floor with a one (1) meter clearance from walls or rails Do
not use on or under balconies made of wood
NEVER attempt to light burner with lid closed A build up of non-
ignited gas inside a closed Barbecue is hazardous
Never operate Barbecue with fuel bottle out of correct position
Always close fuel bottle valve before moving fuel bottle from specified
operating position
ATTENTION:
 The regulator supplied is for Butane gas only and can be used with 15Kg
or smaller Butane bottles Char-Broil Barbecues can run on Propane
gas, but only with an approved 37 mbar PROPANE GAS REGULATOR
(see instructions)
 Do not use a variable regulator If in doubt contact your Local gas
stockist
Warranty Information
Model Number ________________________________
Date Purchased _______________________________
Important: Fill out Warranty Information below
1)Fuel hose from fuel bottle must not touch barbecue body A distance of at
least 18 cm must be maintained between fuel hose and barbecue body! Do
not exceed 1 5 m length of hose Do not twist fuel hose for any reason
Visually inspect hose before each use of appliance If there is excessive
abrasion, cracking or wear, hose is cut, or when National safety regulation
and standards require, hose must be replaced prior to operation Barbecue
must only be used with Nationally approved fuel hoses and bottles. Fuel
bottle must sit to side of barbecue unless a means of attachment is provided
2) Installation of barbecue must conform with National safety regulations and
standards Barbecue must only be used outdoors and must not be installed
or used within 1 metre (back and sides) of combustible material Do not
locate barbecue under overhead made of combustible materials Do not
place over drains or gullies Avoid use of electrical cables and petrol hoses
near heated areas
) Use only Nationally approved regulator and gas as shown below:
GB,ES,PT,IT,GR,LU,BE,IE
NO,FI,SE,DK,IS
CH,DE,AT
NL
Butane 28-30 m ar
Propane 37 m ar
Propane 30 m ar
Propane 50 m ar
Butane 30 m ar
FR Butane 28-30 m ar
COUNTRY GAS PRESSURE

4644450-04 3
Key Qty -- Description --------------------------------- Part#
A ----- 1 ----Lid Handle -------------------------------------------- 4154399
B ----- 1 ----Base --------------------------------------------------- 4154381
C ----- 1 ----Cooking Grill ----------------------------------------- 4157097
D------1 ----Valve Assembly -------------------------------------- 4158212
F ----- 1 ----Barbecue Lid----------------------------------------- 4509232
G ----- 1 ----Barbecue Bottom ------------------------------------ 4509233
H ----- 2 ----Blank Legs-------------------------------------------- 4302534
I ------ 1 ----Valve Cover ------------------------------------------ 4502445
J ------ 1 ----Hose/Regulator Bag-------------------------------- 4158191
K ----- 1 ----Control Leg ------------------------------------------- 4526182
L ----- 1 ----Burner ------------------------------------------------- 4068082
M----- 1 ----Leg Handle ------------------------------------------- 4150357
N ----- 1 ----Ignitor -------------------------------------------------- 4153713
O ----- 1 ----Ignitor Wire ------------------------------------------- 4153761
P ----- 1 ----Electrode ---------------------------------------------- 4153800
Q ----- 1 ----Control Knob ----------------------------------------- 4154214
Parts List - Model 464445004
R
GG X
U
Z
V
X
AA
Y
W
X
R ----- 3 ----Lid Hanger ------------------------------------------ 4154245
S ----- 1 ----Heat Indicator w/ Nut ------------------------------ 4156896
T ----- 1 ----Grease Cup ----------------------------------------- 5156609
U ----- 1 ----Grease Clip ----------------------------------------- 5156610
V ----- 1 ----Heat Plate -------------------------------------------- 4156439
#10 Fasteners Bag: 4254038
W----- 6 ----#10-24 x 7/16 T- Nut ----------------------------- 4080094
X ---- 20----#10-24 Hex Nut (keps) --------------------------- 4080208
Y ----- 3 ----#10-24 Dome Nut---------------------------------- 4080251
Z ---- 14 ----#10-24 x 1" Machine Screw -------------------- 4080302
AA --- 3 ----#10-24 x 3/8" Machine Screw ------------------ 4080345
BB --- 3 ----#10-24 x 2" Machine Screw -------------------- 4080377
CC --- 3 ----1-1/2" Spacer --------------------------------------- 4080724
Misc. Fasteners Bag: 4253106
DD --- 2 ----#6-32 x 3/8" Machine Screw -------------------- 4080361
EE --- 1 ----5/16 Flat Washer ----------------------------------- 4080413
FF --- 2 ----#10 x 3/8 Self-tap Screw ------------------------- 4080735
GG --- 3 ----#12-14 x 1/2" Self-tap Screw ------------------- 4080772
HH --- 2 ---- 175ID x 25OD x 1/8" Spacer ------------------ 4080139
Z
A
S
S
GG GG
F
X
R
R
T
G
Z
Z
X
X
M
DD
K
N
Q
H
BB
X
B
Z
Z
X
X
X
CC
W
L
AA
W
X
C
CC
EE
X
H
BB
I
X
O
ZP
A
1
ZZ
J
D
FF
FF
HH

44644450-04
Before Beginning Assembly
Remove all contents from box. Lay cardboard on the ground when unpacking, assemble Barbecue parts on the cardboard to
avoid scratching surfaces.
Carefully read and follow all assembly instructions, paying particular attention to parts orientation.
Easily find fasteners by referring to each item shown actual size) at the start of each step.
Minimum tools...for assembly of your Barbecue include screwdrivers cross head), adjustable
wrench and pliers. A 3/8" nut driver would be ideal.
1#10 Bag
W
X
ZN
MZ
X between Leg and Barbecue Bottom (Finger
tighten fully onto screws)
W
( nside Barbecue
Bottom)
Note: Tighten by
turning screws only.
s Use top t o holes of
four-hole pattern.
G
K
s Be sure that holes in Barbecue bottom for
electrode are pointing up ard to ard control leg.
To
Barbecue
Bottom
X2 X2
X2

4644450-04 5
2
#10 Bag
W
X
Z
3
Z
X
between Leg and Barbecue Bottom
(Finger tighten fully onto screws) Z
To Barbecue
Bottom
W ( nside
Barbecue
Bottom) Note:
Tighten by
turning screws
only.
s Rotate Barbecue bottom
to attach blank legs.
H
X
between Leg and Barbecue Bottom
(Finger tighten fully onto screws)
#10 Bag
Z
X
B
Z
K
Control leg ( ) properly
attached to base(B)
B
s Wheels face
away from
control leg.
Repeat assembly
on blank legs(H).
X4
X4
X4 H
X6
X6

64644450-04
C
Misc. Bag
5
4
J
N
DD
K
DD
I
L
Valve
I
L
sVERY IMPORTANT:
Burner tube must pass through hole
in valve cover and engage valve
attached to control leg.
Valve Cover must be
BETWEEN flanges of
Control Leg
A
I
B
X2
D
X2
HH
HH
Assemble bottom
spacer first.
A
1
D

4644450-04 7
AA
6 7
#10 Bag
K
Burner Tube
Be sure Valve Cover is INSIDE Control Leg.
IMPO TANT
X
AA
CC
BB
Insert long end of electrode
from beneath Barbecue
bottom
CC
BB
#10 Bag
8
Round
End
Flat End
P
View of electrode (P)
from beneath Barbecue
bottom(G).
Rear view of control leg
Y
V
O
N
G
Y
#10 Bag
X2 X2
AA
Q
AA X
X1 X4
X3
X3
X3
O
P

84644450-04
For your safety
Leak test must be repeated each time fuel bottle is exchanged or refilled
Do not smoke during leak test
Do not use an open flame to check for gas leaks
Barbecue must be leak checked outdoors in well-ventilated area, away
from ignition sources such as gas fired or active electrical appliances
During leak test, keep Barbecue away from open flames or sparks
Never remove injector at end of valve (A)
Assembly - Lea Test
To leak test your Barbecue:
1. Turn control knob to OFF
2. Be sure regulator is tightly connected to fuel bottle
Turn gas on at the tank by using the regulator
4. Brush soapy solution onto following connections:
 Regulator fitting, face at crimps and vent hole (2);
 Hose (3) and all connections;
 All fuel bottle welds (fuel bottle collar, middle and bottom) (4)
5. "If growing" bubbles appear, there is a leak Close fuel bottle
valve immediately Retighten connections and repeat leak test
procedures If leaks cannot be stopped replace parts
Use a clean paint brush and 50/50 soap and water
solution Use mild soap and water. s Do not use
household cleaning agents. Damage to gas train
components can result
 If "growing" bubbles appear do not use or move the fuel
bottle. Contact gas supplier.
A
1
3
2
3
4
 Do not use Barbecue until leak checked.
 If leak is detected at any time, STOP. Immediately close fuel
bottle valve, stay away from the Barbecue and call local gas
supplier.
Postion tank to side of barbecue on level surface.

4644450-04 9
11
Feed wire through hole from
INSIDE Barbecue Bottom.
Misc. Bag
FF
U
FF U
T
A
BC
Rear View
12
C
Grill rests on T- nuts(W).
X2
14 Z (Tighten using screw only.)
S
EE X
Thermometer Nut
(Remove from thermometer)
#10 Bag
X
Z
EE
Misc. Bag
X1
X2
X2
A
F

10  4644450-04
15
GG
Misc. Bag
R
GG
Use & Care
Safety Tips
sIf you have a Barbecue problem see the "Troubleshooting
Section".
sWhen Barbecue is not in use, turn off control knob and fuel
bottle valve.
sNever move Barbecue while in operation or still hot.
sUse long-handled barbecue utensils to avoid burns and
splatters.
sGrease cup must be attached to grease clip and emptied
after each use. Do not remove grease cup until Barbecue
has completely cooled.
sIf you notice grease or other hot material dripping from
Barbecue onto valve, hose, or regulator, turn off gas supply at
once. Determine the cause, correct, and clean valve, hose
and regulator before continuing. Perform a leak test.
sThe regulator may make a humming or whistling noise
during operation. This will not affect safety or use of
Barbecue.
Before Your First Cookout
 Light burner, check to make sure it is lit, close the lid and
warm up Barbecue on HIGH for 15 minutes. Curing of paint
and parts will produce an odor only on first lighting.
 NEVER attempt to light burner ith lid closed. A
buildup of non-ignited gas inside of closed
Barbecue is hazardous.
 Never operate Barbecue ith fuel bottle out of
correct position specified in assembly
instructions.
 Putting out grease fires by closing the lid is not
possible. Barbecues are ell ventilated for safety
reasons. Do not use ater on a grease fire. Personal
injury may result. If a grease fire develops turn knob
and fuel bottle off.
 Do not leave Barbecue unattended hile preheating
or burning off food residue on high. If Barbecue has
not been regularly cleaned a grease fire can occur
that may damage the product.
X3

4644450-04 11
Ignitor Lighting
sDo not lean over Barbecue hile lighting.
1. Open lid. Turn on gas at fuel bottle.
2. Push in and turn knob on control leg to HIGH.
3. Push IGNITOR button rapidly to light. Be sure burner lights
and stays lit.
4. If IGNITOR does not work, follow match lighting
instructions.
Match Lighting
sDo not lean over Barbecue hile lighting.
1. Open lid. Turn gas on at fuel bottle.
2. Place lit long-stem match into one of
three large match lighting holes around
burner tube from beneath Barbecue.
3. Push in and turn control knob to HIGH.
Be sure burner lights and stays lit.
Burner Flame Check
1. Light burner in Barbecue bottom using long-stem match as
described in Match Lighting.
2. Push in and rotate knob from HIGH to LOW. You should see
a noticeably smaller flame in LOW position from that seen in
HIGH position. Al ays check flame, as described above,
prior to each use.
Use & Care
If burner does not light turn knob to OFF, wait 5 minutes,
try again. If the burner does not ignite with valve open, gas
will continue to flow out of the burner and could accidently
ignite with risk of injury.
Match lighting holes
Turning Barbecue Off
 Turn knob to OFF position.
Ignitor Check
Turn gas off at Fuel Bottle. Press ignitor button rapidly.
"Click" should be heard each time at electrode. See
Troubleshooting if no click is heard.
Valve Check
Important: Make sure gas is OFF at Fuel bottle before
checking valve. Knob locks in place. To check valve, first
push in knob and release, knob should spring back. If knob
 Clean burner twice a month when in regular use.
Clean burner prior to use after storage. Spiders
and insects like to build nests in burner tube
especially during colder months). These nests
can cause flashback fire in burner tube).
Typical spider eb inside burner
does not spring back, replace valve assembly before using
Barbecue. Turn knob to LOW position then turn back to OFF
position. Valve should turn smoothly.
Hose Check
 Before each use, check to see if hose is cut or worn. Replace
damaged hose before using Barbecue. Use only valve/hose/
regulator specified by manufacturer.
General Barbecue Cleaning
 Clean porcelain Barbecue lid and bottom with soap and
water or nonabrasive cleaner to remove dust and grease. Use
Creme of Tartar for stubborn stains. Do not use a Barbecue
cleaner on outside of Barbecue. Wipe with vinegar. Do not
paint inside of Barbecue.
 Replace ceramic briquets as frequently as necessary to avoid
grease buildup and flare-ups.
 Porcelain grill: Because of glass-like composition, most
residue can be wiped away with baking soda/water solution
or specially formulated cleaner. Use nonabrasive scouring
powder for stubborn stains.
epainting Your Barbecue
 After extended use and exposure to weather, paint on
Barbecue
legs may deteriorate or become spotted. Although this
detracts from Barbecue's appearance, it will not impair its
performance.
 To refinish Barbecue legs, use wire brush and lightly sand
with fine
grit sandpaper. Sanding allows new paint to adhere more
easily. Refinish legs with heat-resistant paint.
Storing Your Barbecue
 Clean cooking grill.
 Apply a light coating of vegetable oil to heat plate.
 Store in dry location.
 When fuel bottle is connected to Barbecue, store both
outdoors in well-ventilated space and out of reach of children.
Store Barbecue indoors ONLY if fuel bottle is disconnected,
removed from Barbecue and stored outdoors.
 Cover Barbecue if stored outdoors. Choose from a variety of
Barbecue covers offered by manufacturer.

12  4644450-04
Use & Care
Cleaning the Gas Train
1. Turn gas OFF at knob and Fuel Bottle.
2. Remove cooking grill and grease cup A).
3. Disconnect ignitor wire from electrode. Wipe ceramic
portion of electrode with rubbing alcohol and cloth D).
4. Examine upper and lower surfaces of burner tube closely
E). If any cracks or holes are found, replace burner tube.
sVERY IMPORTANT:
When replacing burner tube, burner
tube must pass through hole in valve
cover and engage valve attached to
control leg.
7. Using garden hose preferably with nozzle), force water
through burner tube to clean.
8. Replace burner plate and dome nuts.
9. If Barbecue is to be stored, coat tube burner lightly with
cooking oil. Wrap protective cover over each end to keep
insects out.
10. Attach flat end of ignitor wire to electrode.
11. Replace cooking grill and grease cup.
12. Before cooking again on Barbecue, follow Gas Flow Check.
13. Barbecue must be completely dry before cooking.
A
VALVE
BURNER TUBE
A
D
C
E

4644450-04 13
Possible Cause
Wire and/or electrode covered with cooking residue
Electrode and burner are wet
Electrode cracked or broken "sparks at crack"
Wire is loose or disconnected
Wire is shorting (sparking) between ignitor and
electrode
Bad electrode
No gas flow
Obstruction of gas flow
Disengagement of burner to valve
Is Barbecue assembled correctly?
Out of gas
Excess flow valve tripped
High or gusting winds
Low on gas
Excess flow valve tripped
Grease buildup
Excessive fat in meat
Excessive cooking temperature
Grease trapped by food buildup around burner
system
Burner and/or burner tube blocked
Prevention/Cure
Clean wire and/or electrode with rubbing alcohol and clean swab
Wipe dry with cloth
Replace electrode
Reconnect wire or replace electrode/wire
Replace ignitor wire/electrode
Replace electrode
Check to see if fuel bottle is empty If fuel bottle is not empty, refer to
"Sudden drop in gas flow"
Clear burner tube
Reengage burner and valve
Check steps in assembly instructions
Check for gas in fuel bottle
Turn off knob and fuel bottle valve Wait 30 seconds and light
Barbecue
If flames are still low turn off knob and fuel bottle valve Disconnect
regulator Reconnect regulator and leak test Turn on fuel bottle
valve, wait 30 seconds and then light Barbecue
Turn front of Barbecue to face wind or increase flame height
Refill fuel bottle
Refer to "Sudden drop in gas flow" above
Clean Barbecue
Trim fat from meat before Barbecuing
Adjust (lower) temperature accordingly
Turn knob to OFF Turn gas off at fuel bottle Open lid carefully
and let fire burn out After Barbecue cools, remove & clean all
parts.
Clean burner and/or burner tube
Troubleshooting
Problem
Burner will not light
using ignitor.
Burner will not match
light.
Sudden drop in gas
flow or low flame.
Flames blow out.
Flare-up.
Persistent grease fire.
Flashback...
(fire in burner tube)

14  4644450-04
SIZE/QUANTITY
1 inch
1/2 inch
1 inch
9kg
79kg
23kg
1 each
9kg
23kg
1 each
1 each
1 each
Patio Caddie Cooking Chart
Cooking times and temperatures may vary according to specific recipes, cooking conditions, or barbecue equipment used. Take
this into consideration to insure best results. Please note: High = 260 - 343 C / Medium = 177- 260C / Lo = 93-260 C
ITEM
Beef Steak
Hamburgers
Pork Chop
Boneless Pork Loin
Baby Back Pork Ribs
Boneless, Skinless,
Chicken Breast
Cut Chicken
Turkey Breast with
Ribs
Shrimp, Medium,
peeled and deveined
Corn on Cob
Baking Potatoes
Yellow Onion
TEMPERATURE
High/medium high
Medium
High/medium
Low
Medium/low
Low
Medium/high
Medium
Low
Medium/high
Medium
Medium
Medium/high
TIME
Rare - 7-10 minutes, Medium - 12-15 minutes
Well - 18-20 minutes
Medium - 10 minutes, Medium/well - 12 minutes
Well - 15 minutes
30 minutes, Internal temp 71C
1 hour, Internal temp 71C
50 minutes
20 minutes
Wings - 20 minutes, Leg/thigh - 35 minutes
Breast - 40 minutes, Internal temp 74C
1 hour, Internal temp 74C
5 minutes
40 minutes
1 hour
12-15 minutes
TIPS
Sear over high heat Reduce
to medium high Cover
Cover Turn once
Sear over high heat Reduce
to medium Cover
Brown roast over direct heat
Cover Remove to side for
indirect cooking Cover
Brown over medium/low for 10
minutes Cover Reduce to
low Cover Baste last 15
minutes with sauce
Pound, rub with oil Sear over
high heat Cover Reduce to
medium Cover
Cook skin side first Cover
Cook skin side down first to
brown Cover
Skewered, oiled Cover
Husks on, soaked in cold
water Direct heat, cover Turn
during cooking
Wrap in aluminum foil Indirect
heat Cover Turn once during
cooking
1/2 inch whole rings Oiled
Cover
Food Safety
Food safety is a very important part of enjoying the outdoor cooking
experience To keep food safe from harmful bacteria, follow these four
basic steps:
Clean: Wash hands, utensils and surfaces with hot soapy water
before and after handling raw meat and poultry
Separate: Separate raw meats and poultry from ready-to-eat
foods to avoid cross contamination Use a clean platter and
utensils when removing cooked foods
Cook: Cook meat and poultry thoroughly to kill bacteria Use a
thermometer to ensure proper internal food temperatures
Chill: Refrigerate prepared foods and leftovers promptly
How To Tell If Meat Is Barbecued Thoroughly
 Meat and poultry cooked on a Barbecue often browns very fast on the
outside Use a meat thermometer to be sure food has reached a safe internal
temperature and cut into food to check for visual signs of doneness
 Whole poultry should reach 82C ; breasts, 77C Juices should run clear and
flesh should not be pink
 Hamburgers made of any ground meat or poultry should reach 71C and be
brown in the middle with no pink juices Beef, veal and lam steaks, roasts and
chops can be cooked to 63C All cuts of pork should reach 71C
 NEVER partially Barbecue meat or poultry and finish cooking later Cook
food completely to destroy harmful bacteria
 When reheating takeout foods or fully cooked meats like hot dogs, Barbecue
to 18C, or until steaming hot

4644450-04 15
[e-mail]
[e-mail]
E-MAIL ADDRESS
For Warranty and replacement parts
(For U.K. Residents only)
Char-Broil International L.L.C.
Bradley House
Bircholt Road
Parkwood,Maidstone,Kent, ME1 9XY
Phone [phone]
Fax [phone]
GB
SERVICE