Char-Broil Patio Caddie 4754960 User manual

4754960 1
4754960
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.
Combustion by-products produced when using
this product contain chemicals known to the
State of California to cause cancer, birth
defects, or other reproductive harm.
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 -
especially as noted in the manual! Wear
protective gloves if necessary.

If you have any questions or need assistance
during assembly, please call 1-800-241-7548.
Visit us on the web at: www.charbroil.com
4754960 / 0 - 4165144 (06-05-02)
FOR YOUR SAFETY
1. Do not store or use gasoline or ot er
flammable vapors and liquids in t e
vicinity of t is or any ot er appliance.
2. An LP Tank not connected for use s all
not be stored in t e vicinity of t is or any
ot er appliance.
FOR YOUR SAFETY
If You smell gas:
1. S ut off gas to t e appliance.
2. Extinguis any open flame.
3. Open lid.
4. If odor continues, immediately call your
gas supplier or your fire department.
®

24754960
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.
This grill is designed for use with an LP (propane) gas tank
using the regulator/ al e assembly supplied. Do not use with
any other fuel source, including fixed fuel (propane or natural
gas) systems.
Grill installation must conform with local codes, or in their
absence with National Fuel Gas Code, NFPA 54 / ANSI
Z223.1 or CAN/CGA-B14 .2 Propane Installation Code.
Handling and storage of LP cylinders must conform to LP
Gas Code NFPA/ANSI 58. Grill is not for use in or on
recreational ehicles and/or boats.
 All electrical accessories (such as rotisserie) must be
electrically grounded in accordance with local codes, or
National Electrical Code, ANSI / NFPA 70 or Canadian
Electrical Code, CSA C22.1. Keep any electrical cords and/
or fuel supply hoses away from any hot surfaces.
 This grill is safety certified for use in the United States and
Canada only. Do not modify for use in any other location.
Modification will result in a safety hazard.
For safe use of your grill and to avoid serious injury:
 Do not let children operate or play near grill.
 Keep grill area clear and free from materials that burn.
 Do not block holes in bottom or back of grill.
 Check burner flames regularly.
 Use grill only in well- entilated space. NEVER use in
enclosed space such as carport, garage, porch, co ered
patio, or under a surface that can catch fire.
Do not use charcoal in a gas grill.
Use grill at least 3 ft. from any wall or
surface. Maintain 10 ft. clearance to
objects that can catch fire or sources
of ignition such as pilot lights, li e
electrical appliances, etc.
 Apartment Dwellers:
Check with management to learn the requirements and fire
codes for using an LP Gas Grill in an apartment. If allowed
use outside on the ground floor with a three (3) foot
clearance from walls or rails. Do not use on or under
balconies made of wood.
NEVER attempt to light burner with lid closed. A buildup of
non-ignited gas inside a closed grill is hazardous.
Ne er operate grill with LP tank out of correct position.
Always close LP tank al e and remo e coupling nut before
mo ing LP tank from specified operating position.
Installation Safety Precautions
Warranty Information
Serial Number ________________________________
Model Number ________________________________
Date Purchased _______________________________
Carton Label # GG ___ ___ ___ ___ ___ ___
Call Grill Ser ice Center for Help and Parts
If you need help or warranty parts call (1-800-241-7548 or
send a FAX to 1-706-576-6355.
 Business hours: Open 24 hours - Se en days a week
 To order non-warranty replacement parts or buy accessories
(grill cover, cleaners, paint) call 1-800-993-2677 or send a FAX
to 1-706-565-2121.
 Please know your Model number, Date of Purchase and
Carton Label number prior to calling.

4754960 3
Key Qty -- Description --------------------------------- Part#
A ----- 1 ----Lid Handle -------------------------------------------- 4154399
B ----- 1 ----Base --------------------------------------------------- 4154380
C ----- 1 ----Cooking G ate --------------------------------------- 4157097
D ----- 1 ----LP Tank ----------------------------------------------- 4158069
E ----- 1 ----B iquets Bag ----------------------------------------- 4158125
F ----- 1 ----G ill Lid ------------------------------------------------ 4509232
G ----- 1 ----G ill Bottom -------------------------------------------- 4509233
H ----- 2 ----Blank Legs -------------------------------------------- 4302534
I ------ 1 ----Valve Cove ------------------------------------------ 4502445
J ------ 1 ----Valve/Hose/Regulato ------------------------------ 4524493
K ----- 1 ----Cont ol Leg ------------------------------------------- 4525834
L ----- 1 ----Bu ne ------------------------------------------------- 4068082
M ----- 1 ----Leg Handle ------------------------------------------- 4150357
N ----- 1 ----Ignito -------------------------------------------------- 4153713
O ----- 1 ----Ignito Wi e ------------------------------------------- 4153761
P ----- 1 ----Elect ode ---------------------------------------------- 4153800
Parts List Model 4754960
R
GG X
E
U
Z
V
X
AA
Y
W
X
X
Q ----- 1 ---- Cont ol Knob ---------------------------------------- 4154214
R ----- 3 ----Lid Hange ------------------------------------------ 4154245
S ----- 1 ----Heat Indicato w/ Nut ------------------------------ 4156896
T ----- 1 ---- G ease Cup ----------------------------------------- 5156609
U ----- 1 ---- G ease 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 Aco n Nut ---------------------------------- 4080251
Z ---- 14 ----#10-24 x 1" Machine Sc ew -------------------- 4080302
AA --- 3 ----#10-24 x 3/8" Machine Sc ew ------------------ 4080345
BB --- 3 ----#10-24 x 2" Machine Sc ew -------------------- 4080377
CC --- 3 ----1-1/2" Space --------------------------------------- 4080724
Misc. Fasteners Bag: 4253106
DD --- 2 ----#6-32 x 3/8" Machine Sc ew -------------------- 4080361
EE --- 1 ----5/16 Flat Washe ----------------------------------- 4080413
FF --- 2 ----#10 x 3/8 Self-tap Sc ew ------------------------- 4080735
GG --- 3 ---- #12-14 x 1/2" Self-tap Sc ew ------------------- 4080772
Z
A
S
S
GG GG
F
X
R
R
T
D
G
H
Z
J
BB
I
FF
Z
X
Z
X
M
DD
K
N
Q
H
BB
X
X
O
Z
B
P
Z
Z
X
X
X
CC
W
L
AA
W
X
C
CC
EE

44754960
Before Beginning Assembly
Remo e all contents from box. Lay cardboard on the ground when unpacking, assemble grill parts on the cardboard to a oid
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 grill include screwdri ers (Phillips), adjustable
wrench and pliers. A 3/8" nut dri er would be ideal.
You may fill your LP gas tank prior to assembly. The tank must also ha e the safety cap installed onto the tank al e when
not in use, see Use & Care section.
1#10 Bag
0 4
208
302 Ignitor
Handle
302
208 between Leg and Grill Bottom (Finger
tighten fully onto screws)
0 4
(Inside Grill Bottom)
Note Tighten by
turning screws only.
s Use top two holes of
four-hole pattern.
Grill Bottom
Control Leg
s Be sure that holes in grill bottom for electrode
are pointing upward toward control leg.
To
Grill
Bottom

4754960 5
2
#10 Bag
0 4
208
302
3
302
208
between Leg and Grill Bottom
(Finger tighten fully onto screws) 302
To Grill Bottom
0 4 (Inside
Grill Bottom)
Note: Tighten
by turning
screws only.
s Rotate grill bottom to
attach blank legs.
Blank Leg
Blank Leg
208
between Leg and Grill Bottom
(Finger tighten fully onto screws)
#10 Bag
302
208
208
Base
302
Control Leg
Control leg properly attached to base
Base
sWheels face
away from
control leg.
Repeat assembly
on blank legs.

64754960
C
Misc. Bag
5
4
Valve/Hose/
Regulator
Valve Stem
Ignitor
361
Control Leg
361
Valve
Cover
Control Leg
Burner Tube
Valve
Valve Cover
Burner
Tube
sVERYIMPORTANT:
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
Correct Engagement
Valve
Valve
Cover
B
Burner Tube

4754960 7
345
6 7
#10 Bag
Control Knob
Control Leg
345
Burner Tube
208
Be sure Valve Cover is INSIDE Control Leg.
IMPORTANT
208
208
345
724
377
Insert long end of
electrode from
beneath grill bottom
208
208
345
724
377
#10 Bag
8
Round
End
Flat End
Ignitor
Wire
Electrode
View of electrode from
beneath grill bottom
Rear view of control leg
251
Heat Plate
Ignitor
Wire
Ignitor
Grill
Bottom
251
#10 Bag

84754960
9
sLP gas tank should be filled at this time to a
maximum of 80% fill level with LP gas before
attaching to cart.
sPosition LP tank as shown for placement into
plastic base.
Failure to install tank correctly may allow gas hose to
be damaged in operation.
Tighten thumbscrew to hold tank in position
LP Tank
Base
10
1. Tu n cont ol knob OFF.
2. Tu n LP tank OFF by tu ning hand wheel clockwise to a full stop (A).
3. Remove the p otective cap f om LP tank valve. Always use cap and
st ap supplied with valve.
4. Hold regulator, insert nipple (B) into LP tank valve. Nipple
must be centered in LP tank valve. Hand tighten coupling nut,
holding regulator in a straight line (C) with LP tank valve
so as not to cross thread the connection.
5. Tu n coupling nut clockwise to tighten to a full solid stop. The egulato
will seal on the back-check featu e in LP tank valve, esulting in some
esistance. An additional one-half to three quarters turn is
required to complete connection. Tighten by hand only - do not
use tools.
Note: If you cannot complete the final connection, disconnect egulato and
epeat steps 4 and 5. If you a e still unable to complete the
connection, do not use this valve and regulator!
6. Follow "Leak Test" inst uctions.
Safety Relief
Valve
OPD Hand Wheel
Strap and Cap
Nipple has to be centered
into the LP tank valve
AB
Hold coupling nut and regulator as shown for
proper connection to LP tank valve
Regulator
Coupling
Nut
ON
C
Off
Clock
wise
Type 1 outlet with
thread on outside

4754960 9
For your safety
Leak test must be epeated each time LP tank is exchanged o efilled.
Do not smoke du ing leak test.
Do not use an open flame to check fo gas leaks.
G ill must be leak checked outdoo s in well-ventilated a ea, away f om
ignition sou ces such as gas fi ed o active elect ical appliances. Du ing
leak test, keep g ill away f om open flames o spa ks.
Neve emove opening at end of valve (A).
Assembly Leak Test
To leak test your grill:
1. Turn control knob to OFF
2. Be su e egulato is tightly connected to LP tank.
3. Completely open LP tank valve by tu ning hand wheel counte
clockwise. If you hea a rushing sound, tu n gas off immediately. The e
is a majo leak at the connection. Correct before proceeding.
4. B ush soapy solution onto following connections:
 LP tank valve (1) including th eaded po tion into tank;
 Regulato fitting, face at c imps and vent hole (2);
 Hose (3) and all connections;
 All LP tank welds (LP tank colla , middle and bottom) (4).
5. "If growing" bubbles appea , the e is a leak. Close LP tank
valve immediately. Retighten connections and epeat leak test
p ocedu es. If leaks cannot be stopped eplace pa ts. O de new pa ts
by giving the se ial, model numbe and name of items needed to the
G ill Se vice Cente at (1-800-241-7548.
6. Always close LP tank valve afte pe fo ming leak test by tu ning hand
wheel clockwise.
Use a clean paint b ush and 50/50 soap and wate
solution. Use mild soap and water. sDo not use
household cleaning agents. Damage to gas t ain
components can esult.
 If "growing" bubbles appear do not use or move the LP
tank. Contact an LP gas supplier or your fire department.
A
1
2
3
3
4
 Do not use grill until leak checked.
 If leak is detected at any time, STOP. Immediately close LP
tank valve, stay away from the grill and call an LP gas
supplier or your fire department!

10  4754960
11
Feed wire through hole from
INSIDE Grill Bottom.
Misc. Bag
735
Grease Clip
735 Grease Clip
Grease Cup
A
BC
Rear View
12
Cooking Grate
Grate rests on T- nuts.
Briquets should be evenly distributed around
lowest part of grill bottom.
Briquet
(Maximum 16)
13