I bought a new Charbroil grill, and the regulator leaks every time I open the propane tank. A few times I was able to play with it until I could open the tank without smelling gas, but the next time I go to use it, I it leaks when I open the tank again. I called them and they sent a new regulator, with the same result. Now no matter how many times I try, I can't connnect it without a leak at the tank. I'm only hand-tightening it, and the tank worked fine with my previous Charbroil grill (the tank is about 4-5 years old). I tried teflon tape on the tank threads, but it didn't help either.
I could try exchanging the tank, but it looks like they all have the same threads and it might not help. I don't know what else to do.
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Re: New Charbroil gas regulator leaks
The connector on the grill side that connects to tank may be bad. Call manufacturer and they should send you a new hose and regulator for free since it is a new grill. If grill does the same then replace tank.
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follow this steps and fix it. God bless you Test the propane tank valve for leaks:
Turn the grill control knobs on the front (and, on some models, the side) of the barbecue to the off position.
Turn the propane tank valve fully counterclockwise to close it.
Mix a test solution of equal parts of dishwashing liquid and water in a small container.
To test for leaks, apply the test solution liberally to the
connection between the regulator fitting and the tank valve using a
small paint brush. Apply the test solution to the valve handle and
threads, the length of the hose, and the connection between the hose and
the regulator. If bubbles appear at any point, there is a gas leak.
Tighten the connections and retest.
If you still see bubbles at any of the tested connections, close the tank valve and replace the leaking component.
Test the hose fittings for leaks:
With the tank valve open, brush the test solution on the fitting at the other end of the hose, located under the control knobs.
Turn the control knob to high and test the hose and fittings leading
from the control knob to the grill. Turn the right control knob to off.
Repeat the process for the other control knobs.
If you see any bubbles during any of these tests, close the tank
valve and contact your propane dealer or your local gas utility. Do not
use the barbecue until the leak is corrected
If you have already disconnected the hose from the tank. Track it back to where it connects to the burner(s) manifold. It should be up under the grill head. You should see a brass nut. Using an appropriately sized open end wrench, loosen this nut and the hose will disconnect from the grill.
The new Hose/Regulator Assembly will simply attach in the reverse order of how you removed the faulty one. After installing the new one and connecting the hose to the tank. Open the valve on the tank about halfway and check the connections for leaks. Thick soapy water, brushed on with a paint brush will work for detecting leaks. Look for bubbles other than those made by the soapy water. If you see one, tighten the connection a bit more. Be sure not to cross thread the nut, when installing it.
If you haven't purchase a new one yet, you can the Hose/regulator Assembly at any home center or hardware store that sell gas grills and accessories. They run about $30.00.
The problem is more than likely the OPD Valve in the gas tank. To solve this problem, turn the Tank Valve OFF and disconnect the hose from the tank. Wait 5 minutes and reconnect the hose to the tank. Turn the tank valve ON VERY,VERY SLOWLY (Slow motion, slow). Once it's fully open, light the burner farthest from the tank first and turn it to it's highest setting. Does the flame height look correct? If so, light the remaining burners following the same procedure. Now, to all the flame heights look correct? If so, you solved the problem. Just remember to always turn the tank valve ON very, very slowly. If it didn't solve the problem, make sure you have adequate gas in "old propane tank from the other grill."
I had the same problem years ago with an old charbroil and ended up fixing by replacing the threaded female gas connector on the regulator with one of the old style male inside threaded type. This is the connector that connects the hose/regulator to the propane tank.