Question about Thermos Stainless Steel Gas Grill

1 Answer

We have a sunbeam 540 gas grill with a leak in the connector between the gas tank and the hoses leading to the grill. How can we fix the leak?

Posted by on


1 Answer

  • Level 1:

    An expert who has achieved level 1.


    An expert who has answered 20 questions.


    An expert that hasĀ over 10 points.


    An expert whose answer gotĀ voted for 2 times.

  • Contributor
  • 30 Answers

If the leak is in the black fitting you turn to tighten it onto the tank, that is a replaceable part.

It is part# 86495 from Music City Metals.

You can get it for $13.99+ at

Posted on Mar 10, 2010


1 Suggested Answer

  • 2 Answers

SOURCE: I have freestanding Series 8 dishwasher. Lately during the filling cycle water hammer is occurring. How can this be resolved

a 6ya expert can help you resolve that issue over the phone in a minute or two.
Best thing about this new service is that you are never placed on hold and get to talk to real repairmen in the US.
the service is completely free and covers almost anything you can think of.(from cars to computers, handyman, and even drones)
click here to download the app (for users in the US for now) and get all the help you need.

Posted on Jan 02, 2017


Add Your Answer

Uploading: 0%


Complete. Click "Add" to insert your video. Add



Related Questions:

1 Answer

How do i replace my sunbeam grillmaster regulator?

the problem is going to be the QCC handwheel or it is the o-ring in the tank. if you're swapping tanks instead of refilling, get a new tank but before attaching it turn the bbq on without a tank attached. leave it on for a few minutes so any residual pressure dissipates into the atmosphere. turn everything off, attach the regulator and turn the tank on very slowly before lighting the grill. the QCC handwheel can be problematic although it is rare. You can replace it with the older style POL connection which is a more reliable connection for the LP cylinder. Simply trace the gas line from the regulator to the manifold and unscrew it. the connection is a 3/8" flare which means you do not need putty or tape, just replace the gas hose and regulator as tight as possible. pressurize the line and pour soapy water on it to make sure it is not leaking.

Feb 17, 2014 | Sunbeam Grilling

1 Answer

Full tank but no gas smell and just bought a new hose and regulator

follow this steps and fix it. God bless you
Test the propane tank valve for leaks:
  1. Turn the grill control knobs on the front (and, on some models, the side) of the barbecue to the off position.
  2. Turn the propane tank valve fully counterclockwise to close it.
  3. Mix a test solution of equal parts of dishwashing liquid and water in a small container.
  4. 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.
  5. Tighten the connections and retest.
  6. 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:
  1. With the tank valve open, brush the test solution on the fitting at the other end of the hose, located under the control knobs.
  2. 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.
  3. 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

Oct 29, 2013 | Weber Genesis Silver A Grill

1 Answer

Our food doesn't seem to be cooking is taking a long time, and seems to kind of "simmer", rather than grill, even though the burners are both on and turned full on.

If this is a propane (LP) grill, try replacing the regulator and hose that goes to the tank. It sounds like the grill is not getting enough gas.

Jul 19, 2011 | Sunbeam Grill Series 540

1 Answer


If all you need to know is how to connect the grill's hose to the tank, I think I can help you.

Properly set the LP tank in the grills tank holder. If the tank has a plastic cap over the tank valve, remove it and discard it. Connect the hose to the tank by attaching the hose's connector coupling to the tank valve. Align it properly and turn the coupling counterclockwise to attach it to the tank valve.
Once you have the coupling as tight as you can by hand, turn the tank valve on the top of the tank ON VERY, VERY SLOWLY (Slow motion, slow). Once the valve is fully open, check the coupling for leaks. Soapy water brushed or sprayed on will be fine. Look for bubbles around the coupling, where it attaches to the tank valve. If you don't see any bubbles that grow in size, then there are no leaks. If you find a leak, turn the tank OFF and disconnect the hose slowly. There will be a whoosh of gas, but that's normal. Reconnect the hose coupling again and follow the same procedure above.

If everything checks out the first or second time, you're ready to go. Happy Grilling!!

May 01, 2011 | Char-Broil CharBroil Master Flame Gas...

1 Answer

I have a gas leak coming from grill, gas is turned off. Is this a common problem and is it a simple fix?

If you still have a leak when the gas tank is turned OFF, it's not the grill leaking it's the propane tank valve leaking. Carefully disconnect the hose from the grill (No Smoking) and move the tank as far from the house as you can, into an open area, where the gas can dissipate. Propane gas is heavier than air, it doesn't rise it falls. If after doing this and you still smell gas leaking from the tank, contact your local fire department.

Apr 06, 2011 | Broilmaster P4BL Gas

1 Answer

Noise coming from tank

Yours is a DOT type tank (portable not fixed)

What is the noise? Is it gas coming from the tank to the burner? Hissssssssssss Are you properly connected? Is this a OPD equipped tank? Is there a hole or crack in the hose letting the gas out before it gets to the burner?

Do not examine it with a match!!!!!!!!!!!!!!!!!!!!!!!!!!!!

If your tank is very old, you may not have a OPD equipped tank (is the handle three sided?) Yes = OPD No = old style. Only OPD equipped tanks can be filled in the USA. Old style tanks can leak if not properly connected.

New OPD tanks will not let gas out unless there is something properly connected to the tank. You are NOT fooling around with the 80% valve are you? If you are - STOP. (small screw on the right hand side of the connection fitting.)

If there is any fault in the equipment, connector, regularor, hose or any fitting - get it fixed! One gallon of liquid propane becomes more than 350 cubic feet of highly combustible gas. If it leaks out and gets ignited, at least it will be quick! Dont become the entertainment!

Any parts that are questionable ... replace them!

Please seek additional assistance from your professional propane supplier.

Thanks for your interest in

May 31, 2010 | Weber Genesis Silver B Grill

1 Answer

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.

Apr 25, 2010 | Char-Broil CharBroil Master Flame Gas...

1 Answer

I am about to buy a Sunbeam WG541HPB9 grill secondhand and need advice about whether it comes apart from the stand in order to fit it in my car.

most gas grills do cant speack specifically for this one but i dont think i have ever seen one that doesnt come apart

Oct 30, 2009 | Sunbeam Grill Series 540

1 Answer

Need new burner. model number for sunbeam 540 grill please rate me if this was any help..good luck!!

Jul 06, 2009 | Sunbeam Grill Series 540

Not finding what you are looking for?
Thermos Stainless Steel Gas Grill Logo

Related Topics:

223 people viewed this question

Ask a Question

Usually answered in minutes!

Top Thermos Grilling Experts

Paul Carew

Level 3 Expert

2598 Answers

Gary Kenady
Gary Kenady

Level 2 Expert

140 Answers


Level 3 Expert

744 Answers

Are you a Thermos Grilling Expert? Answer questions, earn points and help others

Answer questions

Manuals & User Guides