The most common Char Broil regulator problems you’ll face are that either the OPD in the regulator has been tripped or the regulator is damaged. In the first scenario, you’ll have to reset the regulator, and that’ll fix the issue. But when the regulator is faulty, you’ll have to replace it.
I’ll walk you through how you can do all these things in detail and also show you how to prevent these issues in the future. If you follow the instructions properly, you won’t have to face this issue anytime soon. So, let’s dive in!
Char Broil Regulator Problems [Completely Fixed]
The most common sign that you are facing Char Broil gas grill regulator problems is that there are flame issues. Typically, you’ll have low heat when you’re facing this issue. Now, let’s look at the main reasons behind it and how you can actually fix it.
1. Tripped Out Gas Regulator
First things first, before blaming the regulator, make sure that you have a proper gas supply. So, how do you check this? You just need to weigh it. Typically, an empty cylinder weighs about 17-18 pounds, and a full cylinder weighs around 30 pounds.
You can check it with a scale to get an idea of how much gas you have. If it’s below 20, there’s a good chance that the issue is with low gas supply and not the regulator. But if there’s enough gas, you have to check the regulator.
Another pretty common symptom that there’s an issue with the regulator is when you get the grill beyond 300 degrees. You are supposed to reach 500 degrees or more easily when you turn on the burners to the highest settings.
But if it doesn’t get that high even after you push the burners to the maximum, something is most likely wrong with the gas regulator. There’s a 99% chance that the overpressure device, or the OPD of the regulator, is being tripped.
The job of the gas regulator is to restrict or prevent the gas flow when there’s a gas leak. So, when the OPD is tripped, it triggers that mechanism. It starts to prevent the gas flow to the grill. That’s why you get a low flame in this situation. Now, the gas regulator is often tripped due to these two reasons:
- Not following the lighting instructions correctly.
- Turning on the gas knob too quickly.
The mistake that most people make when starting up the grill is that they turn on the control knobs of the grill first. They do it before they turn on the knob of the liquid propane tank valve. But you can’t do that. You have to always turn on the gas valve knob first and then the controls of the grill.
In terms of turning on the gas knob quickly, there’s a sudden rise in the gas pressure. It activates the safety mechanism in the regulator. It closes a valve and restricts the flow of gas. That’s why you end up getting little to no flame in your grill.
Solution:
Thankfully, the solution to this problem is fairly simple. All you’d have to do is reset the regulator, and that’ll fix the issue. Here’s how you can easily do the Char Broil regulator reset:
- Open the lid of the grill.
- Turn off everything—all the knobs in the front panel of the grill.
- Turn off the propane tank knob.
- Disconnect the regulator from the propane tank.
- Wait for 30 seconds and reconnect the regulator to the propane tank.
- Slowly open the propane tank valve all the way.
Yes, that’s how you can reset the grill. If the OPD was tripped, then going through this reset process should fix it. If you still have a low flame even after resetting the regulator, repeat the process 3-4 more times.
Sometimes, it takes multiple attempts for the gas regulator to be properly reset. If it still doesn’t work, then there could be other issues with the grill. In that case, you’d have to keep on diagnosing.
2. Faulty Gas Regulator
If resetting the gas regulator doesn’t work, then there’s always the possibility that the gas regulator has gone bad. There’s another component in the regulator. It’s called the excess flow valve.
Sometimes, the excess flow valve can get completely stuck, and it can restrict the flow of gas for good. In that case, you’d have low heat, and sometimes, the flames can completely blow out.
That’s how you can get an idea that the Char Broil grill regulator is out of order. Here are some more symptoms that usually point to a faulty gas grill regulator:
- No flame at all
- The flame keeps going up and down
- Weird noises from the burners
Solution:
When the regulator no longer works and the excess valve is stuck, your only option is to replace it. Here’s how you can easily do the Char Broil regulator replacement job on your own:
How To Replace The Regulator On A Char Broil Grill
Before you begin, make sure the propane tank is turned off completely. Do this repair in a well-ventilated outdoor area. When you’re done, check for any gas leaks before using the grill again. You can follow these steps to do it:
Step 01 – Take The Old Regulator Out
Turn off the valve on your propane tank completely to ensure no gas is flowing. Unscrew the gas regulator from the propane tank. You can remove the entire tank to make it easier. Use your adjustable wrench to unscrew the regulator fitting from the grill. Be gentle to avoid damaging the gas line.
Step 02 – Install The New Regulator
Take a look at the new regulator. Make sure:
- The fittings match the old regulator.
- The rubber gasket (black ring inside) is in place.
- Everything looks clean and undamaged.
You can also wrap Teflon tape around the threads for extra leak protection, even though it’s not always required.
Screw the new regulator into the grill’s gas line fitting using your wrench. Tighten it until snug. Don’t over-tighten, as it could damage the line. Then attach the other end to the propane tank.
Step 03 – Check For Leaks And Start The Grill
Before lighting it, turn the gas on slightly and listen for any hissing sounds. You can also apply soapy water to the connections—bubbles mean there’s a leak. Once you’re sure there are no leaks:
- Open the grill lid.
- Turn the burner knobs on.
- Light the grill using the ignition or a lighter.
You should hear a strong gas flow and see steady, strong flames.
3. Propane Tank Fault
Technically, this isn’t an issue with the regulator. But some people mistake it for an issue with the regulator. That’s why it’s important to mention it. I’ve had this issue with a customer where their heater was leaking at the regulator.
He thought that the issue was with a Char Broil regulator leak and replaced the regulator. But the same thing happened even after the replacement job. That’s when he asked me to take a look at it. I checked it, and everything with the regulator was fine.
Turns out, the issue was with the propane tank and not the regulator. In his case, the O-ring was missing, and that leaked out the gas. Visually, it looked like the leak was coming from the regulator. But it was actually coming from the tank itself.
Solution:
In his case, the problem was fixed after exchanging the propane tank. And that’s something you’d have to do in most cases to fix this issue. But these problems with the propane tank come in various shapes and forms. Keep on reading to know more about it.
Why Won’t A Full Tank Let Propane Out?
It’s obvious that when there’s an empty fuel tank, there won’t be enough fuel to let out. But when it comes to a full tank, you can also face this issue. Weird? I know, and that’s why it’s confusing to many people.
Now, the main reason behind the propane regulator not letting gas through is due to a tank that’s slightly overfilled. It normally opens on a hot day when it could be just a little expanded. There are also safety devices in the propane tank. Those can get triggered and keep the propane locked in such situations.
Thankfully, you can easily fix it. Just turn off all the gas control knobs and take the tank to an open area. What you’ll have to do is manually let some propane out. Make sure you’re not smoking or there’s nothing remotely flammable in the area where you do it.
There’s a screw that you can manually turn to let some propane out. I recommend letting the propane out for 15 to 30 seconds. That way, you get rid of enough propane to take it to a normal level. Then, you can connect it to your grill and fire it up using the right lighting instructions.
How To Prevent The Char Broil Regulator From Tripping
The Char Broil gas grill regulator is a very sensitive component. And rightly so, because if it slips up, it could lead to an accident. So, you should never try to bypass it and let it do its job.
However, what you can do is avoid doing something that triggers it, even when there’s no reason for it to trip. The number one mistake people often make to trip this Char Broil grill unnecessarily is not following the right startup procedure.
On top of that, turning on the gas valve too quickly can also cause an abrupt change in the gas pressure and fix the issues. So, you need to follow the right startup method when firing up your Char Broil grill.
Make sure that you turn on the gas knob slowly as well so that there are no sudden pressure changes. Don’t know how to start the grill correctly? Here, you can follow these steps to do it:
- Make sure all burner knobs are OFF.
- Slowly open the propane tank valve—just a little crack at first.
- After a second or two, you can open the valve the rest of the way.
- Then, turn on your burner knobs and light the grill.
FAQs
Can any external factors cause Char Broil regulator problem?
Yes, when it’s a really hot day, the LPG can expand and restrict the flow of gas even if there’s nothing wrong with the regulator. In that case, you’d have to let out a bit of gas manually.
Is it important to preheat the grill?
Yes, it’s a good practice, as doing so will protect the Char Broil grill parts from being damaged and also ensure great cooking. I 100% recommend doing this and letting it be at your desired temperature for 15-20 minutes before you put anything in it.
Are there other things that could cause a low flame issue besides a bad regulator?
Yes, there are many things that can keep the grill from reaching full flame. The most common culprits are underlying issues like other damaged components, obstructions, or poor connections.
How do I check the Char Broil grill for leaks?
To check for gas leaks: Mix dish soap with water. Spray the soapy water on the hose and connections. If you see bubbles forming, you have a leak and need to fix it before using the grill.
Is it necessary to use Teflon when changing the regulator?
No, it’s not something that’s always necessary. Sometimes, the instructions will say to use Teflon—in those cases, it’s essential. But apart from that, not using them is also okay. Generally, it’s better to use them for extra sealing.
Conclusion
Now, you know about the two most common types of Char Broil regulator problems and how you can fix them. You just have to follow the instructions, and you’ll find the solution. Start by resetting the gas grill regulator and repeat the process a few times.
If that doesn’t work, replace it with a new one. And I also showed you what to do when something is wrong with the propane tank itself. I’ve tried to make this guide as informative as possible. If you’re facing any Char Broil grill flaming issues, check out my guide on it.
