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DIY Grill Repair

Friday, May 27, 2016
by James Savage
Blog for Do It Yourslef Gas Grill Repare

How to Replace a Pressure Regulator on a Propane Gas Grill

Friday, May 27, 2016
by James Savage

How to Replace a Pressure Regulator on a Gas Grill

 

 
 
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This step-by-step repair blog shoes how to replace the pressure regulator on a gas grill. A problem with the pressure regulator can prevent the burners from getting enough gas, or any gas at all, and the burners won't ignite. Reset the regulator as described in the owner's manual for your grill. If the regulator still doesn't allow gas to flow, replace it with a manufacturer approved replacement part from Gas Grill Warehouse.

Repair difficulty:
     
Time required:

Less than 15 min.

 

Parts Required

  • Gas grill pressure regulator

Tools Required

  • Adjustable wrench

Before you begin

Wear work gloves to protect your hands.

Instructions

 Warning: Undertaking repairs to appliances can be hazardous. Use the proper tools and safety equipment noted in the guide and follow all instructions. Do not proceed until you are confident that you understand all of the steps and are capable of completing the repair. Some repairs should only be performed by a qualified technician.

Step 1: Shut off the gas supply

Close the shut-off valve on the propane gas tank. 

 Tip: Arrows on the tank knob show which way to open and close the valve.

Shut off the gas.

Step 2: Disconnect the hose from the manifold

Using an adjustable wrench, remove the gas supply hose from the manifold.

Remove the regulator hose from the manifold.

Step 3: Disconnect the hose from the tank

Disconnect the gas supply hose from the propane tank. 

Remove the regulator hose from the tank.

Step 4: Detach the hose from the grill frame

Remove the cotter pin that secures the gas supply hose to the frame of the grill. Pull the hose and regulator off of the grill and set them aside for disposal.

Step 5: Attach the new regulator hose

Connect the new hose to the manifold on the grill. Hook up the other end of the hose to the propane tank.

Step 6: Restore the gas supply and check for leaks

Open the valve on the propane tank to restore the gas supply. To check for leaks, use a clean paint brush to apply soapy water (50/50 mild detergent such as dish soap and water) to the manifold fitting and the gas tank fitting.  Bubbles on the soapy solution indicate a gas leak. Tighten the fittings if necessary to close the leaks.

How to troubleshoot Burner Won't Light

Friday, May 27, 2016
by James Savage

Easy DIY Gas Grill Repairs If the Burner Won't Light

 

One of the hardest parts of any DIY repair can be diagnosing the exact cause. The same problem can have different solutions, and finding the fix often is a simple process of elimination. Our diy gas grill repair section has troubleshooting tips and common questions that can help you find the problem, and our easy-to-follow repair guides make fixing the problem a snap.

So what do you do when you've planned for the big backyard BBQ for weeks just to discover the burners on your gas grill won't light? The neighbors are all coming, and the office crowd—even the in-laws will be there. You've decided on the menu and bought all the food. Don't panic! You might be able to figure this one out, get your get your part from Gas Grill Warehouse and fix it yourself.

Start with the Obvious

Make sure the propane tank has gas in it or that you have gas comming from your natural gas meter.. Once you confirm you have plenty of propane/natural gas, check the regulator hose and propane tank for signs of a leak or gas line from meter. Turn off the gas if you find a leak, and replace the tank or the hose if needed; the hose is usually available as part of the pressure regulator.

How to Test Gas Grill Burners

If the tank and hose or the natural gas supply are not the issue, narrow down the problem a bit more. It could be the gas flow or ignition, or a clogged or damaged burner. The easiest way to check is to test the burners for gas flow. Check to see if the burners are getting gas by carefully attempting to light them manually. Use a long-handled lighter or match with the burner valve turned on.

Possible Causes

If none of the burners light, the most likely cause is a gas flow issue from the pressure regulator. If the burners all ignite manually, gas flow is good and the problem is most likely with the spark igniter. If one or more ignite manually, the problem could be a damaged or clogged burner, the spark igniter or the manifold.

Repair: Gas Grill Pressure Regulator

The pressure regulator controls the propane gas pressure from the propane tank to the grill. Reset the regulator following the instructions in your owner's manual. (Sometimes due to the change in weather(pressure) the gas bottles will engage the safety lock and not allow gas to flow or reduce the flow.  To attempt to unlock the bottle turn off the bottle remove the regulator and reseat the reguler, and try to light again, you may have to do this several times for it to unlock.  If not able to unlock, bring your bottle to your propane supplier to unlock or replace the bottle) or if the regulator doesn’t allow gas to flow after resetting it, replace it. 

Repair: Gas Grill Igniter Electrode

The igniter electrode produces a spark that ignites the gas in the burner. Check the alignment of the igniter and make any adjustments needed. Check the electrode for any buildup of food spills, carbon or other debris, and clean the electrode if needed. Some ignition systems use a battery; check for a weak battery and replace it if necessary.

If the igniter still doesn't produce a spark, or if you find damage to the electrode, replace the igniter electrode. 

Repair: Clogged or Damaged Gas Grill Burner

The burner distributes the propane gas that creates the flame once ignited. Damage to the burner or a clog will prevent it from lighting. Remove the burner grates and flavor bars, and inspect inside the burner tubes and burner ports for clogs such as spider webs or food spills. Clean the burners and ports with a bottlebrush or stiff wire as needed.

If you find rust or damage to the burner, you can replace it easily by :

Warning: Undertaking repairs to appliances can be hazardous. Use the proper tools and safety equipment noted in the guide and follow all instructions. Do not proceed until you are confident that you understand all of the steps and are capable of completing the repair. Some repairs should only be performed by a qualified technician.

 

 

 

 

Step 1: Turn off Gas Supply

Close the shut-off valve on the propane gas tank. or natural gas line.

Step 2: Remove the grates and flavor bar

Remove the cooking grates from the top of the burner box and then remove the flavor bar from the top of the damaged burner.

Step 3: Unfasten the burner

Using a pair of needle-nose pliers, straighten the ends of the cotter pin and remove it from the back of the burner. Detach the mounting screw from the back of the burner using a Phillips screwdriver.

 

Step 4: Remove the burner

Push the burner back and up slightly to release it from the manifold and then remove the burner.

 

Step 5: Install the New Burner

Push the new burner into the manifold and then secure it in place with the cotter pin and screw.

Step 6: Restore the gas supply

Open the valve on the propane tank or turn the natural gas on. Light the burner and check the flame. Adjust the burner if necessary.

Step 7: Reinstall the flavor bar and the grates

Allow the burner to cool. Reinstall the flavor bar and grates.

How to Replace a Spark Control Module on a Gas Grill

Friday, May 27, 2016
by James Savage

How to Replace a Spark Control Module on a Gas Grill

 

 
 
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This step-by-step guide shows how to replace an electronic spark control module on a gas grill. The spark control module connects to the igniter electrode that arcs to light the gas. If the igniter won't spark, the electronic spark control module could be the problem. If the electronic spark control module fails, replace it using a manufacturer-approved replacement part from Gas Grill Warehouse. 

Repair difficulty:
     
Time required:

Less than 15 min.

 

Parts Required

  • Gas grill spark control module

Tools Required

  • Adjustable wrench

Before you begin

Wear work gloves to protect your hands.

Instructions

 Warning: Undertaking repairs to appliances can be hazardous. Use the proper tools and safety equipment noted in the guide and follow all instructions. Do not proceed until you are confident that you understand all of the steps and are capable of completing the repair. Some repairs should only be performed by a qualified technician.

Step 1: Shut off the gas supply

Close the shut-off valve on the propane gas tank. or at the meter for Natural Gas

 Tip: Arrows on the tank knob show which way to turn it to open and close the valve.

Shut off the gas.

Step 2: Remove the battery

Twist off the ignition knob and pull out the battery, noting the which end goes in first so you reinstall it the same way.

Remove the battery.

Step 3: Remove the spark control module

Using a 20 mm wrench, remove the nut holding the spark control module to the faceplate. 

Pull the spark control module out from the back of the grill faceplate.

Step 4: Disconnect the wires

Disconnect the wires from the spark control module.

Disconnect the igniter wire.

Step 5: Attach the wires to the new spark control module

Connect the wires to the new spark control module and push it into place from the back of the faceplate.

Step 6: Connect the wires to the new module

Secure the spark control module in place, using the mounting nut. Insert the battery in the housing, making sure the terminals are oriented correctly. Twist on the cap.

Step 7: Restore the gas supply

Open the valve on the propane tank  or natural gas line to restore the gas supply. Test that the grill lights properly.

Common Gas Grill Q & A

Friday, May 27, 2016
by James Savage

Gas Grill Common Questions

These common questions about gas grills are the ones our experts hear the most often from our customers. You might also find the help you need by checking the DYI Grill Repair Blog and solutions for gas grills. When you’re ready to make a repair, GasGrillWarehouse.com has the part you need, no matter where you bought your gas grill.

 

How do I reset the regulator on my propane gas grill?

1. Turn off all burner control knobs on the gas grill. 

2. Shut the cylinder valve on the LP gas tank. 

3. Disconnect the pressure regulator/hose assembly from the LP gas tank.

4. Wait about 2 minutes to allow the leak limiter on the pressure regulator to reset.

5. Reattach the pressure regulator/hose assembly to the LP gas tank.

6. Slowly open the cylinder valve on the LP gas tank.

The leak limiter device on the pressure regulator is now reset.

Why is the pressure regulator on my gas grill humming?

The pressure regulator uses a diaphragm to regulate the LP gas pressure going to the grill. The humming noise is caused by changes of gas flow across that diaphragm. The humming noise is normal.

How do I check a gas grill for gas leaks?

If you suspect that gas might be leaking from the gas hose or connectors on your gas grill, follow these steps to check for it:

1. Prepare a solution of water and liquid dish soap in a spray bottle. 

2. Shut the cylinder valve on the LP gas tank.

3. Squirt the soapy solution along the gas supply hose and on all gas line connections.

4. Slowly open the cylinder valve on the LP gas tank.

5. Check the hose and all gas line connections for soap bubbles, which indicate that gas is leaking. 

If a leak appears during this test, shut the cylinder valve on the LP tank. Repair the leak or replace the leaking component before using the grill.

Why don’t gas grills have lava rocks anymore?

Most gas grills manufactured since 2005 now have metal distribution plates or flame tamers instead of lava rocks. The distribution plates cover and protect the gas burners in the firebox. Food drippings fall on the distribution plates and vaporize to add smoke flavor to the food. 

Why won’t my propane gas grill get hot?

If the gas grill won’t heat up, check that the tank has fuel; a nearly empty tank won’t provide an adequate gas supply to the burners. 

If the fuel tank is full, reset the pressure regulator. Check the burners for clogs or deposits that could affect the flame. Clean the burners according to the guidelines in your owner's manual.

If the grill still won’t heat properly, replace the gas supply hose and regulator.

Which kind of grill is better, gas or charcoal?

Neither type of grill is better. Each type of grill has unique traits that may best fit your grilling preferences. 

A  gas grill is easier and quicker to start, and you can adjust the burners to control the heat. 

 Charcoal grills give more smoke flavor to the food being cooked. You can use different types of wood or charcoal to vary the smoke flavor in a charcoal grill. 

How do I prevent fire flare-ups on my gas grill?

To prevent fire flare-ups,  clean the grill regularly to prevent grease from building up in the firebox. When the grease residue in the firebox gets hot during cooking, the grease can ignite to cause large flare-ups. Follow the directions in your owner’s manual to clean the burner box and other grill components.

When cooking greasy meats, use an indirect grilling method to avoid flare-ups.

How can I tell how much propane is in the fuel tank?

To determine how much propane is left in the tank, weigh the tank on a bathroom scale. A propane tank usually weighs 17 or 18 pounds when empty—you can find the actual weight engraved beside the handle at the top of the tank, preceded by the letters TW. TW17 indicates that the tank weighs 17 pounds. A 20-pound capacity TW17 tank weighs 37 pounds when full. When the tank weighs 18 pounds, you have about 30 minutes of gas supply left in the tank.

If you don’t want to remove the tank from the grill, pour hot water down the side of your tank. Feel the side of the tank with your hand. The portion of the tank that stays warm is empty. The part of the tank that feels cool is full because the propane inside the tank is at -42 degrees fahrenheit an absorbs the heat of the water.

What is an OPD valve on a gas grill?

An OPD (Overfill Protection Device) valve limits the fill level of the tank to 80% of its rated capacity, allowing room for the propane to expand safely in higher temperatures without releasing gas. As of 2002, all propane tanks sold or refilled must have an OPD valve.

How can I convert my LP grill to natural gas?

Check yourowners manual. Not all grills can be converted from one gas source to the other. If the owner’s manual indicates that your grill can be converted, check the parts list in the manual for the part number for a conversion kit and then search for that part online or contact your grill manufacture for a conversion kit. Gas Grill Warehouse does not stock grill conversion kits.

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