Portable generator battery access

[Fodeman]

I have an older 7500w Generac generator with an electric start, model 1019-3, that I've needed to replace the battery in a couple of times. The problem, in order to remove the battery, is having to
remove the gas tank to gain access to the hold-down bolts to lower the battery tray to slide the battery out over top of a lip on the tray.

To compound the problem, the hold-down bolts aren't long enough to drop the battery tray. If you try to remove the hex nuts to drop the tray entirely, the bolt heads will turn, thus having to remove the gas tank! Engineering at it's worst!

Here's what I did:

I took a deep breath and removed the gas tank one last time. I then removed the bolts that were too short (only 1/2" long) and replaced them with 1" long hex bolts, only this time, I also put a glob of JB Weld on the head of each bolt. I then let them sit overnight.

I then reinstalled the battery tray, now being able to lower the battery tray to remove the battery.

I've seen similar Generac units with the same (or similar engineering problems) on YouTube. They can do better!

 

[RTM]

Mine is better, no battery, so pull start.

Or wait, is that better?

 

[Fodeman]

I've got both, but my pulling arm ain't what it used to be, pal.

 

[redmondjp]

Buy a black plastic battery box (as used on many trailer tongues for the emergency braking application battery), and some longer pieces of 6-gauge wire and make a remote battery box for your unit so you have ready access to the battery without having to take anything apart.

Google "Group U1 battery box" and you will see what I am talking about.

 

[Fodeman]

Buy a black plastic battery box (as used on many trailer tongues for the emergency braking application battery), and some longer pieces of 6-gauge wire and make a remote battery box for your unit so you have ready access to the battery without having to take anything apart.

Google "Group U1 battery box" and you will see what I am talking about.

I've already got it fixed. All I have to do now is loosen the nuts on the longer bolts and drop the tray (see last pic with the bolts and nuts circled) so the tray lip clears the bottom of the battery. A separate battery box would just be something else to haul around with the generator.