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Old 01-23-2020, 12:31 AM   #1
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Onan generator battery terminal sheared

While at Quartzsite, one item on my to-do list was to check the battery terminal connections on the rear panel of my 10kw generator. I turned off both the chassis battery and house battery master switches and I pulled at the gen. Crawled underneath and removed the cables to clean and burnish them with a wire brush. In the process of reinstalling them, the negative/ground stud sheared off about half way up the bolt. Dang! Removed one of the washers to expose enough thread to secure the cable. Has anyone had to replace the terminal block before? The part is available and reasonably priced, but some folks say the entire generator has to be removed in order to access the back of the terminal block. That would really be an extra layer of difficulty for me. Any ideas?
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Old 01-23-2020, 09:21 AM   #2
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Is there a nut under the cable as well . You may be able to remove some material off that nut for a bit more threads . The gamble is to get it loosened stud/bolt ,back together.and tightened again if it normally would need a back up wrench A small impact like 1/4 3/8 battery driver/impact may help to accomplish it if the bolt/stud wants to spin on you. It may not spin and be a captured or double butted in side the cabinet. Nuts also have a bit of a starter thread indent area that doesn't actually grab/engage threads that you may remove off cable side off the outer nut . You would need to clean the nuts threads with tap or steel bolt and not snap it off or again . You only need as much threads as to get nut torqued to properly. Good luck I kinda figure at least one of the nuts is thin\jam nut as well if not all the better .
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Old 02-12-2020, 05:40 PM   #3
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Those battery studs are copper based, never put an impact on them or even a 3/8 drive. Very low torque or you can twist them right off.

The rear panel must be removed to replace, not a huge deal beyond that.
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Old 02-12-2020, 05:55 PM   #4
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...not sure what the differences might be between the 7.5k and the 10k gensets when it come to removing the back panel to get at the bat studs....there is also a suppressor module mounted behind one of the studs on the 7.5 to reduce static feedback in the 12v systems--think dash radio???? Depending on how the genset is mounded in the RV [eg on a slide vs fixed position] removing the back panel could be a challenge….assuming the genset stud is SAE thread, an option I have used to extend the threaded studs on batteries is to use an "all-thread" connector and a short piece of all-thread to create a new stud....
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Old 02-17-2020, 08:38 AM   #5
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Ace Hardware...extension nut to use the broken stud, then a bolt to attach cable. Mine's been on that way for a long time.
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Old 02-17-2020, 09:47 AM   #6
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They also make what's called a half nut....
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