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Kohler GM96386-KA1 - User Manual

Kohler GM96386-KA1
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TT-1702 10/16
INSTALLATION INSTRUCTIONS
Original Issue Date:
10/16
Model:
Generator Sets
Market:
Industrial 15-500 kW
Subject:
6 Amp, 12/24 Volt Battery Charger Kits
1 Introduction
The battery charger is designed to both recharge your batteries and extend your battery’s life in applications where it is
stored for long periods of time. The charger is a multi-stage, completely automatic, lightweight, silent battery charger.
The charger produces an output of 12 Volts DC at a full 6 Amps, while using much less AC current than
other charger
types. When the charger is attached to your battery and plugged into a 115 Volt / 60 Hz AC outlet, the red and green
LEDs let you know the unit is
recharging and maintaining your batteries. Use this battery charger to charge lead acid
flooded, gel, or AGM type 12-volt batteries only. 24-volt battery charger kits include two 12-volt battery chargers.
Save these Instructions
This manual contains important safety and operating instructions for the chargers. Read the entire manual before using.
Also read all instructions and cautions for and on the charger, batteries, and equipment in the vicinity of the batteries.
Battery charger kits covered in this document are listed below. Kits include mounting brackets and hardware for specific
generator set models as shown in the parts lists.
Kit Numbe
r
Description Kit Numbe
r
Description
GM96386-KA1 Battery Charger 12V, 6A GM96390-KP1 Battery Charger 24V, 6A
GM96386-KA4 Battery Charger 24V, 6A GM96391-KA1 Battery Charger 12V, 6A
GM96386-KA5 Battery Charger 12V, 6A GM96391-KA2 Battery Charger 24V, 6A
GM96386-KP2 Battery Charger 24V, 6A GM96391-KA3 Battery Charger 24V, 6A
GM96386-KP4 Battery Charger 12V, 6A GM96391-KP1 Battery Charger 12V, 6A
GM96387-KP1 Battery Charger 12V, 6A GM96391-KP2 Battery Charger 24V, 6A
GM96388-KA1 Battery Charger 12V, 6A GM96391-KP3 Battery Charger 24V, 6A
GM96388-KP1 Battery Charger 12V, 6A GM96392-KP1 Battery Charger 24V, 6A
GM96389-KA1 Battery Charger 12V, 6A GM96392-KP2 Battery Charger 24V, 6A
GM96389-KP1 Battery Charger 12V, 6A GM96395-KA1 Battery Charger 12V, 6A
GM96389-KA2 Battery Charger 24V, 6A GM96395-KA3 Battery Charger 24V, 6A
GM96389-KP2 Battery Charger 24V, 6A GM96404-KP1 Battery Charger 12V, 6A
GM96390-KA1 Battery Charger 24V, 6A
Figure 1 Battery Charger Kits
Figure 2 Battery Charger, 6 Amp, GM96383

Table of Contents

Questions and Answers

  • S
    Susan BakerAug 3, 2025
    Why do the red and green LEDs stay on for more than 24 hours on my Kohler GM96386-KA1?
    • B
      Brenda CaldwellAug 3, 2025
      If the red and green LEDs on your Kohler Battery Charger stay on for more than 24 hours, it could be due to several reasons. First, excessive DC equipment might be drawing more than 2 amps; try turning off all unnecessary DC equipment while charging. Second, there may be faulty or damaged cells in the battery, requiring a load test and potential replacement. Finally, extremely low AC voltage at the charger could be the issue; try applying a higher AC voltage source or reducing the length of any extension cord being used.
  • N
    Nicholas IbarraAug 9, 2025
    Why does the red LED stay on for more than 24 hours on my Kohler GM96386-KA1 Battery Charger?
    • C
      charles91Aug 9, 2025
      If the red LED on your Kohler Battery Charger stays on for more than 24 hours, it could be due to a few reasons. One possibility is that one or more cells in the battery are faulty or damaged, necessitating a load test and potential replacement. Another reason could be that the charger has reduced its output voltage due to a DC overload or short; in this case, remove the source of the overload or short, disconnect the charger's black (NEGATIVE) terminal from the battery, reapply AC power, and check if only the green LED lights up. Lastly, on-board DC systems might be drawing more current than the charger can replace; try turning off all DC equipment while charging.
  • D
    Denise GallowayAug 15, 2025
    What to do if the green LED stays on when the battery is low on my Kohler GM96386-KA1?
    • R
      Rachael WilliamsAug 15, 2025
      If the green LED stays on when the battery is known to be low in your Kohler Battery Charger, there are several potential causes. First, check the DC output fuse and replace it with a 10 amp fuse if it's open. Second, inspect the terminal connections for faults or contamination; clean, tighten, or repair them as needed. Lastly, the battery may have one or more faulty or damaged cells, which would require a load test and replacement if necessary.
  • T
    Todd AustinAug 21, 2025
    Why are the red and green LEDs flashing on my Kohler GM96386-KA1 Battery Charger?
    • A
      Anna MartinAug 21, 2025
      If the red and green LEDs are flashing on your Kohler Battery Charger, it indicates that the charger is unable to charge the battery. Check if the battery is too large for the charger or if there is an issue with the battery itself. To attempt a reset, unplug the charger from the AC power and then plug it back in to restart the charging process.
  • A
    Abigail HarrisAug 27, 2025
    How to fix neither of the LEDs turn on when the AC power is applied to my Kohler GM96386-KA1?
    • G
      Gina SmithAug 27, 2025
      If neither of the LEDs turn on when AC power is applied to your Kohler Battery Charger, the issue could stem from two primary causes. First, there might be no AC power reaching the charger; in this case, clean, tighten, or repair all terminal connections to ensure a proper power supply. Second, a component failure within the charger could be the reason; consider performing a load test on the battery and replace if necessary.

Summary

Introduction

Safety Precautions

Accidental Starting

Precautions to prevent accidental starting of the generator set during maintenance or servicing.

Explosion Hazard

Warning about using the charger only for specific battery types to prevent explosion.

Battery Acid Handling

Protective measures and first aid for handling battery acid to prevent injury.

Battery Gas Safety

Precautions against battery gas explosion and static discharge risks.

Hazardous Voltage

Warning about electrical shock from ungrounded chargers and GFCI protection.

Battery Short Circuits

Risks associated with battery short circuits and proper disconnection procedures.

Important Safety Instructions

General safety guidelines for using attachments, extension cords, and handling the charger.

Installation Instructions

Location

Guidelines for selecting an appropriate and safe location for the battery charger.

Mounting

Instructions on how to securely mount the battery charger using provided hardware.

DC Connection

Procedure for correctly connecting the battery charger to the battery terminals.

Connection Diagram

Illustrates the correct wiring for 12V and 24V battery systems.

Operation

Charge Cycle

Details the stages of the battery charging cycle: Soft Start, Bulk, Absorption, Float, Maintenance.

LED Indicators

Explains the meaning of the RED and GREEN LEDs during charger operation.

Specifications

Troubleshooting

Kohler GM96386-KA1 Specifications

General IconGeneral
Voltage12V
Input Voltage120V AC
Output Voltage12V DC
Compatible Battery TypesFlooded, AGM, Gel
Charging Stages3 Stage
Protection FeaturesReverse Polarity Protection, Overcharge Protection, Short Circuit Protection