The battery charger is designed t o both r echa rge your ba tter ies and exten d 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 re d 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.
Disabling the generator set. Accidental starting can cause severe injur y or death.
equipment connected to the set, disable the generator set as follows: (1) Move the generator set master switch to the OFF
position. (2) Disconnect the power to the battery charger. (3) Remove the battery cables, negative (-) lead first. Reconnect the
negative (-) lead last when reconnecting the battery. Follow these precautions to prevent starting of the generator set by an
automatic transfer switch, remote start/stop switch, or engine start command from a remote computer.
(Decision-Maker® 3+ and 550 Controllers)
Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables before working on the generator set. Remove the
negative (–) lead first when disconnecting the battery. Reconnect the negative (–) lead
last when reconnecting the battery.
Before working on the generator set or
Disabling the generator set. Accidental starting can cause severe injur y or death.
Before working on the generator set or
equipment connected to the set, disable the generator set as follows: (1) Press the generator set off/reset button to shut down
the generator set. (2) Disconnect the power to the battery charger, if equipped. (3) Remove the battery cables, negative (-)
lead first. Reconnect the negative (-) lead last when reconnecting the battery. Follow these precautions to prevent the starting
of the generator set by the remote start/stop switch.
(RDC, DC, RDC2, DC2, Decision-Maker® 3000, 3500, and 6000 Controllers)
WARNING
Explosion.
Can cause severe injury or death.
Use this battery charger to charge lead acid flooded, gel, or AGM type batteries only.
WARNING
Sulfuric acid in batteries.
Can cause severe injury or death.
Wear protective goggles and clothing. Battery acid may cause blindness and burn skin.
Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death.
Battery acid can cause
blindness and burn skin. Always wear splashproof safety goggles, rubber gloves, and bo ots when servicing the battery. Do not
open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the
affected area for 15 minutes with large quantities of clean water. Seek immediate medical aid in the case of eye contact. Never
add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid.
Battery acid cleanup. Battery acid can cause severe injury or death.
Battery acid is electrically conductive and corrosive.
Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a container with 4 L (1 gal.) of water and mix the neutralizing so lution.
Pour the neutralizing solution on the spilled battery acid and continue to add the n eutral izing solution to the spilled battery acid
until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area.
2 TT-1702 10/16
Page 3
WARNING
Explosion.
Can cause severe injury or death.
Relays in the battery charger cause arcs or sparks.
Locate the battery in a well‐ventilated area. Isolate the battery charger from explosive
fumes.
Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or
permit flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a
fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal
objects. Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching
batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger
connections while the battery is charging. Always turn the battery charger off before disconnecting the battery connections.
Ventilate the compartments containing batteries to prevent accumulation of explosive gases.
WARNING
Hazardous voltage.
Can cause severe personal injury or death.
An ungrounded battery charger may cause electrical shock. Do not operate this
battery charger with a two-blade adapter plug or extension cord. After securing the
battery connections, plug the AC line cord into an AC outlet that is protected by a
ground fault circuit interrupter (GFCI) breaker.
Battery short circuits. Explosion can cause severe injury or death. Short circuits can cause bodily injury and/or equipment
damage. Disconnect the battery before generator set installation or maintenance. Remove all jewelry before servicing the
equipment. Use tools with insulated handles. Remove the negative (–) lead first when disconnecting the battery. Reconnect
the negative (–) lead last when reconnecting the battery. Never connect the negative (–) battery cable to the positive (+)
connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together.
2.1 Important Safety Instructions
Use of an attachment or spare part not recommended or provided by Kohler Co. may result in a risk of fire, electric
shock, or personal injury.
1.
To reduce the risk of damage to electric plug and cord , p ull b y plug rather than cord when disconnecting the
chargers.
2. Do not use an extension cord
risk of fire and electric shock. If an extension cord must be used, make sure:
unless absolutely necessary. Use of an improper extension cord could result in a
o
That pins on the plug of t h e extension cord are the same number, size and shape as those of the plug
on the charger;
o
That the extension cord is properly wired and in good elec trical condition; and
That the cord’s wire size is large enough for AC ampere r ating o f the char ger as s pecif ied below:
o
Cord Length 7.6 m (25 ft.) 15.2 m (50 ft.) 30.5 m (100 ft.)
Cable Size
18 AWG
16 AWG
14 AWG
3. Do not operate the charger with a damaged cord or plug – replace the cord or plug immediately.
4. Do not operate the charger if it has received a sharp blow, been dropped, or otherwise damaged in any way.
5. Do not attempt to disassemble the charger.
6. To reduce the risk of injury, unplug the charger from the outlet before attempting any maintenance or cleaning.
Turning off controls alone will not reduce the risk.
7. Do not expose the charger to rain or snow.
2.2 Personal Safety
Adhere to the following personal safety precautions when installing or working with the battery chargers:
Someone should be within voice range or close enough to come to your aid when you work near a lead-acid battery.
Have plenty of fresh water and soap n earby in case battery acid contacts skin, clothing, or eyes.
Wear complete eye protection and clothing protection. Avoid touchi ng your eyes while working near a battery.
If battery acid contacts your skin or clothing, wash immediately with soap and water. If acid enters the eye, flood the
eye with cold, running water for at least ten minutes and get medical attention.
Never smoke or allow an open flame in the vicinity of the battery.
Do not drop a metal tool onto the battery. It may spark, short circuit the battery, and may cause an explosion.
Remove all metal personal item s such as rings, bracelets, necklaces, and watches when working near a lead-acid
battery. A battery can produce short circuit currents high enough to weld a ring or other metal object to metal, causing
a severe burn.
Excessive battery discharge and/or hig h ch arging voltages can cause serious damage to batteries. Do not exceed the
recommended limits of discharge level of your batteries.
TT-1702 10/16 3
Page 4
2.3 Preparing to Charge
Before charging a battery with the battery charger, read the following precautions:
1. Do NOT operate the battery charger if the input or output cables or an LED is damaged or defective.
2. Make sure all accessories connected to the batteries you are charging are OFF.
3. If the battery or batteries must be removed from the equipment, always remove the ground terminal from the battery
first.
4. Be sure the area around the battery is well ventilated while the battery is being charged. Gas can be effectively blo wn
away using a piece of card board or other non-metallic material as a hand fan.
5. Clean the battery terminals. Be careful to keep corrosion from coming in contact with your eyes.
6. For all batteries, carefully follow the manufacturer’s recharging instructions.
7. Never allow the ring terminals to touch each other.
8. Never charge a frozen battery.
3 Installation Instructions
3.1 Location
1.
The case of this charger will become warm during operation. Because the charger is convection cooled
(airflow over the back of the
its back on a horizontal surface may cause the charger t o slightly reduce amperage out put due to the thermal
protection built in. Do not install the charger on carpeted,
Locate the charger as far awa y from battery as DC cab les permit.
2.
3.
Never place the charger directly above the battery being charged; gases from the battery will corrode and
damage th e charger.
4.
Never allow battery acid to drip on t h e charger when reading electrolyte specifi c gravity or filling battery.
Do not operate t h e charger in a closed-in area or restrict ventilation in any wa y.
5.
6.
Do not set a battery on top of t h e charger.
3.2 Mounting
1. Refer to the installation drawings for recommended mounting locations.
2. Use the hardware provided with the kit, or use corrosion-resistant 3/16 in. dia. or #10 bolts, backed by a flat washer
and secured to the mounting surface with a split-ring lock washer.
3. Hold the charger to the mounting surface and mark the holes.
4. Remove the charger and drill the mounting holes.
5. Align the charger and assemble the mounting hardware. Secure the charger.
3.3 DC Connection
Connect one battery to one battery charger as shown in the connection diagrams. For 24 volt systems with two
batteries, two battery chargers are required.
Observe the following precautions when connecting and disconnecting the battery charger :
1.
Connect and disconnect DC output clips only after removing AC cord from electric outlet. Never allow the ring
terminals to touch each other.
2. Check polarity of the battery posts. The POSITIVE (POS., P, +) battery post usually has a larger diameter than the
NEGATIVE (NEG., N, –) post.
Connect the red charger output lead to the POSITIVE post. Connect the black charger lead to NEGATIVE. See
3.
the connection diagrams for more details.
Do not face the battery when making the final connection.
4.
5.
When disconnecting the charger, disconnec t the AC cord a nd then r emove the clips from
terminals.
charger), the optimum mounting position for the charger is vertical. Mounting on
upholstered, or varnished surfaces.
the
battery
4 TT-1702 10/16
Page 5
3.4 Installation Drawings
,
,
1
5
2
GM96386-KP2
3, 4
6
2
12 Volt Kit
2
3, 4
5
1
6
3
4
6
5
2
5
6
GM96386-KP4, 24 Volt Kit
1.Bracket, GM28557
2.Battery charger, GM96383
3.Screw, M6
4.Nut, M6
5.Connect ring terminals to battery
6.Plug AC cord into outlet (after connecting to battery)
Figure 3 Battery Charger Installation, GM96386-KP2 and GM96386-KP4
TT-1702 10/16 5
Page 6
View A-A
1
2, 3, 4
5
6, 7
8
1.Battery charger GM96383
2.Screw, M933-06020-60, qty. 4
3.Washer, M125A-06-80, qty. 4
4.Nut, M6923-06-80, qty. 4
5.Bracket, GM32862
6.Screw, M933-08020-60, qty. 2
7.Washer, M125A-08-80, qty. 2
8.Connect ring terminals to battery
9.Plug AC cord into outlet (after connecting to battery)
5.Plug AC cord into outlet (after connecting to the battery)
Figure 6 Battery Charger Installation, GM96389-KP1, 12 Volt Kit
5
8 TT-1702 10/16
Page 9
4, 5
1
2
1.Battery charger, GM96383, qty. 2
2.Plug AC cord into outlet (after connecting to the battery)
3.Connect ring terminals to battery
4.Washer, M125A-06-80, qty. 8
5.Screw, M933-06020-60, qty. 8
Figure 7 Battery Charger Installation, GM96389-KP2, 24 Volt Kit
3
TT-1702 10/16 9
Page 10
1, 2, 3
4
5
6
9
8
1.Washer, M125A-06-80, qty. 8
2.Nut, M6923-06-80, qty. 8
3.Screw, M933-06025-60, qty. 8
4.Bracket, GM78810, qty. 1
5.Battery charger, GM96383, qty. 2
6.Screw, M933-06025-60, qty. 4
7.Connect ring terminals to battery 2
8.Connect ring terminals to battery 1
9.Plug AC cord into outlet (after connecting to each battery)
Figure 8 Battery Charger Installation, GM96390-KP1, 24 Volt Kit
7
10 TT-1702 10/16
Page 11
1
2, 3
9
6
7, 8
4
GM96391-KP1, 12 Volt Kit
1.Battery charger, GM96383, qty. 1
2.Screw, M933-06020-60, qty.2
3.Nut, M6923-06-80, qty.2
4.Connect ring terminals to battery
5.Plug AC cord into outlet (after
connecting to battery)
5
10
11
GM96391-KP2 and -KP3, 24 Volt Kits
6.Battery charger, GM96383, qty. 2
7.Screw, M933-06020-60, qty.4
8.Nut, M6923-06-80, qty.4
9.Connect to battery 1
10. Connect ring terminals to battery 2
11. Plug AC cord into outlet(after
connecting to battery)
NOTE : For GM96391-KP2 kits, replace the
existing battery cable and boots with cable
X-545-65 and battery terminals 345039 and
345056.
Figure 9 Battery Charger Installation, GM96391-KP1, KP2, and KP3
TT-1702 10/16 11
Page 12
3.5 Connection Diagram
Two-Battery Connection, 24 Volt System
(requires two battery chargers)
Figure 10 Connection Diagrams, 12 Volt (one battery) and 24 Volt (two batteries) Systems
12 TT-1702 10/16
Page 13
4 Operation
4.1 Charge Cycle
1. Soft Start : The charger verifies connections are good and the battery is capable of accepting a charge. Batteries with
very low voltage will be charged slowly to not harm the battery. When the battery voltage reaches 10V for 30 seconds
the charger switches to the next stage.
2. Bulk Stage : The charger uses constant current and charges the battery to 14.3 volts. When the battery holds the
voltage of 14.3 volts for 30 seconds the charger switches to the next stage.
3. Absorption Stage : The charger uses constant voltage to charge the battery until the charge current drops. At this
point the charger will switch to the next stage.
4. Float Stage : The charger finishes the charge cycle by keeping the battery at 13.3 volts for a period of time and then
moves to the next stage.
5. Maintenance : The charger monitors the battery. If the battery voltage drops below 12.8 volts or if 14 days have
passed since the last charge, the charge cycle will start automatically.
4.2 LED Indicators
RED GREEN Condition
ON
ON
OFF
OFF
OFF
ON
ON
OFF
Charger is in the “Soft Start” or “Bulk Stage” and the battery is being charged. If the red
LED stays on for more than 24 hours refer to the troubleshooting section.
Charger is in the “Absorption Stage” and delivering constant voltage to the battery. If
the red and green light stay on for more than 24 hours refer to the troubleshooting
section.
The charger has moved to the “Float Stage” and is topping off the cha r ge to the battery
and keeping the battery ready to use. The green light indicates your battery is ready to
use. If the green light stays on when your battery is known to be low, refer to the
troubleshooting section.
No AC power to the charger, or component failure.
BLINKING
BLINKING Blinking LEDs indicate a fault.
Figure 11 LED Indicator Operation
5 Maintenance
Periodically clean both battery terminals with baking soda and tighten all connections. No other maintenance on the
charger is required.
6 FCC Class B EMC Notice
This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC
Rules. These limits are designed to provide reasonable protection against harmful interference in a commercial environment.
This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the
instructions, may cause harmful interference to radio communications. Operation of this equipment in a residential area is
likely to cause harmful interference, in which case the user will be required to correct the interference at their o wn expense.
If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the
equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:
- Reorient or relocate the receiving antenna.
- Increase the separation between the equipment and receiver.
- Connect the equipment into an outlet on a different circuit than the receiver.
Consult the dealer or an experienced radio/TV technician for help.
13.3 +/- 0.20 V per bank
6 amps
Any 12V lead-acid battery (Flooded, GEL and AGM)
Battery charger capacity
(based on 50% drained battery):
AC Cable Length:
DC Cable Length:
Fuse Size:
Protection Type:
Dimensions: (LxWxD)
Weight
Group 24 through 31
(up to 120 Amp-Hours)
1.8 m (6 ft.)
1.8 m (6 ft.)
10 amps
IP68 (casing)
89 x 198 x 58 mm
(3.5 x 6.4 x 2.3 in.)
1.8 kg (4.0 pounds)
8 Troubleshooting
Display Operating Condition Solution
Red LED stays on for
more than 24 hours.
The red and green
LEDs
stay on for
more than 24 hours.
Green LED stays on
when
the battery is
known to be low.
Neither of the LEDs
turn on when the AC
power is applied.
1. One or more faulty or damaged
cells.
2.
Charger has reduced its output
voltage below the normal level due
to a DC overload or a DC short.
3.
On-board DC systems are drawing
more current than the charger can
replace.
1.
On-board DC systems are drawing
more than 2 amps.
2. One or more faulty or damaged
cells.
3.
Extremely low AC voltage at the
battery charger.
1.
Open DC output fuse.
2.
Faulty or contaminated terminal
connections.
3.
One or more faulty or damaged
cells.
1.
No AC power available at the
charger.
Component failure.
2.
Load test the battery and replace if
1.
necessary.
Remove the source of the overload or
2.
short. Disconnect
(NEGATIVE)
Reapply AC power and the gree n LED only
should now light.
3.
Turn off all DC equipment while charging.
Turn off all excess DC equipment while
1.
charging.
Load test the battery and replace if
2.
necessary.
Apply a higher AC voltage source or reduce
3.
the length of the extension cord.
Check battery manufacturer’s specs on
4.
battery charging.
1.
Replace DC output fuse with a 10 amp
fuse.
Clean and tighten or repair all terminal
2.
connections.
Load test the battery and replace if
3.
necessary.
1.
Clean and tighten or repair all terminal
connections.
Load test the battery and replace if
2.
necessary.
the charger's black
terminal from the battery.
Red and green
are
flashing
14 TT-1702 10/16
LEDs
1.
Charger is not charging the battery.
1.
Charger cannot get the battery to charge.
Check to see if the
the
the battery. Unplug the
AC power to
battery is too large for
charger or if there is a problem with
charger from the
start the charger again.
Page 15
9 Parts List
Parts lists for field-installed loose battery charger kits are shown below. Factory-installed kits are not listed here.
Assembly drawing numbers are shown for reference only. See the installation drawings in Section 3.4.
KOHLER CO., Kohler, Wisconsin 53044 USA Kohler Power Systems
Phone 920‐457‐4441, Fax 920‐459‐1646 Asia Pacific Headquarters
For the nearest sales and service outlet in the 7 Jurong Pier Road
US and Canada, phone 1‐800‐544‐2444 Singapore 619159
KOHLERPower.com Phone (65) 6264‐6422, Fax (65) 6264‐6455
vailability is subject to change without notice. Kohler Co. reserves the
right to change the design or specifications without notice and without an
obligation or liability whatsoever. Contact your local Kohler® generator set
distributor for availability.