1-1. GENERAL
1-2 The data and instructions in this manual pertain to BJC Automatic Smart Battery Chargers, manufactured by the Big Joe Manufacturing Company, 7225 North Kostner Avenue, Chicago, Illinois 60646. The battery charger is shown in Figure 1-1
1-3. Proper industrial battery care requires that batteries be maintained at full charge. Generally, a lift

Figure 1-1. Battery Charger.

Figure 1-2 Battery Charger Status Lights.

c. Abnormal Cycle Indicator. Aback-up auto reset 16 hour timer is added to indicate an “abnormal cycle”.. This would occur if the batteries are too large for the charger or if the control circuit failed. In either case, the charge cycle will terminate and the ABNORMAL CYCLE light will come on.
e. 80% Charge Indicator. When the battery is gassing and approximately 80% charged, the 80% CHARGED light will come on.
f. Discharged Indicator. When the battery has not accepted a charge from the BJC Battery Charger, the DISCHARGED light will come on indicating a bad battery.
2-1. INSTALLATION.
2-2.Installation of a 'Smart" Charger consists of providing a proper AC power source and selecting a proper location. Even though the charger is portable, a permanent location for operation is strongly recommended. The permanent location must have enough room to bring in equipment for charging.
2-3. Always set the charger on a flat, Hard surface to insure proper air circulation under and around it. The area must be well ventilated, because explosive hydrogen gas is generated while charging batteries. Exercise caution to avoid possible open flame or electrical sparks near the area of operation. If the charger storage area is not suitable for operation, the charger

may be made accessible by keeping it on a sturdy. roller-type stand.
2-4. For general Safety. do not place the charger on the floor. When the equipment is not in use, make sure that the AC line cable and DC output cables do not obstruct traffic.
2-5. PRE-OPERATING PROCEDURE.
a. Open cover on battery case and remove vent caps from battery.
b. Check that each vent cap is clean and that each vent hole is open.
CAUTION:
Impurities in tap water will damage battery plates.

c. Check fluid level in each cell and, if necessary, add enough filtered or distilled water to cover the battery plates but do not allow fluid to rise into the cell filler necks.

d. Check the specific gravity of each cell to determine the need for charging.
e. Recharge the battery if any cell indicates a reading 1.250 or less.
f. Install vent caps on battery and close cover on battery case.
2-6 OPERATING PORCEDURE. 
a. Make sure the pre-operating procedure has been performed (para 2-5).
WARNING:
Hydrogen gas, formed while charging, is explosive. Avoid open flame or electrical spark near battery. To avoid accumulation of gas, be sure batteries are charged in a wll ventilated area.
b. Check that there is no open flame or electrical spark in the area.
CAUTION:
Improper AC power can damage the charger.
c. Consult data plate on the charger to veiriy AC input power requirement.
WARNING:
An ungrounded or improperly grounded AC power source can cause severe electrical shock to the user.
 

d. Connect the AC line cord into a properly grounded AC power source.
e. Disconnect the battery from the electrical system at the DC connector.
NOTE: Reverse polarity connection activates the circuit breaker and prevents the charger from operating.

f. Connect the battery DC connector to the charger DC connector, being careful to match polarity. All 5 indicator lights will flash 2 times, then each light will flash once, checking AC power. All 5 lights will then flash again and each light will flash once checking DC power connection. When the indicator light self-test sequence is complete there is a 5 second delay and the charger turns on. If this sequence does not occur, see TROUBLESHOOTING GUIDE. Charger should shut off in approximately 2 hours.
g. After the charge is complete, disconnect the DC connector from the battery. If the charge cycle needs to be interrupted, use STOP button to turn the charger off.

h. Disconnect the AC line cord from the power source.
i. Remove each battery cell vent cap and check the fluid level.
CAUTION:
Impurities in tap water will damage battery plates.

j. Add, if necessary, enough filtered or distilled water to each cell to cover the battery plates, but not enough to allow fluid to rise into the cell filler neck.
k. Replace the battery cell vent cpas.
l. Reconnect the battery to the lift truck electrical system.
3-1. PARTS IDENTIFICATION.
3-2. The parts list and illustrations (Figure 3-1) identify replaceable parts. The callouts on the illustration correspond to the index numbers in the parts list. By visually comparing the part in the illustration with the part in the equipment, errors in ordering can be minimized.
3-3. ORDERING PARTS.
3-4. When ordering parts, be sure to include all of the following:
a. Battery Charger Model No. (See data plate.)

b. Battery Charger Serial No. (See data plate.)

c. Battery Charger Spec. No. (See data plate.)
d. Big Joe part number.
e. Part name.
f. Quantity of parts required.