DP2 OPERATION & MAINTENANCE REPAIR PARTS LIST BJC-12-60 AND BJC-12-75 12 VOLT BATTERY CHARGERS [BJC-1260]
Written by Nash Bernardo
Updated at November 1st, 2024
OPERATION & MAINTENANCE
REPAIR PART LIST
BJC-12-60 AND BJC-12-75
12 VOLT BATTERY CHARGERS
FIGURE 1-1. BJC BATTERY CHARGER
SECTION I
INTRODUCTION
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1-1. GENERAL. 1-2. The data and instruction in this manual pertain to Model BAJ-60 Battery Charger, manufactured by the Big Joe Manufacturing Company, 7225 North Kostner Avenue, Chicago, Illinois 60646. 1-3. Proper industrial battery care requires that batteries be maintained at full charge. Generally, a lift truck battery should be recharge at the end of each work day. BJC chargers provide fully automatic recharging and shut odd operation for convenient overnight service. 1-4. DESCRIPTION. 1-5. Battery Charger Models BJC-12-60 and BJC-12-75 (figure 1-1) are self-contained units designed to charge 12-volt batteries automatically. 1-6. The table of specifications is a quick reference list of input power requirements, output power ratings, special features and physical characteristics, The data in this table is supplemented by the text in the operation section of this manual. 1-7. A timer On-OFF switch mounted on the front panel is the only manual control. An ammeter that indicates the charging current flow, a data plate, and the ac input fuse are also mounted on the front panel. The data splate includes condensed operating instructions. The ac line cord and dc output cable extend from the front panel. 1-8. ORDERING REPAIR PARTS. 1-9. When ordering repair parts always specify the model and serial numbers of the battery charger as well as the |
proper part number and part name as selected from the repair parts list. The model serial number are given on the front plate. 1-10. PRINCIPLES OF OPERATION. 1-11. BJC Series Battery Chargers convert ac power into direct current suitable for charging 12-volt batteries. They automatically vary the rate of charge (ampere-hour) to suit the initial condition (degree of discharge) of the battery and the change in condition throughout the charging cycle. For a slightly discharged battery the initial charge current is low and continues at a low level. For a battery low state of charge the initial charge current is high and gradually decrease as the battery approaches full charge. The BJC supplies a low current finishing rate continuously to the battery until is shut off by the automatic timer or manually turn off. 1-12. The dc output voltage is approximately 15.0 V. This output is shunted by the battery being charged and the BJC regulator circuit. As the battery approaches full charge the regulator circuit decrease the output current of the BJC and continues this reduction until the final or “finishing” rate is achieved. 1-13 The charging current flow is indicated on the ammeter (1, figure 1-1) during the charging cycle. Since the charging current is inversely proportional to the charge held by the battery, the ammeter gives an indication of the battery state of charge (low meter reading-high charge and vice versa). The BJC-12-60 completely charges a 12-volt, 360-ampere-hour industrial battery in approximately eight hours. The BJC-12-75 completely charges a 12-volt, 510-ampere-hour industrial battery in eight hours. |
Table of Specifications
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|
BJC-12-60 |
BJC-12-75 |
|
Power input (Standard)* |
115 Vac, single phase, 60 Hz, 14 A |
11 Vac, single phase, 60 Hz, 17 A |
|
Power output |
900 W (15.0 Vdc, 60 A) |
1125 W (15 Vdc, 75 A) |
|
Safety features |
|
|
|
Fuse |
20 A |
30 A |
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Circuit breaker |
Reversed polarity (break) |
Reversed polarity (break) |
|
Cooling |
Convection |
Convection |
|
Dimensions |
8-1/2in. deep |
10 in. deep |
|
|
10-/8in. wide |
12 in. wide |
|
|
13in. high |
15 in. high |
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Weight |
44 lb. |
55 ib. |
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*Other inputs optional. See data plates on charger. | ||
SECTION II
OPERATION AND MAINTENACE
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2-1. INSTALLATION. 2-2. Installation of a BJC Charger consists of providing a proper ac power source and selecting proper location. Even though the charger is portable, a permanent location for operation is strongly recommended. In this permanent location. In this permanent location insure enough room to bring in lift truck. 2-3. Always set the BJC 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 BJC may be made accessible by keeping it on a sturdy, roller-type stand. 2-4. for general safety, do not place charger on the floor. When the equipment is in use, make sure that the ac line cord (3, figure 1-1) and dc output cable (5, figure 1-1) do not obstruct traffic. 2-5. PRE- OPERATING PROCEDURE. a. Open cover on battery case and remove vent caps from battery. b. Check tjat 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 of 1250 or less. 2-6 OPERATING PROCEDURE. 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 especially when charging. To avoid accumulation of gas, be sure batteries are charged in a well ventilated area. b. Disconnect the battery from the lift struck electrical system at the dc connector. c. Turn the BJC timer ON-OFF switch (2, figure 1-1) to OFF, and check that the ac line cord is not connected to power. NOTE Reverse polarity connection activates the circuit breaker and prevents the BJC from operating. d. Connect the battery dc connector to the charger dc connector (4, figure 1-1) being careful to match polarity. CAUTION: Improper ac power can damage BJC Charger. e. Consult data plate on charger to verify ac input power requirement. WARNING: An ungrounded or improperly grounded ac power source can cause severe electrical shock to the user. f. Connect the ac line cord (3, figure 1-1) into a properly grounded ac power source. g. Check that there is no open flame or electrical spark in the area. h. Turn the timer ON-OFF switch (2, figure 1-1) to the ON position. |
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NOTE: The BJC Charger will shut off automatically after the completion of the timer cycle. If battery must be placed in use prior to completion of timer cycle, advance the timer ON-OFF knob in a counterclockwise direction to shut off the charger. This is not a recommended procedure in that a full state of charge may not have been reached. 2-7. SHUT DOWN PROCEDURE. NOTE: If the BJC has completed its full cycle as controlled by the timer, the timer ON-OFF switch will be in the OFF position. a. If the charger has not completed its full cycle, turn the timer ON-OFF switch to OFF. b. Disconnect the ac line cord from the power source. c. Disconnect the dc output cable from the battery. d. Removed each battery cell vent cap and check the fluid level. CAUTION: Impurities in tap water will damage battery plates. e. 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. |
f. Replace the battery cell vent caps.
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Troubleshooting Guide
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SYMPTOM |
POSSIBLE CAUSE |
PROCEDURE |
|
Ammeter indicates no current flow |
1. Circuit breaker open |
Reverse polarity of dc connection to battery. |
|
2. No power at source |
a. Check that ac line cord is plugged in properly. |
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|
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b. Check that power is on at source. |
|
|
3. Blown fuse |
Replace fuse |
|
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4. Defective component such as ac line cord, dc output cable, ammeter, circuit breaker, or timer. |
Replace defective component. |
|
|
Ammeter indicates low current flow. |
1. Fully charged battery |
Disconnect charger, if desired. |
|
2. Low charger output (refer to para 2-14) |
Replace automatic regulator. |
|
|
Ammeter indicates excessive current and current does not decrease |
Defective regulator circuit or reactor |
Replace automatic regulator or reactor |
|
Ammeter indicates current flow after the 14 hour operating period. |
Defective timer. |
Replace timer. |
Figure 2-1 BJC Schematic Diagram.
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2-13. CHECKOUT PROCEDURE. 2-14. After the equipment is repaired it is advisable to check that the output is satisfactory. a. Check that the charger is not connected to a power source and that the timer ON-OFF switch is OFF. b. Connect a dummy load resistor (0.284 ohm, 1 kW for BJC-12-60 and 0.218 ohm, 1 kW for BJC-12-75) across the dc output connector. CAUTION: Improper ac power can damage BJC charger. c. Consult data plate on charger to verify ac input power requirement. |
WARNING: An undergrounded or improperly grounded ac power source can cause severe electrical shock to user. d. Connect the ac line cord to a properly grounded ac power source. e Turn the timer ON-OFF switch to ON. f. Note that ammeter should read approximately 60 A for BJC-12-60 or 75 A for BJC-12-75. g. Turn the timer ON-OFF switch to OFF. h. Disconnect the ac line cord from the power source. i Remove the dummy load. |
SECTION III
REPAIR PARTS
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3-1. PARTS IDENTIFICATION. 3-2. The part list and illustration (firgure3-1) identify replaceable parts. The callouts on the illustration correspond to the index numbers in the part list. By visually comparing the part in the illustration with the part in the equipment errors in ordering can be minimized. 3-3. The REPAIR PARTS LIST include the Big Joe part number to facilitate ordering. The COMMERCIALLY AVAILABLE HARDWARE list includes sufficient description to select replacements from your supplies or to purchase replacements locally. The PARTS NOT NORMALLY |
FURNISHED FOR REPAIR list includes those parts which are not likely to require replacement, but if needed can be ordered by description and figure and index number.
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SERIAL NO,2825 AND LOWER
FIGURE 3-1. (For chargers with Serial numbers 2825 and lower. See page 6 for Serial numbers 2826 and higher.)
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BJC-12-60 REPAIR PARTS |
BJC-12-75 REPAIR PARTS |
||||||
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INDEX NO. |
PART NO. |
PART NAME |
NO. REQD |
INDEX NO. |
PART NO. |
PART NAME |
NO. REQD |
|
|
004927 |
BJC-12-60 Battery Charger |
1 |
|
004928 |
BJC-12-75 Battery Charger |
1 |
|
1 |
021806 |
Transformer |
1 |
1 |
900245 |
Transformer
|
1 |
|
2 |
018364 |
Reactor |
1 |
2 |
900246 |
Reactor
|
1 |
|
3 |
005002 |
Circuit Breaker |
1 |
3 |
900248 |
Circuit Breaker
|
1 |
|
4 |
900242 |
Timer (Includes Knob) |
1 |
4 |
900242 |
Timer (Includes Knob)
|
1 |
|
5 |
005805 |
Ac Cord with Plug |
1 |
5 |
005805 |
Ac Cord with Plug
|
1 |
|
6 |
009501 |
Fuse Holder (includes Caps) |
1 |
6 |
009501 |
Fuse Holder (includes Caps)
|
1 |
|
7 |
008914 |
Fuse, 20 A. |
1 |
7 |
900249 |
Fuse, 30 A.
|
1 |
|
8 |
013813 |
Pilot Light |
1 |
8 |
013813 |
Pilot Light
|
1 |
|
9 |
005804 |
Dc Cable, 72 in. |
2 |
9 |
005804 |
Dc Cable, 72 in.
|
2 |
|
10 |
005421 |
Dc Connector |
1 |
10 |
005421 |
Dc Connector
|
1 |
|
11 |
900242 |
Ammeter |
1 |
11 |
900247 |
Ammeter
|
1 |
|
12 |
900243 |
Rubber Mounting Feet |
4 |
12 |
900243 |
Rubber Mounting Feet
|
4 |
|
13 |
018361 |
Diode |
2 |
13 |
900250 |
Diode
|
2 |
|
14 |
018362 |
Regulator Circuit Board |
1 |
14 |
018362 |
Regulator Circuit Board
|
1 |
|
15 |
900244 |
Handle |
2 |
15 |
900244 |
Handle
|
2 |
|
COMMERCIALLY AVAILABLE HARDWARE |
PARTS NOT NORMALLY FURNISHED FOR REPAIR |
||||||
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INDEXNO. |
PART NAME |
NO. REQD |
INDEX NO. |
PART NAME |
NO. REQD |
||
|
16 |
Round Head Machine Screw, 10-32x1/2 |
18 |
23 |
Cabinet |
1 |
||
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17 |
Nut, Assembled Washer, 10-32 |
21 |
24 |
Timer Decal |
1 |
||
|
18 |
Flat Washer, No. 10 |
8 |
25 |
Data Plate |
1 |
||
|
19 |
Round Head Machine Screw, 10-32x3/4 |
6 |
26 |
Strain Relief Bushing (AC Cord) |
1 |
||
|
20 |
Round Head Machine Screw, 6-32x1/2 |
8 |
27 |
Strain Relief Bushing (Dc Cables) |
2 |
||
|
21 |
Nut, Assembled Washer, 6-32 |
8 |
28 |
Plastic Standoff |
4 |
||
|
22 |
Sheet Metal Screw, No 6x3/8 |
10 |
29 |
Heatsink |
2 |
||
|
|
|
|
30 |
Heatsink Insulator |
8 |
||
SERIAL NO. 2826 AND HIGHER
Figure 3-1. (For battery chargers with Serial numbers 2826 and higher. See page 5 for Serial numbers 2825 and lower)
|
BJC-12-60 REPAIR PARTS |
COMMERCIALLY AVAILABLE HARDWARE |
|||||
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INDEX NO. |
PART NO. |
PART NAME |
NO. REQD |
INDEX NO. |
PART NAME |
NO. REQD |
|
|
004927 |
BJC-12-60 BATTERY CHARGER |
1 |
16 |
Flat Head Machine Screw, 10-32 x 3/8 |
8 |
|
1 |
900325 |
Transformer |
1 |
17 |
Nut, 10-32 |
14 |
|
2 |
900329 |
Reactor |
1 |
18 |
Star Washer, No. 10 |
14 |
|
3 |
005002 |
Circuit Breaker |
1 |
19 |
Round Head Machine Screw, 10-32 x 3/4 |
4 |
|
4 |
900242 |
Timer (Includes Knob) |
1 |
20 |
Round Head Machine Screw, 8-32 x 5/8 |
8 |
|
5 |
005805 |
Ac Cord with Plug |
1 |
21 |
Round Head Machine Screw, 6-32 x 1/2
|
8 |
|
6 |
009501 |
Fuse Holder (includes Caps) |
1 |
22 |
Star Washer, No.6 |
8 |
|
7 |
008914 |
Fuse, 20 A |
1 |
23 |
Nut, 6-32 |
8 |
|
8 |
900326 |
Pilot Light |
1 |
24 |
Round Head Machine Screw, 10-32 x 3/8 |
6 |
|
9 |
005421 |
Dc Cable, 72 in. |
2 |
25 |
Round Head Machine Screw, ¼-20 x 1/2 |
4 |
|
10 |
005421 |
Dc Connector |
1 |
26 |
Nut, ¼-20 |
|
|
11 |
90024 |
Ammeter |
1 |
27 |
Star Washer, 1/4 |
|
|
12 |
900327 |
Rubber Mounting Feet |
4 |
28 |
Sheet Metal Screw, No. 8 x3/8 |
|
|
13 |
018361 |
Diode |
2 |
|
|
|
|
14 |
900343 |
Regulator Circuit Board |
1 |
PARTS NOT NORMALLY FURNISH FOR REPAIR |
||
|
15 |
900328 |
Handle |
2 |
INDEXNO. |
PART NAME |
NO.REQD |
|
|
29 |
Cabinet |
1 |
|||
|
30 |
Timer Decal |
1 |
||||
|
31 |
Data Plate |
1 |
||||
|
32 |
Strain Relief Bushing (Ac Cord) |
1 |
||||
|
33 |
Strain Relief Bushing (Dc Cable) |
2 |
||||
|
34 |
Heatsink |
2 |
||||
|
35 |
Heatsink Insulator |
16 |
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