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Electric Pallet Jack (EPJ) Charger
(For 401586 models only)
Maintenance Manual
Page 1: ...Revision A July 2022 T TK K 5 56 69 91 17 7 1 11 1 M MM M E EN N Electric Pallet Jack EPJ Charger For 401586 models only Maintenance Manual ...
Page 2: ...ny y o ot th he er r d di ir re ec ct t i in nd di ir re ec ct t s sp pe ec ci ia al l o or r c co on ns se eq qu ue en nt ti ia al l d da am ma ag ge es s w wh ha at ts so oe ev ve er r a ar ri is si in ng g o ou ut t o of f t th he e u us se e o of f t th hi is s m ma an nu ua al l o or r a an ny y i in nf fo or rm ma at ti io on n r re ec co om mm me en nd da at ti io on ns s o or r d de es sc ...
Page 3: ... Note 401586 inverters are identified as being black in color not white For further information refer to Electronic Parts Catalog EPC The information in this manual is provided to assist owners operators and service people in understanding the operation as well as the proper upkeep and maintenance of the Thermo King EPJ charger I In nt tr ro od du uc ct ti io on n ...
Page 4: ...eral Description Gives an overview description of your EPJ Charger including standard and optional features illustrations and general information System Components Explains each EPJ Charger component location and function Operating Instructions Provides EPJ Charger operating instructions Power Inverter Overview Provides an overview of power inverter operation and features Diagnostic Procedures Pro...
Page 5: ... EPJ Charger Overview 14 Features 14 S Sy ys st te em m C Co om mp po on ne en nt ts s 1 15 5 Charger Enclosure 15 Power Inverter 15 DC Power Cables 15 DC Power Disconnect Switch 16 AC Output Power Cable 16 GFCI Outlet 16 O Op pe er ra at ti in ng g I In ns st tr ru uc ct ti io on ns s 1 17 7 Charging a EPJ 17 P Po ow we er r I In nv ve er rt te er r O Ov ve er rv vi ie ew w 1 18 8 Inverter Operat...
Page 6: ...val 30 Inverter Installation 31 Inverter Mode Settings 31 M Ma ai in nt te en na an nc ce e a an nd d I In ns sp pe ec ct ti io on n S Sc ch he ed du ul le e 3 32 2 Routine Service and Maintenance Information 32 P Po ow we er r I In nv ve er rt te er r D Di im me en ns si io on ns s 3 33 3 S Sc ch he em ma at ti ic c D Di ia ag gr ra am m 3 34 4 T Ta ab bl le e o of f C Co on nt te en nt ts s ...
Page 7: ...a at te e i in nj ju ur ry y a an nd d u un ns sa af fe e p pr ra ac ct ti ic ce es s N NO OT TI IC CE E H Ha az za ar rd d I In nd di ic ca at te es s a a s si it tu ua at ti io on n t th ha at t c co ou ul ld d r re es su ul lt t i in n e eq qu ui ip pm me en nt t o or r p pr ro op pe er rt ty y d da am ma ag ge e o on nl ly y a ac cc ci id de en nt ts s Electrical Hazards Danger D DA AN NG GE E...
Page 8: ...eq qu ui ir re em me en nt ts s f fo or r a ar rc c f fl la as sh h p pr ro ot te ec ct ti io on n P PR RI IO OR R t to o s se er rv vi ic ci in ng g t th he e u un ni it t N NE EV VE ER R P PE ER RF FO OR RM M A AN NY Y S SW WI IT TC CH HI IN NG G D DI IS SC CO ON NN NE EC CT TI IN NG G O OR R V VO OL LT TA AG GE E T TE ES ST TI IN NG G W WI IT TH HO OU UT T P PR RO OP PE ER R E EL LE EC CT TR RI...
Page 9: ...c ca an n b be e d da an ng ge er ro ou us s A A b ba at tt te er ry y c co on nt ta ai in ns s a a f fl la am mm ma ab bl le e g ga as s t th ha at t c ca an n i ig gn ni it te e o or r e ex xp pl lo od de e A A b ba at tt te er ry y s st to or re es s e en no ou ug gh h e el le ec ct tr ri ic ci it ty y t to o b bu ur rn n y yo ou u i if f i it t d di is sc ch ha ar rg ge es s q qu ui ic ck kl l...
Page 10: ... he e O OF FF F p po os si it ti io on n b be ef fo or re e c co on nn ne ec ct ti in ng g b ba at tt te er ry y c ca ab bl le es s t to o t th he e b ba at tt te er ry y t to o p pr re ev ve en nt t u un ni it t f fr ro om m s st ta ar rt ti in ng g u un ne ex xp pe ec ct te ed dl ly y a an nd d c ca au us si in ng g p pe er rs so on na al l i in nj ju ur ry y N NO OT TI IC CE E E Eq qu ui ip pm ...
Page 11: ... A 401364 N A N No ot te e When calling the dealer or factory for information or parts please have the Bill of Material BOM number for your particular unit handy Serial Number Location IMPORTANT NOTE This manual is for 401586 Inverters only These Inverters are identified as being BLACK This manual does not pertain to earlier Inverter s These Inverters are identified as being WHITE Figure 1 Power I...
Page 12: ...de Temperature Warning Yes with warning code Temperature Shutdown Yes with shutdown code Display Specifications LED Status Indicator Green inverter is operating normally Amber An amber warning light will happen often under normal operation and should not be a cause for major concern See Power Inverter Diagnostics p 28 for various warning conditions Red an error has been detected and the inverter h...
Page 13: ... the lift gate LG battery DC Disconnect Switch Red knob located on outside of enclosure disconnects all 12 Vdc battery power to the inverter Ground Fault Circuit Interrupter GFCI Outlet Located inside the truck box or trailer A power indicator light on GFCI alerts that 120 Vac power is present The GFCI outlet monitors the amount of power going to the EPJ If the GFCI detects the interruption in cur...
Page 14: ... safe simple and reliable charging for your EPJ batteries Please take the time to read this manual to familiarize yourself with the features of your EPJ charger Features Ensures your EPJ stays charged Generates 120 volt power directly from lift gate battery pack Built in low voltage protection to preserve liftgate operation Hermetically sealed IP69K waterproof plastic enclosure Easy to operate and...
Page 15: ...Pure Sine Wave Power Inverter 5 Positive Battery Cable and Stud 11 AC Output Power Cable 6 Inverter Chassis Ground Wire Power Inverter The Thermo King 2000 watt pure sine wave power inverter is mounted inside the enclosure Cables are attached from the inverter s DC terminals to the power studs on the enclosure Cables from the LG batteries are connected to these power studs The inverter changes the...
Page 16: ...It is normal operation for no power to be available at the GFCI outlet when operating parameters are not met which typically is when source batteries are at a low voltage I Im mp po or rt ta an nt t The inverter s AC power cable must be connected only to a single GFCI outlet No other electrical connections should be made to this cable GFCI Outlet A GFCI outlet is typically located inside the cargo...
Page 17: ... in n w wh hi il le e i in n t tr ra an ns si it t unplug EPJ when in use N No ot te e Ensure power cable does not interfere with door operation or by product moving in and out of the truck or trailer Figure 6 EPJ Shown Connected to GFCI Outlet RCS1476 IMPORTANT NOTE Depleting the EPJ battery and then trying to rapidly recharge it is not recommended The EPJ should be connected to GFCI while in rou...
Page 18: ...inverter settings 6 R Re em mo ot te e P Po or rt t not used Figure 7 Front Panel AC Output Pure Sine Wave Output 120VAC 60Hz 2000W 16 6A 3 4 5 6 2 1 RCS1673 R Re ea ar r P Pa an ne el l 7 C Co oo ol li in ng g F Fa an ns s intake cooling fans automatically turn on when the inverter s internal temperature rises above a safe level and turn off when the inverter s internal temperature falls to a saf...
Page 19: ...e DC disconnect switch to the OFF position to disconnect all power to the inverter Figure 9 Power Select Button and Digital Display Shown AC Output Pure Sine Wave Output 120VAC 60Hz 2000W 16 6A 2 1 RCS1682 1 Power Select Button 2 Digital Display Status Indicator When the inverter is on the indicator light may illuminate green amber or red to display the inverter s status G Gr re ee en n inverter i...
Page 20: ...blems with the inverter and are used in conjunction with the troubleshooting tables to resolve any operating issues Table 1 Examples of Digital Display Readings Display Meaning 12 5 Measured battery voltage 0 80 Total AC output power in kW 800W as shown E01 Error or warning code See Diagnostic Procedures using Power Inverter Error Codes p 29 for details P01 P04 Unit s setting See table on page 21 ...
Page 21: ...r Saver Mode 12 2V 1 minute ON P03 Northern colder climates Liftgate battery prioritized EPJ not compatible with Power Saver Mode 12 5V 3 minutes OFF P04 Northern colder climates Liftgate battery prioritized EPJ compatible with Power Saver Mode Note P04 is the factory default setting 12 5V 3 minutes ON Operating Time after Under Voltage Setting is reached M Mo od de e s se et tt ti in ng g w wi it...
Page 22: ...ctor reefer for at least 5 minutes 4 Ensure GFCI outlet s lights are on or flashing every 5 seconds if not hold reset button for 5 seconds until you hear and feel a click If you can t get the outlet GFCI lights to light up or flash notify your supporting maintenance people 5 Ensure EPJ equipment battery is not fully charged if they are the EPJ equipment may not be calling for a charge from the out...
Page 23: ...r rv vi ic ce ea ab bl le e p pa ar rt ts s A At tt te em mp pt ti in ng g t to o s se er rv vi ic ce e t th he e u un ni it t y yo ou ur rs se el lf f c co ou ul ld d r re es su ul lt t i in n a an n e el le ec ct tr ri ic ca al l s sh ho oc ck k o or r b bu ur rn ns s GFCI Outlet Output Diagnostics TEST MONTHLY TEST MENSUEL FOLLOW INSTRUCTIONS SUIVEZ INSTRUCTIONS RESET RESET TEST TEST RCS1853 1 ...
Page 24: ...ected Check for damaged extension cord Equipment may not be calling for a charge Use equipment and plug back in to outlet There may be compatibility problems between EPJ and Power Save mode Try plugging in an alternative EPJ or connect a test light greater than 40W to the GFCI outlet If an alternative EPJ or test light works assign a compatible EPJ to the trailer or adjust mode setting to P01 or P...
Page 25: ...the charger box is in the ON position Rotate knob to ON position Note The power inverter will also need to be turned on anytime the DC disconnect switch was turned OFF Open EPJ box and ensure Inverter has power at the display press green power button to turn on if necessary If Inverter was powered down check inverter screen for Error codes OR if Inverter will not Power Up reference Power Inverter ...
Page 26: ...dicates power inverter is working and has AC output Check for power at GFCI Outlet and go through the GFCI Outlet Output Diagnostics which start on page 23 Alternating YELLOW GREEN LED indicates with Code E05 is a warning indicating battery voltage is under the mode threshold P01 P02 12 2v P03 P04 12 5v and AC output is about to turn off Recommended operating charging source to charge up battery v...
Page 27: ... grounding terminal Wire Connector LINE cable brings power to the GFCI Yellow sticker remains in place to cover terminals About Wire Connections Side Wire For Back wire Insert bare wire fully and tighten terminal clamp on conductor ONLY Wire 3 4 1 9 cm Back Wire Wire 5 8 1 6 cm For Side wire Loop clockwise 2 3 of the way around screw Connect the LINE cable wires to the LINE terminals The white wir...
Page 28: ... lights on nor flashing on the GFCI outlet on pg 25 Inverter will not Power Up or No Power at GFCI on pg 26 No Power at GFCI Outlet on this page below Table 3 GFCI Outlet Output Diagnostic Procedures Condition Diagnostic Procedures No Power at GFCI Outlet 1 Confirm DC disconnect switch located on the outside of the charger box is in the ON position a Rotate knob to ON position Note The power inver...
Page 29: ...ar code 2 Check for loose or poor lift gate battery connections and tighten as necessary E02 Shutdown High battery voltage 15 75VDC Note The unit will stop inverting 1 Check voltage regulation of the external charging system of lift gate battery i e alternator E03 Shutdown AC output overload Note The unit will stop inverting 1 Verify load is less than 2000 watts 2 Reduce AC load verify if code cle...
Page 30: ...ct tr ri ic ca al l S Sh ho oc ck k a an nd d B Bu ur rn n H Ha az za ar rd d D Do o n no ot t d di is sm ma an nt tl le e t th he e T Th he er rm mo o K Ki in ng g P Po ow we er r I In nv ve er rt te er r I It t d do oe es s n no ot t c co on nt ta ai in n a an ny y u us se er r s se er rv vi ic ce ea ab bl le e p pa ar rt ts s A At tt te em mp pt ti in ng g t to o s se er rv vi ic ce e t th he e...
Page 31: ...ate to 31 in lb 3 5 Nm Reattach the 12 Vdc positive and 12 Vdc negative cables onto the DC inverter connections Tighten hardware to 108 120 in lb 12 13 5 N m Tighten the 12 AWG ground wire to the inverter chassis securely Inverter Mode Settings After replacing the power inverter the Inverter Mode Settings must be reset See Mode Settings p 21 D Di ia ag gn no os st ti ic c P Pr ro oc ce ed du ur re...
Page 32: ...rly Repair or replace as necessary Verify all DC battery cables are properly routed secured and have no abrasions or damage Repair or replace as needed Verify DC cable connections at rear of EPJ Charger enclosure are free of corrosion Clean and apply additional dielectric grease and reinstall protective cap Verify all AC power wires cables are properly routed secured and have no abrasions or damag...
Page 33: ...TK 56917 11 MM EN 33 Power Inverter Dimensions Figure 14 Power Inverter Dimensions 9 0 in 230 mm 15 in 381 2 mm 8 5 in 216 mm 12 5 in 317 4 mm 13 9 in 353 4 mm 4 5 in 114 mm RCS1854 ...
Page 34: ...34 TK 56917 11 MM EN Schematic Diagram Figure 15 Wiring Schematic RCS1208 3 ...
Page 35: ...TK 56917 11 MM EN 35 N No ot te es s ...
Page 36: ...cluding trailers truck bodies buses air shipboard containers and railway cars since 1938 For more information visit www thermoking com or www tranetechnologies com Thermo King has a policy of continuous product and product data improvements and reserves the right to change design and specifications without notice We are committed to using environmentally conscious print practices TK 56917 11 MM EN...
